Tag Archives: risk

FDA

FDA Proposes FSMA Rule on Food Traceability

By Food Safety Tech Staff
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FDA

On Thursday, October 1, Frank Yiannas, deputy commissioner for food policy and response at FDA, will give the keynote presentation during the 2020 Food Safety Consortium Virtual Conference SeriesKeeping in line with commitments made under FDA’s New Era of Smarter Food Safety, the FDA has announced a food traceability proposed rule to create more recordkeeping requirements for specific foods. The proposed rule, “Requirements for Additional Traceability Records for Certain Foods”, puts additional requirements on companies that manufacture, process, pack or hold foods on the Food Traceability List to establish and maintain records related to critical tracking events (i.e., growing, receiving, transforming, creating and shipping).

Foods on the proposed traceability list have been selected based on a risk-ranking model for food tracing and include:

  • Cheese
  • Shell eggs
  • Nut butter
  • Cucumbers
  • Herbs
  • Leafy greens
  • Melons
  • Peppers
  • Sprouts
  • Tomatoes
  • Tropical tree fruits
  • Fresh-cut fruits and vegetables
  • Finfish
  • Crusteaceans
  • Mollusks
  • Ready-to-eat deli salads

The requirements of the proposed rule pertain to the above-foods as a standalone product as well as when an ingredient in a product.

 

Sudip Saha, Future Market Insights
FST Soapbox

Five Trends Defining the Food Industry Post-COVID

By Sudip Saha
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Sudip Saha, Future Market Insights

Food retailers and the entire food and beverage (F&B) industry are now operating very differently than they did some six months ago. The pandemic has brought immense shifts in supply chains, imposed new hazard controls, and—perhaps most importantly—turned consumer preferences upside down.

To accommodate these changes, food manufacturers, retailers, restaurants and others stepped up to innovate and secure the continuity of their services. But now, as many industries begin to drop the notion of ever going back to what once was, it’s time we started thinking about how many of the newly introduced processes will stick around for the long-term.

What will be the main trends defining the food industry as a whole post-COVID?

Learn more about COVID-19 Lessons Learned during a special episode of the 2020 Food Safety Consortium Virtual Conference Series on October 1Adopted Habits Aren’t Going Anywhere

The pandemic brought radical changes to our everyday lives, and it’s clear that many of the newly adopted behaviors won’t disappear overnight. Consumers will continue to rely on grocery retailers to keep them both fed and healthy while expecting minimum disruptions and a high respect for safety regulations—both in terms of handling and the state of delivered products.

Take-home grocery sales grew by 17% between April and July, breaking the record for the fastest period of growth since 1994. Online grocery shopping also gained popularity while managing to engage entirely new demographics. Some 10% of baby boomers now say they would buy more groceries online once the pandemic is over—compared to 34% of Gen Xs and 40% of millennials.

Due to consumer hyper-awareness of safety and sanitation, the whole food industry will continue to be defined by safety practices. Sanitizing common surfaces like keyboards, door handles, tables and chairs regularly will remain the norm. Beyond “manual” rules such as the mandatory use of facemasks, requirements such as regular health checks could boost the adoption of technology across the industry—transforming not only customer-facing interactions but also the processes behind the curtain.

Technology as an Enabler

Every crisis sparks innovation, and the food industry has certainly proved this thesis. Technology has become the ultimate aide, enabling interactions that would otherwise be impossible. These include contactless ordering, payments and pickup—processes that are likely to stick around even beyond COVID-19.

At the same time, the pandemic accelerated the usage of innovations that previously struggled to become mainstream. This includes virtual tipping jars or mobile order-and-pay, such as the options introduced by fast-food giants including McDonald’s, Subway, KFC, and Burger King.

There’s an obvious appetite for F&B companies to further incorporate technology. For example, the Coca-Cola Company is rolling out a touchless fountain experience that can be used with a smartphone for contactless pouring. Heineken, on the other hand, turned to virtual tech to launch a new product—a cardboard topper for multipack beer that will eliminate plastic from millions of cans. With travel restrictions hindering the mobility of engineers, the company leveraged virtual technology to install the new machinery needed at its Manchester-based factory.

But it’s not just solitary innovations; the market has already seen new AI-based technologies that help food businesses better manage risk in their workforce. Food manufacturing, distribution and provision require many different touchpoints; by predicting, monitoring and testing the health and safety of the workers involved in these processes, companies can ensure they keep their operations running, even if another wave of COVID-19 hits. Solutions like these will be crucial when looking to add another layer of safety that goes beyond mandatory governmental regulations.

Food Safety Revamped

Even though COVID-19 is transmitted through airborne respiratory droplets, and the risk of contracting the virus through food is low, people around the world are concerned about the possibility. After all, 40% of people are more careful about washing unpackaged fruit and vegetables than before the pandemic.

The pandemic has already made societies rethink various established concepts, such as wet markets or the consumption of wild animals. The pandemic could, therefore, lead to changed behaviors, and newly imposed rules such as formalizing small and micro food enterprises, provisions for direct sales by farmers, leveraging technology to ensure safety, and investments in a more robust food infrastructure altogether.

Such changes could also irreversibly affect street food—a sector that is bound to feel the hit of COVID-19. Particularly in countries with diverse street food culture, one of the emerging trends will be the rise of gourmet street food brands that can provide both great taste and high hygiene standards.

Food Sustainability to the Forefront

2020 will be a year of reckoning for the world’s food systems. The pandemic exposed the flaws of the global food supply chain that continues to be highly centralized and operating on a just-in-time basis. This is why we have seen panic food runs, urgent supply shortages and high amounts of food waste as many businesses were shut down overnight. In developing countries, several agencies expect that a “hunger pandemic” and a doubling of people starving could happen unless serious action is taken.

As we rethink the underlying principles of the food industry such as safety and supply, other concepts such as transparency and visibility into product sourcing and manufacturing also come into the spotlight. Consumers across the globe are more likely to prioritize offerings that are healthy and locally sourced than they were before COVID-19.

Food produced with the overuse of chemicals in monoculture cropping systems and large-scale animal farming significantly impact the availability of natural resources and cause substantial greenhouse gas emissions. Added to that, practices like industrial animal farming that operate with large numbers of livestock in confined spaces are a breeding ground for viruses, and have been linked to prior outbreaks such as the outbreak of swine flu in 2009. They also enable the spread of antibiotic-resistant organisms due to the common overuse of antibiotics administered to prevent infections caused by cramped living conditions.

Consumers are increasingly aware of this: Nearly 25% of Americans are now eating more plant-based food. As we move forward, diverse food companies are likely to tap into this trend, resulting in great opportunities for plant-based, nutritious, local, and even healthy DIY meals and products. For example, an Australian food producer has recently announced the launch of a new proprietary product range that will offer the first vegan ready-to-drink protein shakes on the Australian market.

A New Way of Dining

The restaurant market has been one of the direct victims of the pandemic but has shown impressive elasticity in adapting to the new realities. Many businesses have introduced service extensions such as deliveries and take-outs, as well as pop-up grocery stores. Enjoying great popularity, some of these options will stick around far beyond the pandemic.

However, there’s a counterforce hindering significant expansion: The simple fact that many consumers discovered a new joy in cooking. A recent study notes that 54% of Americans are now cooking more than they were before the pandemic, with 35% saying that they “enjoy cooking more now than ever.” But at the same time, 33% of consumers say they’re getting more takeout than before the pandemic. This implies that the post-pandemic normal will likely see a shift toward eating at home more often, whether that means cooking or takeout and delivery.

Therefore, restaurants are likely to continue diversifying their services, experiment with food bundles and DIY meal kits, or even luxurious in-home chef visit experiences as an alternative to high-end restaurant dining.

The past crises have shown that economic uncertainty is directly linked to changes in demand for private-label and value brands. After the 2008 financial crisis, 60% of U.S. consumers were more interested in reasonably priced products with core features than in higher-priced, cutting-edge products. So while luxury dining is not completely disappearing, it could take on other aspects.

In Denmark, for example, a two-Michelin star restaurant is moving to serve burgers. In China, a country that many look to as the model for the post-COVID world, there has also been a clear push toward more affordable dining as well. Hot pot and barbecue venues have been thriving, particularly among customers in their 20s and 30s. Many fine dining restaurants, on the other hand, have started offering affordable lunch menus or have cut prices to correspond to the current value-conscious behaviors.

It’s clear that the future of food retail and the F&B industry will be significantly marked by the pandemic. Its prolonged nature will also cause the newly adopted habits to become further solidified—and many processes will adapt to match them. For example, while contactless deliveries were accelerated in the past months, businesses are working hard to make them as efficient as convenient as possible, making it unlikely that such investments would be erased overnight, once COVID-19 is no longer a threat.

Shawna Wagner, DNV GL
FST Soapbox

Pandemics and Your Business Continuity Plan

By Shawna Wagner
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Shawna Wagner, DNV GL

Who would have even thought to put the topic of a pandemic in your business continuity plan? I know, I sure never thought of it, even as a senior auditor. I think that most of us are familiar with the typical subjects of tornados, floods, power outages and disgruntled employees, to name a few. We now need to focus on adding a pandemic to the to-do list of your plan, as this global issue has become a reality since early 2020.

It is quite likely that your plant has been affected by COVID-19 in some way, therefore your site has put into place actions to mitigate the risks posed by the pandemic. What may not be likely, is that any of these actions have been documented. I have currently seen plants evolve actions based on the severity of the pandemic in their locations. Travel restrictions, reduced work force, changing employee personal protective equipment, additional employee monitoring, and remote work environments are some of the examples directly affecting sites that I have witnessed during the first half of this year. As plants learn and experience more issues, they tend to adapt to how they are mitigating the risks in their facilities.

Capturing what actions went smoothly and what has gone astray will aid in strengthening your business continuity plan. Pandemics as well as other extraordinary events are handled by a multi-step approach that needs organization and good communication. That is why it is imperative to build and document actions, then verify how those steps are to be used. Involving key personnel–not just the quality manager–at the site is a best practice in getting a full grasp on what needs to happen during an emergency. In several instances, I have witnessed that key personnel are not informed about where a site’s business continuity plan is located; or the plan was updated right before an audit and after goes back on the shelf for the next 12 months, collecting dust. Employees should be trained on the contents of the plan, their responsibilities (if they are part of the business continuity team), current contacts, updates, and ways to initiate proper channels, if or when a time comes to do so. Hopefully, it never does, but it sure does not hurt to be prepared.

The business continuity plan is not a “one-size-fits-all” approach for plants. An important consideration, when defining what actions to take, if your area has been plagued by a pandemic includes determining what risks are brought by employees, visitors (i.e., contractors), location, and type of product being produced. Plant A making a high-risk open product may implement additional hand washing and sanitation, whereas Plant B making a low-risk closed product may implement additional health screening (i.e., temperature checks) for employees. You should ensure that it makes sense, and it is beneficial for your site and your interested parties, such as customers, consumers and stakeholders.

Your business continuity plan should be built to be a great resource to you in the time of need. And in return, you will have to put some elbow grease into shaping the document in a way that fits the ever-changing food environment. Keeping your plant current will assist your business to quickly respond to a negative event. In consequence, not having a plan that works for your site, or any at all, could lead to closed doors.

LIMS, Laboratory information management system, food safety

How Advanced LIMS Brings Control, Consistency and Compliance to Food Safety

By Ed Ingalls
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LIMS, Laboratory information management system, food safety

Recent food scandals around the world have generated strong public concerns about the safety of the foods being consumed. Severe threats to food safety exist at all stages of the supply chain in the form of physical, chemical and biological contaminants. The current pandemic has escalated the public’s concern about cross contamination between people and food products and packaging. To eliminate food risks, manufacturers need robust technologies that allow for reliable monitoring of key contaminants, while also facilitating compliance with the ISO 17025 standard to prove the technical competence of food testing laboratories.

Without effective data and process management, manufacturers risk erroneous information, compromised product quality and regulatory noncompliance. In this article, we discuss how implementing a LIMS platform enables food manufacturers to meet regulatory requirements and ensure consumer confidence in their products.

Safeguarding Food Quality to Meet Industry Standards

Food testing laboratories are continually updated about foodborne illnesses making headlines. In addition to bacterial contamination in perishable foods and ingredient adulteration for economic gains, chemical contamination is also on the rise due to increased pesticide use. Whether it is Salmonella-contaminated peanut butter or undeclared horsemeat inside beef, each food-related scandal is a strong reminder of the importance of safeguarding food quality.

Food safety requires both preventive activities as well as food quality testing against set quality standards. Establishing standardized systems that address both food safety and quality makes it easier for manufacturers to comply with regulatory requirements, ultimately ensuring the food is safe for public consumption.

In response to food safety concerns, governing bodies have strengthened regulations. Food manufacturers are now required to ensure bacteria, drug residues and contaminant levels fall within published acceptable limits. In 2017, the ISO 17025 standard was updated to provide a risk-based approach, with an increased focus on information technology, such as the use of software systems and maintaining electronic records.

The FDA issued a notice that by February 2022, food testing, in certain circumstances, must be conducted in compliance with the ISO 17025 standard. This means that laboratories performing food safety testing will need to implement processes and systems to achieve and maintain compliance with the standard, confirming the competence, impartiality and consistent operation of the laboratory.

To meet the ISO 17025 standard, food testing laboratories will need a powerful LIMS platform that integrates into existing workflows and is built to drive and demonstrate compliance.

From Hazard Analysis to Record-Keeping: A Data-Led Approach

Incorporating LIMS into the entire workflow at a food manufacturing facility enables the standardization of processes across its laboratories. Laboratories can seamlessly integrate analytical and quality control workflows. Modern LIMS platforms provide out-of-the-box compliance options to set up food safety and quality control requirements as a preconfigured workflow.

The requirements set by the ISO 17025 standard build upon the critical points for food safety outlined in the Hazard Analysis and Critical Control Points (HACCP) methodology. HACCP, a risk-based safety management procedure, requires food manufacturers to identify, evaluate and address all risks associated with food safety.

LIMS, laboratory information management system
LIMS can be used to visualize control points for HACCP analysis according to set limits. Graphic courtesy of Thermo Fisher Scientific.

The systematic HACCP approach involves seven core principles to control food safety hazards. Each of the following seven principles can be directly addressed using LIMS:

  • Principle 1. Conduct a hazard analysis: Using current and previous data, food safety risks are thoroughly assessed.
  • Principle 2. Determine the critical control points (CCPs): Each CCP can be entered into LIMS with contamination grades assigned.
  • Principle 3. Establish critical limits: Based on each CCP specification, analytical critical limits can be set in LIMS.
  • Principle 4. Establish monitoring procedures: By defining sampling schedules in LIMS and setting other parameters, such as frequency and data visualization, procedures can be closely monitored.
  • Principle 5. Establish corrective actions: LIMS identifies and reports incidents to drive corrective action. It also enables traceability of contamination and maintains audit trails to review the process.
  • Principle 6. Establish verification procedures: LIMS verifies procedures and preventive measures at the defined CCPs.
  • Principle 7. Establish record-keeping and documentation procedures: All data, processes, instrument reports and user details remain secured in LIMS. This information can never be lost or misplaced.

As food manufacturers enforce the safety standards set by HACCP, the process can generate thousands of data points per day. The collected data is only as useful as the system that manages it. Having LIMS manage the laboratory data automates the flow of quality data and simplifies product release.

How LIMS Enable Clear Compliance and Optimal Control

Modern LIMS platforms are built to comply with ISO 17025. Preconfigured processes include instrument and equipment calibration and maintenance management, traceability, record-keeping, validation and reporting, and enable laboratories to achieve compliance, standardize workflows and streamline data management.

The workflow-based functionality in LIMS allows researchers to map laboratory processes, automate decisions and actions based on set criteria, and reduce user intervention. LIMS validate protocols and maintain traceable data records with a clear audit history to remain compliant. Data workflows in LIMS preserve data integrity and provide records, according to the ALCOA+ principles. This framework ensures the data is Attributable, Legible, Contemporaneous, Original and Accurate (ALCOA) as well as complete, consistent and enduring. While the FDA created ALCOA+ for pharmaceutical drug manufacturers, these same principles can be applied to food manufacturers.

Environmental monitoring and quality control (QC) samples can be managed using LIMS and associated with the final product. To plan environmental monitoring, CCPs can be set up in the LIMS for specific locations, such as plants, rooms and laboratories, and the related samples can then be added to the test schedule. Each sample entering the LIMS is associated with the CCP test limits defined in the specification.

Near real-time data visualization and reporting tools can simplify hazard analysis. Managers can display information in different formats to monitor critical points in a process, flag unexpected or out-of-trend numbers, and immediately take corrective action to mitigate the error, meeting the requirements of Principles 4 and 5 of HACCP. LIMS dashboards can be optimized by product and facility to provide visibility into the complete process.

Rules that control sampling procedures are preconfigured in the LIMS along with specific testing rules based on the supplier. If a process is trending out of control, the system will notify laboratory personnel before the product fails specification. If required, incidents can be raised in the LIMS software to track the investigation of the issue while key performance indicators are used to track the overall laboratory performance.

Tasks that were once performed manually, such as maintaining staff training records or equipment calibration schedules, can now be managed directly in LIMS. Using LIMS, analysts can manage instrument maintenance down to its individual component parts. System alerts also ensure timely recalibration and regular servicing to maintain compliance without system downtime or unplanned interruptions. The system can prevent users from executing tests without the proper training records or if the instrument is due for calibration or maintenance work. Operators can approve and sign documents electronically, maintaining a permanent record, according to Principle 7 of HACCP.

LIMS allow seamless collaboration between teams spread across different locations. For instance, users from any facility or even internationally can securely use system dashboards and generate reports. When final testing is complete, Certificates of Analysis (CoAs) can be autogenerated with final results and showing that the product met specifications. All activities in the system are tracked and stored in the audit trail.

With features designed to address the HACCP principles and meet the ISO 17025 compliance requirements, modern LIMS enable manufacturers to optimize workflows and maintain traceability from individual batches of raw materials all the way through to the finished product.

Conclusion

To maintain the highest food quality and safeguard consumer health, laboratories need reliable data management systems. By complying with the ISO 17025 standard before the upcoming mandate by the FDA, food testing laboratories can ensure data integrity and effective process management. LIMS platforms provide laboratories with integrated workflows, automated procedures and electronic record-keeping, making the whole process more efficient and productive.

With even the slightest oversight, food manufacturers not only risk product recalls and lost revenue, but also losing the consumers’ trust. By upholding data integrity, LIMS play an important role in ensuring food safety and quality.

Daniel Erickson, ProcessPro
FST Soapbox

Recall Risk Reduction: An ERP’s Role

By Daniel Erickson
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Daniel Erickson, ProcessPro

Consumer safety is of paramount importance and product recalls are a necessary means to this end. Product recalls are a serious, complex, and costly issue affecting the food and beverage industry in the United States. The FDA estimates that there are around 48 million cases of foodborne illness each year—causing one in six Americans to get sick from contaminated food. In addition to affecting public health, recalls have a dramatic effect on manufacturers by creating economic problems, damaging a company’s reputation, and imposing potential legal penalties and liabilities. In the search for a business management solution to better prepare themselves for and reduce the risk of recalls in their operations, many food manufacturers have discovered that technology, specifically ERP software, is key to lowering the risk of food and beverage product recalls.

An industry-specific ERP solution is a centralized business system with key industry features providing a system of record-keeping, with the tools to support the preparation and reduction of recall risks. While a manufacturer is ultimately responsible for a product recall, an ERP solution is essential in supporting and championing overall recall readiness and reduction. With the streamlined and automated inventory, manufacturing, and quality control processes managed within the software, critical steps and data that assist in recall mitigation are documented—including supplier verification records, audit logs, receipt records, quality testing, lot tracking, and shipment logs. The key to prevention of a product recall is preparation, which can be handled efficiently through an ERP’s functionality specifically in the following areas.

Supplier Management

An ERP facilitates best practices for supplier management and risk assessment within the solution to assure the acquisition of quality raw materials from trusted vendors. Its role is to maintain an approved supplier list for each product ingredient, documenting detailed supplier information, quality control test results, and risk level to ensure in-house and customer-specific standards are met. For approved or activated suppliers, information regarding materials that can be purchased through the vendor, applicable certifications, quality control results, and other pertinent supplier information is stored within the centralized data system of the ERP. A risk assessment for each vendor is also documented to ensure that any potential inherent risk(s) from vendor-issued recalls and to finished goods are limited.

In addition to activated suppliers, an ERP solution also assigns and manages qualified alternates to provide vetted selections should a primary supplier’s materials become unavailable. This positions a company well in the supply chain, as the investigative work has already been conducted on other suppliers, limiting the need and risk associated with onboarding an unknown supplier in a moment of crisis. Vendors are recorded within the system and ranked in order of preference and/or risk level so that they can be identified and put into use quickly if a supplier becomes unavailable—providing the preparation and leverage that companies need to mitigate the risk to safety in the supply chain. In a product recall situation, when a supplier notifies a customer of a contaminated ingredient, the supplier management feature within the ERP solution provides for a qualified replacement vendor that can fulfill the needed raw material quickly and efficiently.

Inventory Control

An ERP system offers end-to-end traceability, maintaining a comprehensive record that tracks raw ingredients, work-in-progress, and final products throughout the supply chain using barcode scanning to link product and lot information to batch tickets, QC testing results, shipping documents, and labels. This full forward and backward lot traceability is necessary to provide a documented audit trail imperative to locating raw materials or finished goods quickly within the initial 24-hour time period of a product recall. With full manufacturing, inventory, and reporting integrations, the ERP supports sound manufacturing practices that assist with recall preparedness – maintaining current Good Manufacturing Practices (cGMP), FDA reporting, GFSI compliance, and other industry-specific regulations to provide a documented audit trail with the ability to adapt as compliance requirements change.

Managing protocols to ensure the quality of inbound and outbound materials is essential in minimizing recall risk across the entire supply chain—from raw materials to the delivered final product. With an industry-specific ERP solution, formulas, recipes and instructions are maintained, scaled and verified to ensure consistency of products within the manufacturing process. This instills preventative measures throughout the production cycle in the form of process steps and quality control test specifications to bolster safety and quality. Quality features such as quarantine status and other status capabilities permit the isolating, removing and disposing of raw ingredients and finished goods that fail to meet quality control standards—triggering an alert to notify the purchasing department to investigate the issue. Having the ability to remove ingredients and finished goods from inventory or production prevents contaminated items from reaching store shelves and consumers, which reduces overall recall risk.

Inventory control practices are an important part of the functionality within an ERP solution that help to reduce overall recall risk. This includes managing and reporting of shelf life and expiration dates to maintain precise and lean control of inventory and reduce variances. Automated inventory transactions with the use of an ERP’s warehouse management solution (WMS) follow industry best practices and improve efficiency to ensure the accuracy of shipments, transfers, and material returns. This real-time visibility allows for the maintenance of FIFO inventory practices necessary to reduce the risk of spoilage.

One of the leading causes of contamination for food and beverage manufacturers that results in a recall event is a lack of allergen control throughout the supply chain and production process. An ERP system helps to track, manage and record the handling, storage and batch steps of raw materials from farm-to-fork. This includes stringent sanitary practices, lot tracking, raw material segregation and process controls to avoid allergen contamination or cross-contamination. Accurate product labeling is also a significant factor in reducing risk and an automated system that generates nutritional and product package labels plays a key role in a company’s recall prevention. To meet the needs of consumers and regulators, an ERP solution automates label creation to include accurate ingredient and allergen statements, nutrient analysis, expiration dates, lot and batch numbers, and regulatory specifications. The labeling history documented in the software allows products to be identified and located quickly in the event of a recall.

Reporting

Utilizing the recall functionality in the ERP solution allows companies to plan and test their recall process in advance. Performing mock recalls permits regular measurement and improvement of procedures to ensure rapid, accurate, and thorough responses by all company stakeholders in the event of a recall. A successful simulated exercise identifies 100% of recalled ingredients/products and notifies appropriate entities in a timely manner. Evaluation and documentation of mock recall exercises help expose inefficiencies, process gaps and procedural adjustments, which are designed to improve recall readiness and minimize consumer exposure to potentially dangerous contaminants.

As proof or documentation of adherence to specific processes, reporting is essential to demonstrate that these processes have been completed—without it, an integral component is missing. Across the supply chain and throughout the manufacturing process, documentation and reporting accentuate steps that have been taken to prepare and reduce recall risk. Risk-based assessments in supplier management, lot traceability reports, and mock recall reporting all provide a starting point of analysis to allow for adjustments to be made across the business. In a recall situation, the system is able to create lot tracking reports that encompass raw ingredients through shipped finished goods. These reports can be produced in minutes, rather than the hours it takes if data is stored within separate software programs.

Due to the amount of time and money that food and beverage companies invest in getting their products to market, it is imperative that preventative measures are taken in order to avoid a product recall. Forward-thinking manufacturers can help prepare for and reduce recall risks by utilizing several important features in ERP software—including supplier management, inventory control, and reporting. Using the tools at their disposal, a company can mitigate liabilities and protect their brand to turn a potential crisis into a future filled with opportunities.

Jennifer van de Ligt, Food Protection and Defense Institute, University of Minnesota

Q&A: Pandemic Puts Worker Health & Safety, Leadership Skills and Business Adaptability at Forefront

By Maria Fontanazza
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Jennifer van de Ligt, Food Protection and Defense Institute, University of Minnesota

Issues with the health of frontline workers, supply chain disruptions, and changes in consumer behavior are just a few vulnerabilities that the food industry is experiencing as a result of COVID-19. Food Safety Tech recently had a conversation with Jennifer van de Ligt, Ph.D., director of the University of Minnesota Integrated Food Systems Leadership Program and Food Protection and Defense Institute about the hurdles that the industry is experiencing and where we go from here.

Food Safety Tech: What challenges is the food system facing in light of the COVID-19 pandemic? Where are the vulnerabilities?

Jennifer van de Ligt, Ph.D.: The food system is facing primary, secondary and tertiary challenges right now. I see two main drivers as disruptors as a result of COVID-19. The health and safety of employees is the first primary driver. As COVID-19 has more broadly spread through the U.S., ensuring the health and safety of employees in the food system has become essential; however, the pandemic has shown us the food system has struggled with that.

The other big primary challenge facing the food system has been the swift change in consumer behavior. Pre-COVID-19, nearly half of food was consumed away from home. When restaurants closed, and stay-at-home orders were in place, it put extreme amounts of pressure on our food retail segment, causing supply and demand issues.

Regarding the health and safety of employees: We’ve seen meat processing struggle with production demands because the health of their employees has been impacted by the virus. In mid-April, the beef and pork capacity in this country went down by over 40%. They are making great improvements and are approaching normal harvest capacity range for both [beef and pork production]. Meat cuts being produced are slightly different than normal, as this part of the meat plants are very labor intensive. This has really highlighted the need to make sure that we keep the health and safety of our food system employees front and center.

During the 2020 Food Safety Consortium Virtual Conference Series, Jennifer Van de Ligt will participate in a panel discussion on November 5 about Professional Development and Women in Food Safety | Register Now Now that the meat supply chain is beginning to recover, we’re also beginning to see increasing effects on non-meat supply manufacturing. This isn’t isolated to food manufacturing; as we experience broader community spread, COVID-19 will impact all aspects of our food system.

On consumer behavior: As consumers shifted to food retail, immense pressure was quickly put on our food supply chain logistics, manufacturing timing and processes, the speed to warehouses and delivery, etc.

One example that demonstrates a challenge in manufacturing and consumer demand is the difference in volumes for food services versus retail. I like to use the example of shredded cheese. At a grocery store, you’ll find a one-pound pack, but shredded cheese in food service might be in a 10-pound bag. There are not a lot of consumers who want to buy a 10-pound bag of shredded cheese. Well, why can’t cheese manufacturers just package bulk product into one-pound packs? There are several reasons that don’t allow producers to pivot quickly: They may not have the machinery or packaging to do that. Also, changing packaging from food service to retail requires different labels and regulatory approvals. Examples like this led to many of the spot outages consumers found in grocery stores. In the produce sector, it led to produce being plowed under in fields because they didn’t have the distribution channels to go into retail instead of into food service.

In the Integrated Food System Leadership (IFSL) program, we’ve recently discussed food equity and food injustice as a result of COVID-19. As food retail became stressed and unemployment increased, we saw a huge demand for our food assistance networks. Because food retail is one of the primary contributors to the food assistance networks, there wasn’t enough volume being donated. In addition, food service foods are not appropriately packaged to go into the food assistance networks and food banks, similar to the issue in moving to food retail. This led to tremendous pressure and innovative solutions to source and distribute food to a newly vulnerable population.

As we look ahead into the coming months, many of the vulnerabilities in the food system will be the same. We have to continuously monitor the health and safety of our employees to keep our food system as a whole functional. There’s a growing recognition that our primary agriculture workers are also at risk—the people in fields harvesting and planting. There are many groups providing recommendations on how to protect agriculture employees and communities where they work and reside.

We’ll see continued adaptation in the food system to the new reality of how restaurants and food service engage with their consumers with the shift in behavior to limited restaurant dining and increases in online ordering.

FST: In what areas do food manufacturers, processors or growers need to adapt moving forward in order to thrive?

Van de Ligt: There are several. First, I think this crisis has really brought worker health and welfare to the forefront, and there will be more emphasis on the essentiality of food system workers. They were previously a behind-the-scenes workforce. The issue of worker health and welfare is going to accelerate in many industries, but I also see a push to more automation. The human workforce is necessary, and people do a really wonderful job, but are there areas that might benefit from automation? I think those go hand in hand.

I also think the global food system needs to rethink how it remains resilient. In the past, there’s been a focus on resilience and efficiency through economy of scale. That still exists and may look different moving forward. Using the meat industry as an example, that economy of scale was also its biggest weakness that had gone unrecognized. Going forward, I think there are many companies that are going to consider alternative supply chains. Should multiple, smaller plants be utilized instead of one large plant to provide a more resilient framework for production? Other companies are going to think about installing equipment or processing lines that could more quickly pivot between food service and food retail. There’s also a huge opportunity now for local and smaller markets to really make an impact as people look for alternative supply chains and sources. We found that many of the local food markets and co-ops, especially those that provided into food service, pivoted pretty quickly to pop-up online marketplaces to provide food direct to consumer. I think we’ll see that trend increase as well.

In order to feed billions of people worldwide, it’s essential that the food industry take a broader systems approach versus the siloed approach path we’ve been using. The pandemic has highlighted how the food system is an intricately functioning balance and requires collaboration. Our food system will only be able to move forward faster with less disruption when we have food system leaders who understand the intricacies and the ripple effects of the challenges we face. Leaders who understand the impacts of decisions outside of their sphere will be essential to plan for impacts from natural disasters, another pandemic, etc.—and to create a more responsive and resilient food system in the future.

FST: Where does this leave folks who are either beginning or rising in their careers in food safety? Do you think the pandemic has changed food safety careers as they’ve historically functioned?

Van de Ligt: I like to say that ‘what got us here is not going to get us there.’ In general, if you think about where food safety careers have been in the past, the roles have been all about consistency, understanding regulations, making sure we do everything precisely right all of the time so we don’t have a food safety outbreak.

The focus on doing things precisely right all of the time will absolutely continue. What I think will shift is the need for food safety professionals to think more broadly than just the regulations that are required for compliance. Food safety professionals need to understand more about the system that is happening outside their facility; the impact of their work going backwards and forwards in the supply chain.

How things have worked historically in a food safety role has been having a consistent supplier network that provides the same type of product every time; you know what to expect, how to produce and distribute safe food for the customers you serve. In a situation like COVID-19, because of the disruptions from farm to fork, the suppliers you need to work with may be different and you need to quickly make decisions spontaneously as supply shifts. Having the knowledge and skills to navigate changes is essential to ensure the quality and safety of your product.

A highly technical focus that many professionals have when they start their career is often too narrow and won’t be enough for emerging food system leaders. Leadership skills are vital as well. In the IFSL program we teach food system professionals how to explore proactive viewpoints, not just managing people or responsibilities. Managers make sure things are done things correctly; leaders make sure we do the right thing. In order to learn how to do the right thing, we teach skills and tools on how to navigate uncertainty; practicing active listening, constructive feedback; and understanding the concerns of a supplier or customer are examples.

We emphasize and teach in the IFSL program that food system professionals and leaders need to be much more proactive. This means equipping them with the food system knowledge and leadership skills so they can predict and prepare for how decisions affect upstream and downstream. Having a broader viewpoint is critical to adaptivity, which will build resilience and help limit disruption.

Coronavirus, COVID-19

Meatpacking Workers Sue OSHA Over Hazardous Working Conditions During COVID-19 Pandemic

By Food Safety Tech Staff
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Coronavirus, COVID-19

View the complimentary webinar, “Instant Replay & Update: Is Your Plant COVID-19 Safe?”A lawsuit filed yesterday against OSHA alleges that the agency did not protect meat packing plant workers during the COVID-19 pandemic. Three workers from Pennsylvania-based Maid-Rite Specialty Foods are suing OSHA for putting workers in “imminent danger” as a result of hazardous working conditions, according to The Washington Post. The lawsuit stated that Maid-Rite did not:

  • Implement social distancing measures on the processing lines
  • Provide acceptable personal protective equipment
  • Address sick workers safely by not separating them
  • Tell all workers who may have been in close contact with sick workers

Maid Rite is also accused of incentivizing sick employees to report to work with bonuses.

Both OSHA and Maid Rite have not yet commented on the lawsuit as of yet.

For months, COVID-19 outbreaks at meat and poultry processing plants have been a problem, with more than 11,000 infections being reported.

During the 2020 Food Safety Consortium Virtual Conference Series, experts will address The Intersection of OSHA and Food Safety Personnel during the episode, COVID-19’s Impact on Food Safety Management. This session will occur on Thursday, November 12. Learn more.

Shub Degupta, Mesh Intelligence
FST Soapbox

Driven by COVID-19 Disruptions to Find a Better, Data-Driven Way to Manage Food Supply Chain Risk

By Shub Degupta
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Shub Degupta, Mesh Intelligence

The COVID-19 pandemic emphatically laid bare the supply chain and supplier vulnerabilities that we face in our increasingly global food supply chains. Last month my company, Mesh Intelligence, convened a group of 14 leading supply chain, risk, sourcing and food safety executives drawn from some of the largest and most innovative food companies around the globe and in all aspects of the supply chain—from manufacturing, importing, distribution, logistics and retail. They volunteered their time to explore new solutions to better manage risk in their global food supply chains and are working together to develop and guide a lasting solution to address the challenges they faced across the past few months and manage supply chain in a more uncertain environment.

Zeroing In on the Need for Practical Solutions to Address Critical Issues

The group discussed how the tools and processes they currently use to manage supply chains are inadequate in identifying the scale, scope and intensity of new issues that arose during the pandemic and, more importantly, how these solutions need to be augmented in the future. To zero in on practical solutions, this group focused on the most critical challenges to address; understanding the best practices to tackle these issues; and guiding the development of data driven, practical and scalable solutions to predict risk.

Key insights from the group discussion include:

  1. The need for early, actionable warning on risk. Food organizations are seeking actionable, early warning signals about upcoming supply chain issues. Risk alerts, if they do exist, currently tend to be disaggregated and dispersed within an organization and executives struggle to understand the full picture.
  2. The need to communicate risk across the organization and the supply chain. Executives are seeking ways to communicate forecasted risk in fact-based and data-driven ways across key stakeholders within and outside the organization. There was clear interest in ways to engage suppliers and parties up and down the supply chain.
  3. Focusing on the most important risks and scenario planning a workable approach. Organizations are seeking ways to future proof their supply chains and increase resilience. By ensuring that their strategies are tested to withstand likely scenarios and situations, organizations improve their ability to work under increased uncertainty.
  4. The ability to continuously monitor and vet suppliers, even in a remote setting. Organizations are looking to get ahead of supplier issues and are seeking ways to work with suppliers to continuously monitor, vet and manage issues as they arise. This requires increased transparency and greater communication across parties in the supply chain.

Participants of the group are also getting early access to the solution and data to support them in their food safety and supply chain risk management efforts. The group will continue to meet on over the next few months to continue to guide the development of a food supply chain risk management solution. We look forward to keeping you updated. If you have insights on this issue, we encourage you to reach out. If you are interested in learning more about us or joining the group, please contact us at nicole@meshintel.com

Mike Edgett, Sage

COVID-19 Leads Food Companies and Meat Processors to Explore AI and Robotics, Emphasize Sanitation, and Work from Home

By Maria Fontanazza
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Mike Edgett, Sage

The coronavirus pandemic has turned so many aspects of businesses upside down; it is changing how companies approach and execute their strategy. The issue touches all aspects of business and operations, and in a brief Q&A with Food Safety Tech, Mike Edgett of Sage touches on just a few areas in which the future of food manufacturing looks different.

Food Safety Tech: How are food manufacturers and meat processors using AI and robotics to mitigate risks posed by COVID-19?

Mike Edgett: Many food manufacturers and meat processors have had to look to new technologies to account for the disruptions caused by the COVID-19 pandemic. While most of these measures have been vital in preventing further spread of the virus (or any virus/disease that may present itself in the future), they’ve also given many food manufacturers insight into how these technologies could have a longer-term impact on their operations.

For instance, the mindset that certain jobs needed to be manual have been reconsidered. Companies are embracing automation (e.g., the boning and chopping of meat in a meatpacking plant) to replace historically manual processes. While it may take a while for innovations like this to be incorporated fully, COVID-19 has certainly increased appetite amongst executives who are trying to avoid shutdowns and expedited the potential for future adoption.

FST: What sanitation procedures should be in place to minimize the spread of pathogens and viruses?

Edgett: In the post-COVID-19 era, manufacturers must expand their view of sanitation requirements. It is more than whether the processing equipment is clean. Companies must be diligent and critical of themselves at every juncture—especially when it comes to how staff and equipment are utilized.

While working from home wasn’t a common practice in the manufacturing industry prior to March 2020, it will be increasingly popular moving forward. Such a setup will allow for a less congested workplace, as well as more space and time for bolstered sanitation practices to take place. Now and in the future, third-party cleaning crews will be used onsite and for machinery on a daily basis, with many corporations also experimenting with new ways to maintain the highest cleanliness standards.

This includes the potential for UV sterilization (a tactic that is being experimented with across industries), new ways to sterilize airflow (which is particularly important in meatpacking plants, where stagnant air is the enemy) and the inclusion of robotics (which could be used overnight to avoid overlap with human employees). These all have the potential to minimize the spread of pathogens and, ultimately, all viruses that may arise.

Mike Edgett, Sage
Mike Edgett is an enterprise technology and process manufacturing expert with 20+ years leading business strategy for brands such as Infor, Quaker Oats and Bunge Foods. At Sage, he leads the U.S. product marketing team focused on the medium segment.

FST: How is the food industry adjusting to the remote working environment?

Edgett: While the pandemic has changed the ways businesses and employees work across most industries, F&B manufacturers did face some unique challenges in shifting to a remote working environment.

Manufacturing as a whole has always relied on the work of humans, overseeing systems, machinery and technology to finalize production—but COVID-19 has changed who and how many people can be present in a plant at once. Naturally, at the start of the pandemic, this meant that schedules and shifts had to be altered, and certain portions of managerial oversight had to be completed virtually.

Of course, with employee and consumer safety of paramount concern, cleaning crews and sanitation practices have taken precedent, and have been woven effectively and efficiently into altered schedules.

While workers that are essential to the manufacturing process have been continuing to work in many facilities, there will likely be expanded and extended work-from-home policies for other functions within the F&B manufacturing industry moving forward. This will result in companies needed to embrace technology that can support this work environment.

FST: Can you briefly explain how traceability is playing an even larger role during the pandemic?

Edgett: The importance of complete traceability for food manufacturers has never been greater. While traceability is by no means a new concept, COVID-19 has not only made it the number one purchasing decision for your customers, but [it is also] a vital public health consideration.

The good news is that much of the industry recognizes this. In fact, according to a survey conducted by Sage and IDC, manufacturing executives said a key goal of theirs is to achieve 100% traceability over production and supply chain, which serves as a large part of their holistic digital mission.

Traceability was already a critical concern for most manufacturers—especially those with a younger customer base. However, the current environment has shone an even greater spotlight on the importance of having a complete picture of not only where our food comes from—but [also] the facilities and machinery used in its production. Major budget allocations will surely be directed toward traceability over the next 5–10 years.