Tag Archives: sensors

Megan Nichols
FST Soapbox

How to Prevent Foodborne Pathogens in Your Production Plant

By Megan Ray Nichols
No Comments
Megan Nichols

Foodborne pathogens, such as bacteria and parasites in consumable goods, can result in illnesses and deaths, wreaking havoc on residents of states and countries. The companies at fault often face severe damage to their reputation as people fear that continuing to do business with a brand is not safe. Moreover, if the affected enterprises do not take decisive steps to prevent the problem from happening again, they may receive substantial fines or closure orders.

Statistics from the U.S. federal government indicate that there are approximately 48 million cases of foodborne illnesses in the American food supply each year. Fortunately, there are proven steps that production plant managers can take to minimize the risk of foodborne pathogens. Being familiar with the preventative measures, and taking steps to implement them prevents catastrophes.

Engage with Suppliers about Their Efforts to Kill or Reduce Foodborne Pathogens

Foodborne pathogens can enter a production plant on items like fresh produce received from farm suppliers. Agricultural professionals commonly use chlorine to decontaminate goods before shipping them. However, researchers used a chlorine solution on spinach leaves to assess its effectiveness in killing common types of bacteria. The team discovered that, even after chlorine exposure, some bacteria remained viable but undetectable by industrial methods.

Foodborne pathogens can originate at farms for other reasons, too. Failing to take the proper precautions during animal slaughter can introduce contaminants into meats that end up in food production facilities. Water impurities can also pose dangers.

All production plants should regularly communicate with suppliers about the actions they take against foodborne pathogens. Food safety is a collective effort. Practicing it means following all current guidance, plus updating methods if new research justifies doing so. If suppliers resist doing what’s in their power to stop foodborne pathogens, they must realize they’re at risk for severing profitable relationships with production plants that need raw goods.

Consider Using Sensors to Maintain Safe Conditions

The Internet of Things (IoT) encompasses a massive assortment of connected products that benefit industries and consumers alike. One practical solution to enhance food safety in a production plant involves installing smart sensors that detect characteristics that humans may miss.

For example, the USDA published a temperature safety chart that explains what to do with food after a power outage. Most items that people typically keep in refrigerators become dangerous to eat if kept above 40o F for more than two hours.

Food production plants typically have resources like backup power to assist if outages occur. But, imagine a cooler that appears to work as expected but has an internal malfunction that keeps the contents at incorrect temperatures. IoT sensors can help production plant staff members become immediately aware of such issues. Without that kind of information, they risk sending spoiled food into the marketplace and getting people sick.

Researchers also developed a sensor-equipped device that detects the effectiveness of hand washing efforts. In a pilot program involving 20 locations, contamination rates decreased by 60% over a month. Most restrooms at food preparation facilities remind people to wash their hands before returning to work. What if a person takes that action, but not thoroughly enough? Specialty sensors could reduce that chance.

Install Germicidal Ultraviolet Lights

With much of the world on lockdown due to the COVID-19 pandemic, many people want to know if germicidal ultraviolet lights could kill the novel coronavirus. Researchers lack enough information to answer that question definitively. They do know, however, that germicidal ultraviolet lights kill up to 99.99% of bacteria and pathogens.

Plus, these lights are particularly useful in food production because they get the job done without harsh chemicals that could make products unsafe. Ultraviolet lights can damage the skin and eyes, so you must only run them when there are no humans in the room. However, it’s immediately safe to enter the environment after switching the lights off.

These specialized light sources do not eliminate the need for other food safety measures. Think about implementing them as another safeguard against adverse consequences.

Teach Workers about Safe Practices

Food contamination risks exist at numerous points along the supply chain. Mishandling is a major culprit that could make several parties partially responsible for a foodborne pathogen problem. For example, if a person does not wear the proper gear when handling food or stores items intended for raw consumption in places where meat juices touch them, either of those things and many others could cause issues with foodborne pathogens.

As you inform employees about which procedures to take to manage the risks, emphasize that everyone has an essential role to play in keeping products free from contaminants. If workers make ready-to-eat foods, such as packaged sandwiches, ensure they understand how to avoid the cross-contamination that happens when reusing cutting boards or utensils without washing them first.

The FDA requires domestic and foreign food facilities to analyze and mitigate risks. Employee training is not the sole aspect of staying in compliance, but it’s a major component. If a person makes a mistake due to improper or nonexistent training, that blunder could have significant financial ramifications for a food production facility.

Widely cited statistics indicate that food recall costs average more than $10 million, which is a staggering figure in itself. It doesn’t include litigation costs incurred when affected individuals and their loved ones sue companies, or the expenses associated with efforts to rejuvenate a brand and restore consumer confidence after people decide to take their business elsewhere.

Ensuring that workers receive the necessary training may be especially tricky if a human resources professional hires a large batch of temporary employees to assist with rising seasonal demands. If a higher-up tells them that time is of the essence and the new workers must be ready to assume their roles on the factory floor as soon as possible, training may get overlooked. When that happens, the outcomes could be devastating. Efficiency should never get prioritized over safety.

Stay Abreast of Emerging Risks

Besides doing your part to curb well-known threats that could introduce foodborne pathogens, spend time learning about new problems that you may not have dealt with before.

For example, scientists have not confirmed the origin of COVID-19. However, since early evidence suggested live animal sales and consumption may have played key roles, Chinese officials cracked down on the wildlife trade and imposed new restrictions on what was largely an unregulated sector cloaked in secrecy.

Much remains unknown about COVID-19, and it’s but one virus for food producers to stay aware of and track as developments occur. The ongoing pandemic is a sobering reminder not to blame specific groups or ethnicities, and to avoid jumping to hasty conclusions. It’s good practice to dedicate yourself to learning about any production risks that could introduce foodborne pathogens. Read reputable sources, and don’t make unfounded assumptions.

A Collective and Constant Effort

There is no single way to combat all sources of foodborne pathogens. Instead, anyone involved in food production or supply must work diligently together and know that their obligation to prevent issues never ceases.

Roelof Koopmans, Semtech
Retail Food Safety Forum

How Technology Simplifies Food Safety Operations

By Roelof Koopmans
No Comments
Roelof Koopmans, Semtech

To get to the restaurant table, food must travel great lengths to preserve that farm fresh quality and in many cases, IoT-enabled sensors are being used to do this. This is especially important as the World Health Organization estimates that one in 10 people fall ill every year from eating contaminated food.

When we think of our favorite dish, we often associate it with delicious flavors, pleasant scents and even memories of a night out with friends. What we likely don’t consider is technology, something that’s critical in ensuring the meal on our plate is safe to consume. Technology plays an essential role in guaranteeing that restaurants are serving fresh food to customers. From identifying operational deficiencies to protecting the overall brand of an organization, there are certain measures restaurants are taking—whether local or country-wide chains—to ensure food quality remains a top priority.

Restaurants are perhaps held to an even higher standard than your local supermarket when it comes to the quality of food on the table. Therefore, it’s imperative that perishables are cared for properly throughout the entirety of the food supply chain and that starts well before the food ever enters the restaurant’s front door. With long-range, low-power wireless IoT technology, farmers can get insights into a number of variables that may impact the growth of their crops. Armed with that knowledge, they can make real-time decisions to optimize crop growth and ultimately produce a greater yield. For example, farmers today can set up a series of sensors throughout their farm to measure real-time soil conditions, including humidity and pH levels. If they notice an especially high pH, for example, they can immediately remedy the situation and provide the crop with the proper nutrients or conditions it needs to grow.

For food safely to arrive at restaurants, it must be kept in a controlled environment during its journey from the farm or warehouse, and carefully monitored during that time. The temperature of refrigerated shipping units or storage facilities is an incredibly important factor, as bacteria growth can increase even by simply opening the refrigerator door or with a slight temperature shift, and employees are often tasked with managing this. With large facilities comes increased labor for employees, which can lead to inefficient temperature monitoring. To eliminate food waste and contamination, IoT sensors deployed throughout facilities can eliminate human error, and deliver more consistent monitoring, via real-time updates when temperatures enter unsafe territories.

Numerous international food handling and food safety laws have been implemented to reduce the risk of foodborne illness resulting from bacterial growth. A major component of most “farm-to-fork” regulations is the ability to track, report and maintain appropriate temperature conditions inside refrigeration and freezer units throughout the entire cold chain—including when the food finally makes it the restaurant.

This is a universal priority for restaurants around the world, including Hattie B’s Hot Chicken, a southern-style food chain, which started in Nashville and now has locations nationwide. To successfully do this, the restaurant turned to technology. They used a supplier of wireless connectivity solutions with integrated long range, low power technology for temperature monitoring sensors. The sensors, which are capable of penetrating stainless steel doors and concrete walls, can monitor temperatures in refrigerators and freezers. This is essential, as the technology eliminates possible human error in manually checking temps and other food safety procedures. In instances where refrigerator temperatures shift out of range, the technology remotely notifies restaurant managers in real-time, allowing them to act quickly, ensuring their perishables remain fresh and safe for customers at all times.

Food waste in restaurants is closely tied to food safety. In the United States alone, food waste is estimated to be between 30–40% of the food supply, according to the USDA. In the restaurant industry in particular, human error is one of the most notable reasons for food waste. To eliminate the human error when handling food and monitoring storage, an IoT solution provider for the industrial, smart city and smart energy segments, integrated long-range low power technology into smart refrigeration solutions for restaurant applications. This IoT solution is designed for humidity and temperature monitoring, delivering real-time updates to managers to ensure the shelf life of food is maximized and it remains safe to consume, ultimately leading to a decrease in food waste.

From farm to table, technology plays an essential role in ensuring restaurants are delivering the highest quality of fresh, safe food. It allows organizations to identify operational deficiencies and reduce overall food safety risk, which is imperative when maintaining a strong business in a competitive industry.

Marc Pegulu, Semtech
FST Soapbox

Increasing Food Safety and Spoilage Prevention in the IoT Era

By Marc Pégulu
No Comments
Marc Pegulu, Semtech

According to the Food and Agriculture Organization of the United Nations, it is estimated that nearly one third of the food produced (about 1.3 billion tons) globally is not consumed. To help tackle this billion-dollar problem, an innovative solution is being deployed to detect one of the key factors driving food waste: Spoilage due to fluctuations in temperature.

To get to the dinner table, food must travel great lengths to preserve that farm fresh quality. Refrigerated shipping units and storage facilities are essential to reducing bacteria growth and by using an automated smart-refrigeration solution, a food-safe environment can be maintained throughout the journey with little supervision. Traditional food temperature monitoring is reliant on staff to periodically check temperature levels and make adjustments as necessary. This process is not scalable, meaning that with a larger facility or an increased number of food displays, it becomes increasingly labor intensive and inefficient. If employees are preoccupied, periodic check-ins may be delayed or missed entirely, leading to gaps where temperature fluctuations are not addressed, opening the door for increased bacteria growth and food waste.

LoRa fights food waste
LoRa devices and LoRaWAN protocol are being integrated into smart refrigeration solutions to fight food waste. Image courtesy of Semtech.

To solve this issue, Internet of Things (IoT) sensors can be deployed in shipping vehicles, displays, refrigerators, and storerooms to provide accurate and consistent monitoring of temperature data. When a temperature fluctuation occurs, the sensors will send a signal to a low power, wide area network (LPWAN) gateway application. The information is then relayed to a network server, where it is routed to application servers or Cloud IoT services. The data is then processed and sent to the end user through a desktop or smartphone application. What’s more, in the event of a power outage, these long range, low power wireless enabled IoT devices are battery powered and consume minimal energy, allowing for consistent off-grid temperature tracking.

These connected devices can be found globally in a variety of use cases ranging from quick service restaurants to full service grocery stores, with an end goal of ensuring appropriate temperature levels for food. To support connectivity for these devices, an open network protocol is used to ensure the devices can be scalable and globally deployed. Two recent use cases where the long range, low power wireless devices and LoRaWAN protocol were used to actively monitor temperature fluctuations are Axino Solutions (Axino) and ComplianceMate.

Axino recently integrated LoRa devices and LoRaWAN protocol into its line of smart refrigeration solutions with the goal of combatting food waste. The solution combines sensor technology with automated data communication providing a substantial increase in measurement quantity and quality. Additionally, stores found a significant reduction in metering and operating costs after sensor deployment. This smart refrigeration solution has been globally deployed and is currently used by Switzerland’s largest supermarket chain, Migos. Axino’s sensors can be quickly installed, utilizing a magnet to attach to a refrigerator’s infrastructure. The sensors monitor temperature in real time, are accurate to one degree Celsius and can be pre-programmed to adjust refrigerator temperatures to ensure that food is stored in a safe environment. By having access to real time data and automatic temperature adjustment, supermarkets were able to eliminate human error, prolong shelf life and pass energy savings off to the customers.

The challenge for any wirelessly connected device is the presence of physical barriers that will block signals. Steel doors, concrete and insulation are some of the key considerations when developing a smart solution, especially in restaurants using large freezers. ComplianceMate partnered with Laird Connectivity and found that devices on a LoRaWAN-based network produces a more reliable signal than its Bluetooth counterpart. This IoT solution has been deployed in some of your favorite restaurant chains such as Shake Shack, Five Guys, Hard Rock Café, City Barbeque, and Hattie B’s and has already proved to be a huge asset. For instance, a sensor deployment saved $35,000 to $50,000 worth of inventory in a Hattie B’s location when downtown Nashville experienced a sudden power outage in 2018. The LoRa-based alert system immediately notified store management, allowing them to act quickly and prevent food spoilage.

Reducing global food spoilage is a monumental task. From farms to grocery stores and restaurants, technology must play a critical role, ensuring food remains at a safe temperature, preventing unnecessary spoilage. In the era of connectivity, businesses will turn to LoRa-based IoT deployments for its flexibility, durability and ability to provide real-time information to employees and decision makers to not only maintain strict industry standards in food safety, but to also pass savings on to their valued customers.

Francine Shaw, Savvy Food Safety, Inc.
Retail Food Safety Forum

How Technology is Elevating Food Safety Practices & Protocols

By Francine L. Shaw
No Comments
Francine Shaw, Savvy Food Safety, Inc.

Technology is elevating food safety practices and protocols, and will help reduce or eliminate food safety incidents and outbreaks in the future. However, a major challenge will be getting food businesses to adopt these tech tools. Food service companies have been slower than other industries to adopt technology, preferring instead to do things “the way they’ve always done them”— often using antiquated pen and paper systems to track food safety standards. Often, food business owners are worried about the cost and implementation of tech solutions, fearing that they’ll be too expensive and/or complex for them to manage.

Something has to change in our industry. Food recalls are on the rise—recently with a huge nationwide romaine lettuce E. coli outbreak and recall. Even a big name packaged breakfast cereal was recently recalled for possible contamination.

America’s food industry has a $55.5 billion safety problem annually, as reported by Fortune magazine (This information was gathered from a 2015 study by Robert Scharff,  an associate professor at Ohio State University, who estimated that foodborne illnesses cost $55.5 billion per year in medical treatment, lost productivity, and illness-related mortality in the United States). This includes foodborne illnesses at restaurants and retailers, food recalls, and other food safety issues.

The CDC reports that 48 million Americans become sick, 128,000 are hospitalized, and 3,000 die from foodborne diseases each year in the United States. Therefore, investing in food safety is one of the smartest things that food service organizations can do. The expense, time and energy necessary to implement—or elevate—your organization’s food safety protocols won’t be overwhelming, and it’s crucial to your business’ success.

Foodborne illnesses are expensive and damaging for businesses. Having a foodborne illness incident or outbreak can cost significant money—including decreased revenues, hefty legal fees, potential lawsuits, diminished sales (and loyalty) from guests afraid to visit the (possibly contaminated) restaurant or store, and a damaged reputation that could permanently shut your doors.

TraceGains Sponsored Content
Are you ready to better leverage your data? With TraceGains, customers accelerate product time to market and boost regulatory compliance performance. Suppliers are significantly aided in their daily activities by working within one common user-interface for many of their customers, completing questionnaires once and leveraging our PostOnce™ technology to automatically share those documents with all necessary customers. It’s your data. Use it. See what TraceGains can do for you!

Food safety should be part of every company’s culture. Everyone—on every shift—should be trained in proper food safety protocols. And, since tech solutions have become more accessible and mainstream, more food businesses should adopt and use them.

The latest technologies are elevating the way many food service businesses operate. Not only do these technological tools make food safer, but they can also save restaurants, convenience stores, hotels and other food service companies a tremendous amount of money each year.

Technological solutions enhance food safety protocols and make it faster, more accurate, and more efficient to conduct inventory, auditing, training and keep food safe. Investing in technology is something that all food businesses should do to help boost the health and safety of their establishments.

Nothing will negatively impact your organization’s brand and reputation more than a foodborne illness outbreak. While human error can never be completely eliminated, advancements in technology help minimize the risks. Some innovative developments include:

  • Sensors. Sensors ensure foods are being held at proper temperatures. For instance, centralized, continuous refrigeration monitoring systems signal when temperatures in coolers or freezers rise above safe holding temperatures, eliminating the need to throw away entire coolers or freezers of food due to improperly working units. As a result, businesses can save thousands of dollars (or more) in lost product and potentially save lives by storing cold foods properly.
  • Digital auditing tools. Innovative digital tools can now be used for food companies’ internal auditing systems, which is a more efficient, cost-effective and accurate solution versus the pen and paper methods that are often (and widely) used in the food service industry. Using pen and paper to audit restaurants, hotels, institutions and stores often results in increased labor, time, errors and expenses. Additionally, hard copy records can be hard to organize and access—and it’s extremely difficult to integrate and analyze the data. Digital tools provide more efficient, cost-effective internal auditing systems, with records that are easy to access and analyze.
  • Mobile solutions. The food service industry is comprised of many employees from younger generations (e.g., millennials and Gen Z), and these populations have grown up on their smartphones. Now, food businesses can leverage digital tools that can be used on cell phones and tablets, which is an easy and effective way to engage younger employees. Many companies are providing downloadable apps that enhance the way food service employees conduct inspections, keep temperature logs, conduct training, manage QA forms, access food code information, and more. Critical food safety information can (literally) be at employees’ fingertips.

These (and other!) tech solutions offer significant benefits to food service businesses, including:

  • Boosting operational systems. Digital tools can help with brand protection and quality assurance concerns by optimizing and improving line checks, shift logs, inspections, auditing and other reporting.
  • Improving the bottom line. Investing in technology boosts companies’ operational efficiencies, which has been proven to improve their bottom line. Technology tools can reduce or prevent food spoilage, reduce labor costs and help avoid foodborne illnesses.
  • Reducing fraud. There’s a widespread “pencil whipping” problem in the food service industry, where employees using paper record systems falsify records or “cheat” on their processes. As much as food service leadership wants to deny that “pencil whipping” happens in their organizations, it’s (unfortunately) a fairly common practice in restaurants, convenience stores and other industry businesses. Pencil whipping can result in increased food safety risks, food code violations and other (potentially costly) issues. Digital tools can help reduce or eliminate “pencil whipping” through real-time data collection, and visual records using photos and videos.

While technology has previously been considered to be a luxury, today, digital tools are affordable, widespread and accessible. Technology that can help minimize labor, reduce (or eliminate) foodborne illness risks, and minimize food waste is not an expense, it’s an important investment.

Technology streamlines operations, improves safety protocols, reduces errors, integrates data—and so much more. The benefits are huge. Often, food service owners tell me that they can’t afford the investment, or that they’re overwhelmed about how to find and implement the right system. I reassure them that it’s truly easier than ever to incorporate tech tools into food companies, and it’s one of the smartest things companies can do. Innovative technology tools are critical to keeping foods, consumers and businesses healthy and safe.