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GFSI, BRC, SQF and beyond: Where food safety is heading and packaging’s role in getting us there
Dr. Claire Koelsch Sand Founder and Owner, Packaging Technology and Research
Adjunct Professor, Michigan State University
2015 Association of Dressings and Sauces Technical Meeting
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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Acknowledgements• Dr. Ted Labuza• Department of Food Science and Nutrition University of
Minnesota • Dr. Tonya Schoenfuss• Department of Food Science and Nutrition University of
Minnesota • Dr. John Spink• Director of Food Fraud Initiative Michigan State University
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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GFSI continues to be relevant2000
“continuous improvement in food safety management systems and ensure confidence in the delivery of safe food to consumers
worldwide”
2007
2015Version 7 launches
GFSI 5
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GFSI: harmony, transparency efficiency, save $Goals• harmonize worldwide food safety standards • increase transparency• efficiency in the supply chain• cut costs for manufacturers
GFSI goals
Best Practices
GFSI Schemes
ISO 22000
Food Laws and Regulations
Codex – HACCP - GMP
6
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GFSI: certifiers
British Retail Consortium
Food Safety System 22000
International Food Standard
Safe Quality Food
7
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Dominates in USA food packaging
1994 developed in Australia2000
Food Marketing Institute (FMI)
2004GFSI approved at level 2 2014
3 unannounced audits
GFSI: SQF8
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Dominates in USA food packaging
GFSI: SQF9
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Gaining ground in USAGFSI: BRC
22,000 certified suppliers in 123 countries
10
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FSSC 22000 Ideal if prior certified ISO 22000
9000+ organizations in 146 countries
GFSI: FSSC 22000
PAS 220
ISO 2200
0
FSSC 2200
0=+
11
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IFS often linked with BRCGFSI: IFS12
(25)
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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How are we doing?
Goals were to: Harmonize worldwide food safety standards
Increase transparency
Improve supply chain efficiency
Cut costs for manufacturers
GFSI: assessment14
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Food safety standardized• Standards and holistic approaches guide industry
• Food safety on radar• Increase in budgets• Combine food safety into HHS
• Food safety now has a common language
• Import knowledge and transparency demands are up
GFSI: assessment15
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Food safety declined for G20 in 2014
(17)
GFSI: assessment16
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Food safety up and down globallyGFSI: assessment17
(17)
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Salmonella declined 38% in EU
(18)
Salmonella declined 38% in EU since 2008
GFSI: assessment18
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Food safety continues to be an issueGFSI: assessment19
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2 classes of foods more discernable
(17)
GFSI: assessment20
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2 classes of foods more discernable
GFSI: assessment21
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Supply chains and manufacturing efficiencies not realized - yet• Motivation to pursue GFSI:• 70% to meet customer requirements • 30% to pursue GFSI to address food safety
• Company audits take resources and time:• 80% companies see no reduction in company audits• Suppliers now need to comply with unannounced SQF
and company audits• Small players bear proportionally higher costs to be
GFSI certified
GFSI: assessment22
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Manufacturer costs may be lowerGFSI: assessment23
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Dressings & sauces - positive results from GFSI
• Dressings and Sauces are a unique packaged product• Lower inherent food safety risk• Packaging consistency making packaging COC tenuous• Multiple ingredients sources increases risk• Packing frequency creates sourcing challenges• Shelf life and oil present issue for unintended migration
from packaging
GFSI: assessment24
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GFSI: status
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Dressings & sauces - positive results from GFSI• Outbreaks threaten stability• Consume time and
resources• Shift company focus• Impact of prevented
outbreaks cannot be measured
• Industry connected by skus and brands
• Liability and legality
GFSI: assessment26
Recent cases• Hummus• Ice cream• Peanuts• Ingredients
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Dressings & sauces - positive results from GFSI
• Audits not equal• 3rd party audits not all equal• FSMA section 307 will equalize
• Pass rates on company audits likely higher• FSMA implementation for GFSI complaint food
manufacturers and packaging suppliers much smoother
GFSI: assessment27
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Dressings & sauces - positive results from GFSI• Consolidation decreased sourcing options• Food safety to more equal footing for large and small
manufacturers• Focused food and packaging industries
GFSI: assessment28
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Net: GFSI is working but much more to do• Industry• Food industry doing what needs to be done for food
safety• Increased realization on bad apples
• Packaging suppliers can do more• Smaller companies benefit most
• Food safety is a strategic advantage
“Foodborne diseases impede socioeconomic development by straining health care systems and harming national
economies, tourism and trade. Food supply chains now cross multiple national borders.” (WHO)
GFSI: assessment29
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• Complexities in abundance
• GFSI will have a positive long term impact
GFSI: assessment
Net: GFSI is working but much more to do
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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Refocus on food fraud and what is next
• Refocus to address food and packaging fraud
• Align value chain to address fraud and then to meet next challenge
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Food fraud is economically motivated (EMA)
ActionIntentionalUnintentional
HarmPublic Health, Economic, or
Terror
FOOD DEFENSE
FOOD SAFETY
Economic FOOD FRAUD
FOOD QUALITY
Food fraud-what’s now
Mot
ivat
ion
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Food fraud prevalence increasing•Global Food fraud ~ $50 billion (3)•10% US food adulterated (4)
Food fraud-what’s now34
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Food fraud prevalence increasing• 10 of 117 countries are responsible for 60% of all food fraud
Current food of concern• Seafood:
• "Sturgeon caviar" was MS paddlefish• Catfish fillets replaced expensive
fish• 77% of USA snapper mislabeled
• Cumin• Honey diluted with beets or corn
syrup• Protein source products • Olive oil• Coffee• Tea• Wine: Pinot Noir from merlot & syrah
grapes
Current packaging of concern• Recycled paperboard• PP • RPET • Laminate layers
Food fraud-what’s now35
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Food fraud increase due to 3 main factorsFood fraud increase is due to:
Consolidated buying that enables:• Focus on lowest ingredient costs that tempts fraud• Technology to covertly transact illegitimate deals• Impedes traceability
Unharmonious regulations• Lack of enforced processing regulations in much of
world• GMO to produce bioplastics
Increase refrigerated distribution for long-term perishables• Increased need for and rising cost of product
stability• Increased value of food
Food fraud-what’s now36
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Impacts of food fraud• Declining public trust in packaged food
• Loss of country of origin business
• Increased funds for further fraud
• Loss of brand value
• Companies become enforcers
Food fraud-what’s now37
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Food fraud varies
(7, 12)
Food fraud-what’s now38
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Food fraud exampleDeliberate intent by senior management to deceive customers was Adulteration & Tampering (5)
1. “Acceptable” mix ratios defined within a manual • Mixing expired meat with fresh meat • Mixing chicken skin with breast meat
2. Cunning was a source of pride • Concealing suspect stock from quality inspectors• Altering expiration dates
3. Quality control department recorded fraudulent practices • Dual sets of records kept
– one for the inspectors and one for company
Food fraud-what’s now39
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Tortuous Meat fraud
(13)
Food fraud-what’s now40
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Food packaging fraud also economically motivated
Packaging fraud-what’s now
Highly competitive and industry• Competitive converters have same
suppliers• Long term contracts• Raw material prices flux
Goals not align with customer• “Meet” environmental goals• Shelf life and migration data not
obtainable
Manufacturing efficiencies• Long material runs
• Substitute materials• Additives to speed up
production• Temptation to expand tolerances
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PET viable to fraud• Replace RPET with PET as prices fluctuate• Lack of harmonization on food contact• EU position paper - food contact RPET if <5% of RPET non-
food sources• RPET COC unsteady• RPET demand exceeds supply• RPET vs PET discernable by DSC
Packaging fraud-what’s now42
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Dressings & sauces packaging vulnerability• Understanding motivation is key• Profit• No punishment• Low risk
• Consistent packaging COC• Long shelf life• Infrequent and established pack dates• Similar to OTC medicine
• Complexities of ingredient hamper:• Tracing• Knowledge of fraud (melamine example)
Packaging fraud-what’s now43
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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How to Refocus and address food fraud
1. Embrace GFSI version 7
2. Implement FSMA
3. Add FSMA packaging elements
4. Focus packaging innovation on prevention and prediction
Refocus to address food fraud
detection & mitigation prediction & prevention
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Embrace GFSI version 7Begins to address food fraud
Refocus to address food fraud
GMA
FSMA
ISO TC 247
Food Chemicals Codex
EP/EU Resolution and Interpol
Corporate Processes and systems6 sigma and Enterprise Risk
Management
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Support whistle blowingWhistle blowing most frequent ID of fraud
Refocus to address food fraud47
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Implement FSMA• New Focus on prevention in:• SEC 101. INSPECTIONS OF RECORDS.• SEC 102. REGISTRATION OF FOOD FACILITIES.• SEC 103. HAZARD ANALYSIS AND RISK-BASED PREVENTIVE CONTR
OLS.• SEC 104. PERFORMANCE STANDARDS.• SEC 105. STANDARDS FOR PRODUCE SAFETY.• SEC 106. PROTECTION AGAINST INTENTIONAL ADULTERATION.• SEC 108. NATIONAL AGRICULTURE AND FOOD DEFENSE STRATEGY.• SEC 109. FOOD AND AGRICULTURE COORDINATING COUNCILS.• SEC 110. BUILDING DOMESTIC CAPACITY.• SEC 111. SANITARY TRANSPORTATION OF FOOD.• SEC 112. FOOD ALLERGY AND ANAPHYLAXIS MANAGEMENT.• SEC 115. PORT SHOPPING.
Refocus to address food fraud
• Fraud direction pending
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Implement FSMA’s expanded HACCPHACCP is adaptable to thwart food fraud
5. Review & Adjust
1. Identify Hazard 2.
Understand Cause
3. Implement Preventive Controls
4. Monitor Effectiveness
Refocus to address food fraud49
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Use FSMA’s VAVulnerability Assessment focuses efforts with attention to motive
Criticality • Measure of public health & economic impacts of an attack
Accessibility • Ability to physically access and egress from target
Recuperability• Ability of system to recover from an attack
Refocus to address food fraud50
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Use FSMA’s VAVulnerability • Ease of accomplishing attack
Effect • Measured by loss in production
Recognizability • Ease of identifying target
Shock • Combined health, economic and psychological impacts of an attack
Refocus to address food fraud51
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Use same solutions for packaging & food fraud
Refocus to address food & packaging fraud
detection & mitigation prediction & prevention
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Add packaging to FSMA • Perform risk analysis• Biopolymers derived contaminants – plant fibers and
allergens• Conversion process – laminations, coextrusions• Effect of post package processing - Irradiation/HPP• Extraction protocol
• Reassess packaging specifications• Tight and too loose windows• Identify critical aspects to fraud
Refocus to address food & packaging fraud53
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Add packaging to FSMA Add packaging to FSMA now• Establish supplier testing protocol • Extraction for food contact
(15)• EU guidelines (14)
• Complete traceability• Lots, lines, location,
transport, storage
Refocus to address food & packaging fraud54
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Add packaging to FSMA Add packaging to FSMA now• Emphasis on material documentation• Documentation and recall linked to packaging• Minimize the damaging effects to human health and brand
reputation
• Consider changes that alter dynamics• Supplier financial pressure• Price fluctuations• Disasters• Global strife and success
Refocus to address food & packaging fraud55
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Packaging innovation for prevention & prediction
• Begin tracking packaging before food is packaged• Address diversion• Selective monitoring• Load monitoring
detection & mitigation prediction & prevention
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Use packaging prevent & predict after VA• Assess innovations on prevention & prediction• Overt is a deterrent and prevention
RFID
Coded track and trace Integrated with tamper evidency
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Use packaging prevent & predict after VAAssess package innovations on prevention prevention & predictionCovert is less of a deterrent and more of detection
Combine covert selectively to verify overt• Steganography• Digital watermarks• Coatings and hidden marks• Covert RFID
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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Need value chain as an operational solution
raw materials for packaging
converted packaging
manufacturedpackagingcomponents
Combinedproduct andpackage
distributedproduct and package
soldproduct and package
discardedproduct and package
Food Packagin
gValue Chain
Interfaces
• Beyond food safety and food fraud there are quality and defense and other challenges
• Need robust system to address all challenges
• Food packaging value chain aligns to meet challenges
• Link of food and packaging is critical
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Technology & regulations offer partial solutions
• Technology offers temporary solutions
• Regulations offer inflexible solution
• Value chain offers operational solution linking food and packaging
Align value chain to address fraud & next challenge
Regulations
Technology
To increase food safety and decrease fraud:
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Valu
e ch
ain
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Connect tangibly within value chainUse value chain to connect food safety and food fraud to packaging by:
1. Inspiring
2. Building tactic knowledge
3. Sharing work and value
4. Rewarding significance
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Build tactic knowledge and trust within value chain
• Knowledge means value is understood
• Build tactic knowledge with food and package suppliers• Expand existing initiatives with safety and fraud focus• Link on goal of decreasing fraud and increasing safety• Build knowledge at all levels• Build trust at all levels
• Build operational processes to align and transfer knowledge that thwart fraud and increase safety
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Lack of trust is an expensive way to run a business• 85 % of consumers do not trust the words spoken by a
corporate executive (16)• Many consumers are executives
• Employees and management conduct or are complicit in:• Poor food safety practices • Intentional food fraud
• Safety and fraud are often money driven and relate to poor ethics
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Share value in an expanded value chain• Shared value links societal issues (safety and fraud) to
business needs
• Expand partners to increase value of working relationships• To address food safety and fraud now• To address next issue
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Shared values link with fraud and safetyIncreasing food safety and decreasing food fraud relate to many concerns:
• Decreased unsaleables• Reduced product diversion and counterfeiting• Tighter chain of custody• Reduced out-of-stocks• Brand erosion• Environment• Product utility
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Reward significance within value chain• Food ingredient and packaging suppliers can not sustain
and or improve safety and address fraud if:• Focus is solely on price• Product is commoditized • They are marginalized
• Just as our brands cannot
• Link rewards to prevention and protection of fraud and food safety
• Provide economic incentive to traceability and COC
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Expand the value chain • Minimal links to externals that address value
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• Create links that are meaningful safety and fraudExpand the value chain
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Value chain to improve microbial safety -example• Situation: Product microbial level so high HPP/irradiation
can not reduce it effectively
• Need to address problem for this plant and others
• Focus on prevention and protection
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Value chain to improve microbial safety - example
5. Review & Adjust
1. Identify Hazard 2. Understand
Cause
3. Implement Preventive Controls4. Monitor
Effectiveness4. Monitor Effectiveness
Expand knowledge base: lack of clean water sources on manufacturing site and in homes
Expand Knowledge base:water borne contaminationpackage seals not consistent
Share work: design an provide clean water sources for homes and manufacturing, address tactic knowledge on washing, manufacturing HACCP, water testing
Share work: Track and stress test
Reward significance: refined relationship with suppliers anchored on safety
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Value chain to reduce recalls – tactical example• Situation: Costly recalls due to repeated product off-
flavors
• Focus away from detection and mitigation to prevention and protection
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Value chain to reduce recalls – tactical example
• Already had COC tactic links with suppliers for sourcing, tracking processes, verification, recall processes
• Expanded knowledge:• Product contaminated from package
• Shared work:• Link migration data to supplier’s converters • Expanded value chain connected on final
product use and sensitive flavor profile• Converter financials and motivation• Prevention vs detection
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Value chain holds in a vuca world• Volatile • Dynamics of change• Catalysts
• Uncertain • Missing predictability
• Complex• Chaos slightly at bay
• Ambiguous • Hazy reality• Misreads
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Agenda1. What are we doing and why ? • GFSI’s meaningful role in packaged food
2. How are we doing?• GFSI assessment
3. What do we need to do now?• Address Food and packaging fraud
4. How can we do this?• Refocus to address food & packaging fraud • Align value chain to address fraud & next challenge
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Checklist Insist upon GFSI Version 7 compliance Implement FSMA with packaging initiatives Forecast vulnerability Assess packaging technology with focus on prevention &
prediction Refine and develop operational solutions
Connect food and packaging within the Value Chain Continue to expand issue to pervade relationships within the value
chain Build trust and align to deliver meaningful packaging innovation Expand to connect with NCFPD and FFI
Share value and work Consider food safety and fraud as a social issue Identify key and critical packaging and food suppliers Develop shared library (ingredients and audit information)
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Relevant Sources and References• Food Fraud Initiative at Michigan State University • National Center for Food Protection and Defense (NCFPD) at University of Minnesota
1. Lupien, J., 1997. Food packaging, international standards related to food safety and quality, and trade. Food Additives and Contaminants, Vol. 14, No. 6-7, 519-5272. Sand, C.K. 2015. Bringing in Innovation with the Packaging Value Chain. IFT Webcast February 26, 2015. 3. José Cuesta, J., Htenas, A., and Tiwari, S., 2014. Monitoring global and national food price crises. Food Policy 49: 84–944. NSF, 2014. The ‘new’ phenomenon of criminal fraud in the food supply chain White Paper.5. 2014-07-21 08:11 Shanghai Daily Web Editor6. Brody, A, Sand, C. Sabbagha, F., 2014. RFID in Packaging using Value Chain. Food Technology. October 7. Spink, J. and Moyer, D., 2011. Developing a Food Fraud Prevention Program. MSU Food Fraud Initiative8. Reig, C., Lopez,A.D., Ramos, M.H., Ballester, V., 2014. Nanomaterials: a Map for Their Selection in Food Packaging Applications. Packag. Technol. Sci. 27: 839–8669. Percy, B., 2011. GFSI Compliance and Automated Food Safety Management Systems. Cereal Foods World. 56, 4; pg. 14410. Busta, F., 2011. Defending the safety of the global food system from intentional contamination. National Center for Food Protection and Defense. University of Mn.11. National Center for Food Protection and Defense12. Spink, J. and Moyer, D., 2011. Defining the Public Health Threat of Food Fraud. Journal of Food Science Vol. 76, Nr. 9, 13. adapted from Guardian14 http://ec.europa.eu/food/food/chemicalsafety/foodcontact/eu_legisl_en.htm
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15.http://www.fda.gov/Food/GuidanceRegulation/GuidanceDocumentsRegulatoryInformation/IngredientsAdditivesGR ASPackaging/ucm081818.htm16. 2013 survey by public relations agency Edelman17. http://foodsecurityindex.eiu.com/18. The European Union summary report on trends and sources of zoonoses, zoonotic agents and food-borne outbreaks in 2013. 2015. European Food Safety Authority & European Centre for Disease Prevention and Control. EFSA Journal 2015;13(1):399119. Consumer Product Fraud: Deterrence and Detection. AT Kerney, 2010.20. Chen, E., Flint, S., Perry, P., Perry, M., and Lau, R., 2015. Implementation of non-regulatory food safety management schemes in New Zealand: A survey of the food and beverage industry. Food Control 47: 569e57621. Mensah, L.D., Julien, D. 2011. Implementation of food safety management systems in the UK. Food Control 22 1216e122522. Exploring new values and new directions in the Forest, Paper & Packaging industry., 2011. PWC.24. http://www.brcglobalstandards.com/25. http://www.ifs-certification.com/index.php/en/23. SQFI.com26. http://www.informationclearinghouse.info/article36743.htm27. Spink, J., 2006, The Counterfeit Food and Beverage Threat, Association of Food and Drug Officials (AFDO), Annual Meeting.28. ACFE, 2012. Report to the Nations.29. US Patent 8,674,834,132.30. Sand, C., 2007. Packaging Value Chain. DesTech Publishing.
Relevant Sources and References