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Cover Story pg. 8

www.foodmanufacturing.com ■ June 2012

With investments in custom equipment and a foot firmly rooted in history, Colony Brands has grow its mail-order bakery business into one of the largest in the country.

Also Inside

Vol. 25, No. 5

IcingIcing on on thethe CakeCake

12 Tech Niche: Drives/Motors

16 Incident Report: Averting DisasterThe food industry disasters of 2011 can teach food processors important lessons about how to keep their facilities safe.

22 Brainstorm: Frozen PackagingIndustry experts weigh in on meet-ing consumer demands for reduced packaging in frozen processing applications.

24 Exclusive Feature: Dust Collection DesignEfficient dust collection systems and easy-to-clean production equipment require a holistic approach to their design.

26 Spotlight On: Feeding

30 Exclusive Feature: The Inside Dirt On CIPDone right, Clean-in-Place can save time and money; done wrong, and the results could be a real mess.

32 Questions and Answers: Michael Antinone from General Mills talks about the company's new, more open approach to product development.

42 Industry Insider: BakerySanitary design standards for bakery equipment are on the way.

7 What's The Buzz? — Insiders reflect on the latest news

38 Product Review — Latest Product Releases

36 HACCP Update Reader Survey — Juice Processing

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Notice to Subscribers: We permit reputable companies to send announcements of their products or services to our subscribers. Requests for this privilege are examined with great care to be sure they will be of interest to our readers. If you prefer not to receive such mailings, and want your name in our files only for receiving the magazine, please write us, enclosing your current address mailing label. Please address your request to Customer Service, P.O. Box 3574, Northbrook, IL 60065-3574.Printed in USA: Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained here-in, regardless of whether such errors result from negligence, accident or any other cause whatsoever. The editors make every reasonable effort to verify the information published, but Advantage Business Media assumes no responsibility for the validity of any manufacturers' claims or statements in items reported. Copyright ©2012 Advantage Business Media. All rights reserved.

The Advertising Index is provided as a reader service. Although every attempt has been made to make this index as complete as possible the accuracy of all listings cannot be guaranteed.

4 CONTENTS www.foodmanufacturing.com

AD INDEX

June 2012

June 2012 ■

Advanced Detection Systems ..............................9Allied Blending & Ingredients .............................17American Wholesale ..........................................41AZZ Inc ...............................................................18Baldor Electric Company ...................................27Bel-Ray Company ..............................................13Big Ass Fans Company .....................................21Bosch Packaging Technology ..............................3Brookfield Engineering ......................................23Bunting Magnetics Company ...............................7CDC Software ....................................................19Clarion White Oils ................................................5Dorner Manufacturing Corp ...............................14

Dynamic Conveyor Corporation .........................41Eriez Manufacturing Co .....................................44FTNON USA Inc ................................................16Gamajet Cleaning Systems ...............................10Goff's Enterprises ...............................................23Grainger ..............................................................15GreCon Inc .........................................................20Kamflex Corp......................................................39Kelly Container ...................................................41K-Tron America Inc ............................................35Leem Filtration Products Inc. .............................41Lubriplate Lubricants Company .........................29Material Transfer & Storage Inc .........................37

Omega Engineering Inc. ................................2, 33Perfex Corporation .............................................28Pfannenberg USA ..............................................34Polyguard Products ............................................12Rogers Machinery Company Inc .......................26Ross, Charles & Son Company .........................41schenckAccuRate ...............................................11Sioux Corporation ..............................................40Sprayon ..............................................................25Sterling ...............................................................22Tuthill Vacuum & Blower Systems......................31Wabash Power Equipment Company ................41

8 Cover Story: A commitment to food safety has met with a traditional product catalog and state-of-the-art production techniques to help Colony Brands, Inc. grow into one of the largest mail-order companies in the nation.

12 Tech Niche: Drives/Motors

16 Incident Report: Averting DisasterThe food industry disasters of 2011 can teach food processors important lessons about how to keep their facilities safe.

22 Brainstorm: Frozen PackagingIndustry experts weigh in on meeting consumer demands for reduced packaging in frozen processing applications.

24 Exclusive Feature: Dust Collection DesignEfficient dust collection systems and easy-to-clean production equipment require a holistic approach to their design.

26 Spotlight On: Feeding

30 Exclusive Feature: The Inside Dirt On CIPDone right, Clean-in-Place can save time and money; done wrong, and the results could be a real mess.

12 Questions and Answers: Michael Antinone from General Mills talks about the company's new, more open approach to product development.

30 Industry Insider: BakerySanitary design standards for bakery equipment are on the way.

7 What's The Buzz? — Insiders reflect on the latest news

38 Product Review — Latest Product Releases

42 HACCP Update Reader Survey — Juice Processing

IcingIcing on on thethe CakeCake

FM1206_TOC.indd 4 5/24/2012 7:41:22 PM

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Despite the unceremonious death of Pepsi’s Pepsi Edge and Coca-Cola’s C2 — lower-calorie bever-ages that fizzled out in the mid-2000s — the

soda giants are again launching mid-calorie products and hoping that this time, the market is ready.

Consumers can already find Pepsi Next on store shelves across the country, and soon they’ll find Coca-Cola’s Sprite Select and Fanta Select alongside it. Pepsi Next bills itself as a mid-calorie soda, clocking in at 60 calories and with 60 percent less sugar than the real deal.

Coca-Cola’s own mid-calorie offerings, due out later this year, will employ a combination of sugar and zero-calorie sweeteners like Truvia in an attempt to create a taste closer to full-calorie beverages without packing the same calorie punch.

This should be a familiar story. In 2004, both soft drink juggernauts released mid-calorie bev-erages — Pepsi Edge and C2. By 2005, Pepsi had already discontinued production, and, after sluggish sales, Coca-Cola ceased production of its own mid-calorie beverage in 2007.

So what has changed in the past half-decade? A lot, actually; a number of industry and con-sumer factors have changed since the soft drink giants last took a stab at calorie reduction.

Obesity Takes Center Stage. America’s obesity epidemic has been growing for quite some time. But recent efforts by public health organizations and the First Lady have brought the issue front and center. Consumers looking to shed some pounds without sacri-ficing the sweet taste they love might be more inclined to try mid-calorie options than they would have just a few years ago.

Sugar Is Toxic These Days. A lot has been made of recent studies suggest-ing that, at Americans’ average level of consumption, sugar is not just bad for you, it’s toxic. Consumers are being fed the message that though calorie reduction is important to curb rising obesity levels, it’s also important in its own right. For the health-conscious who just can’t give up on soft drinks entirely, mid-calorie beverages may offer a neat compromise that cuts sugar intake.

Sweetener Innovations. It’s not just aspartame or sucralose anymore. Over the past several years, a proliferation of zero-calorie, natural sweet-

eners have flooded the market, offering calorie-conscious consumers new alternatives. And these aren’t your mother’s zero-calorie sweeteners. Coca-Cola has announced plans

to use Truvia, a zero-calorie sweetener derived naturally from stevia leaves, in its forthcoming Sprite Select and Fanta Select products.

Process Innovations. Ingredient and consulting companies have grown savvier over the past several years, digging in to R&D manipulations like texture analysis and flavor optimiza-tion. Cargill has specifically targeted the reduced-calorie soft drink market with TasteWise, a technology it bills as a way to “enable beverage manufacturers to deliver better-tasting, reduced-calorie products to consumers by optimizing the balance of texture, sweet-ness and flavor.”

As consumer attitudes evolve, process solutions adapt to meet them. Early indicators are that Pepsi and Coca-Cola might have a bet-ter shot at mid-calorie success this time around. ◆

EDITOR'S NOTE6www.foodmanufacturing.com

June 2012 ■

Volume 25, No. 5973-920-7000 • Fax: 973-920-7531

Vice President of SalesTOM LYNCH • 973-920-7782; Fax [email protected] Editorial DirectorJEFF REINKE • 973-920-7784; Fax: [email protected]

EditorKRYSTAL GABERT • 973-920-7020; Fax: [email protected]

Associate EditorLINDSEY COBLENTZ • 973-920-7795; Fax: [email protected]

Production ManagerSUSAN FRANK • 973-920-7158; Fax: [email protected]

Contracts CoordinatorKAREN MULRENAN • [email protected]

Art DirectorLARRY CORBY • [email protected]

Web Production SpecialistMARCELLUS SCHOOLER • [email protected]

Customer Service SupervisorALYSSA MCCARTHY • [email protected]

Circulation ManagerGAIL KIRBERGER • 973-920-7482; Fax: [email protected]

List Rentals/Account ExecutiveSTATLISTICS Jen Felling - Postal/Telemarketing • 203-778-8700, ext.138Turk Hassan - Email Lists • 203-778-8700, ext. 144

ReprintsThe YGS GroupJESSICA STREMMEL • 717-505-9701, ext.105Reprint Division3650 West Market Street • York, PA 17404 [email protected]

Advisory BoardANDY JUAREZ, Engineering Manager, Tree Top Inc.MIKE SCHMID, Managing Partner, Wolfgang Candy Co.STEVE VAN TASSEL, CEO, Weetabix North AmericaCRAIG SHIESLEY, General Manager of Silk, White Wave Foods

ADVERTISING REPRESENTATIVESNational Sales ManagerKEVIN WARD 100 Enterprise Drive, Suite 600, Box 912 Rockaway, NJ 07866-0912 973-920-7194; Fax: [email protected]

National Sales ManagerANDREA WERTZ199 East Badger Road, Suite 201 • Madison, WI 53713973-920-7774; Fax: [email protected]

CORPORATE OFFICES:100 Enterprise Drive, Suite 600 • Rockaway, NJ 07866-0912973-920-7000; Fax: 973-920-7531

Chief Executive OfficerRICH REIFF

PresidentGEORGE FOX

Vice President, Finance/Treasurer THERESA FREEBURG

Vice President, Human Resources SUSANNE FOULDS

The Rise Of The Mid-Calorie Soft Drink Krystal Gabert, [email protected]

FM1206_EditorsNote.indd 6 5/24/2012 1:51:34 PM

7

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By including provisions of the Dairy Security Act in the Agriculture, Reform, Food and Jobs Act of 2012 (Farm Bill), the committee has taken an important first step in truly reforming the dairy safety net, providing producers the tools they need to remain competitive in the global market and facilitate the industry’s growth and long-term sustainability.

— John Wilson, Senior Vice President, Dairy Farmers of America

The right to know is a fundamental right and a bedrock

American value. This November, the voters of California will surely vindicate our right

to know what’s in the food we eat and feed our children.

— Stacy Malkan, Media Director, California Right to Know campaign

While trends vary within each spirits category, much of the growth occurred at the higher end of the pricing spectrum, and we also saw increases among unique and boutique spirits. This indicates that consumers

are willing to spend for quality spirits, despite the economic trends, whether in a bar or restaurant or at a retail store. What’s more, they remain interested in

exploring new and different expressions.

— Donna Hood Crecca, Senior Director of the Adult Beverage Resource Group, Technomic

This video [from a Wyoming swine farm] was

an incredibly disturbing, saddening and horrific example of the worst

kind of animal handling. What I saw is the antithesis of every profes-

sional standard for animal care andhandling published in any industry guideline or any certification pro-

gram. I cannot imagine that anyone in the swine industry who consid-ers themselves a responsible actor could support what is seen in that video. The handling of the animals shown is scientifically and morally

indefensible.

— Dr. Candace Croney, Purdue University

I am very excited to have the 15% tariff immediately removed on American wine

exports to Korea.

— Michael Parr, Vice President of International Sales, Wente Vineyards

FM1206_WhatsTheBuzz.indd 7 5/23/2012 9:16:40 AM

June 2012 ■

8 COVER STORY

Krystal Gabert, Editor

II n 1926, Ray Kubly founded The Swiss Colony. The company began as a college project for Kubly, who bought, repackaged and sold cheeses through the mail. His cheeses were packaged in a garage and shipped in rail cars to customers across the country.

The company, now known as Colony Brands, Inc., is now one of the largest mail-order companies in the country, employing over 4,500 full-time and seasonal employees. Despite the massive growth, Colony Brands is still a family-owned company, with Kubly’s son as Chairman of the Board. The company has kept its focus on direct-marketing, mail-order distribution, and though it is now testing a small retail line, outside of an outlet store a few blocks from the company’s headquarters, Colony Brands is a strictly mail-order business.

The company ships its products — which include everything from cheese to cured meats to furniture — worldwide and operates data and call centers to take orders. Most of the company’s products ship from

Monroe, Wis., but Colony Brands also owns warehouses in Madison, Wis.; DeWitt, Iowa; Clinton, Iowa; Peosta, IA and Reno, Nev.

Key to Colony Brands’ success, the company runs its bakery operation out of its Monroe, Wis., headquarters, which has gone through several expansions, including ones in the 1960s and 1970s. During peak season the bakery employs 275 workers to produce a huge line of wildly popu-lar baked goods. The line includes over 1,200 SKUs and features Colony Brand’s petits fours; the company made and sold 43 million of the bite-sized treats in 2011.

The bakery has a lot to juggle, as nearly all 1,200 SKUs are baked in-house — not purchased from other vendors — and are hand-decorated. The special care taken to get the decoration just-so is evident in the final prod-ucts. Aaron Blask, the project engineer and maintenance manager at Colony Brands says, “It’s amazing to see the talent of the people working here.”

Colony Brands views its products as part of a family tradition; the com-pany strives to keep recipes consistent from year-to-year and to keep old

favorites in stock for generations to come. Blask says that “operating as we are now means that generations are returning” and buying Colony Brands' products as a tradition. He says consumers come back looking to find “the same product that grandma had on her table.” Because of this product loyalty and repeat business, 75 percent of the company’s catalog offerings are part of its historical product line.

New innovations meet traditional products

This devotion to traditional baked products doesn’t mean that Colony Brands is stuck in the past, however.

Through strategic investment in custom equipment and with an eye on tradition, quality and food safety, Colony Brands, Inc. has become one of the largest mail-order companies in the U.S.

OneOne (Little)(Little) BiteBiteAt A TimeAt A Time

All finished products pass through metal detection before being packaged.

FM1206_CoverStory.indd 8 5/25/2012 7:53:34 AM

■ June 2012

www.foodmanufacturing.com

The company has recently invested in some cus-tom and state-of-the art processing equipment in order to introduce more efficiency into its produc-tion line.

Quest Industrial, LLC recently designed a cus-tom water cutter utilizing robotics for cutting large layer cakes into smaller sizes, such as petit fours. The water cutter uses individualized AutoCAD designs to cut cakes in about 23 seconds. This cutting time is down from one and a half minutes using the company’s old system.

Blask says that Colony Brands chose Quest Industrial to design the system in part because its offices are only four blocks from Colony Brand headquarters but also the for the innovations and problem solving ideas they provide. He says that engineering and R&D are always looking for “a better solution,” and working with local and domestic suppliers whenever possible means that the company can more easily secure customer service and customized solutions.

Colony Brands has also recently invested in new metal detection systems from Advanced Detection Systems. Blask says that the systems are “really cutting edge with the size of products they can see.” Because Colony Brands sells directly to the consumer, the need for unadulterated quality and consistency is paramount, and the new detection systems have size detection capabilities that are

One (Little) BiteAt A Time

A thin layer of baked cake exits a tunnel oven before being sliced into sections by a guillotine.


COVER STORY

much smaller than industry standard. In choosing the new detection systems, Colony Brands presented

challenges unique to processing the specialized kind of bakery items that feature heavily in the company’s catalog. Advanced Detection helped to create solutions for dense products like fruitcake and cheese-cake, which can be difficult to “see” into. The company also designed a power supply to reduce noise and eliminate false rejects.

Colony Brands sees its equipment demands as part of its market-ing plan. The research department is dedicated to developing recipes and patterns and discussing operating and maintenance challenges for potential new products. This team pores over recipe development and partners with quality assurance and marketing for and shelf-life testing. New and custom equipment is often ordered or designed to meet mar-keting goals targeted by this cross-functional team.

One in 43 million The company’s famous petit fours are made with a clever mix of new

technology and hands-on production. The process begins in a mixer where batter is mixed and then extruded

onto a conveyor. The batter is then conveyed through a band oven, which is adjustable for speed and temperature with a digital panel control.

After a very brief trip through the oven, the sheet of cake emerges completely baked, and a guillotine cuts the cake into large squares. The squares are conveyed through a cooling tunnel and then built into a layered cake.

The cake is built in the “bricking station,” which features a large circular conveyor. The cake layers are conveyed through the station, and buttercream or jam is hand-spread across the top. During the sec-ond trip through, another layer of cake is placed on top, followed by a second layer of buttercream or jam. This process is repeated until the desired number of layers have been achieved, and then a final layer of cake tops off the product.

These large sheet cakes are then are weighed for accuracy before being sent to the water cutter, which cuts the big cake into many small-er cakes. The slices are robotically separated from one another and run through a chocolate enrober, which covers them top and bottom.

After being coated in chocolate or confectionery coating — which the Colony Brands tempers itself — each piece is hand-decorated and

After being sliced by a water cutter, small pieces of cake are robotically separated in preparation for chocolate enrobing.

June 2012 ■


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sent through a cool-ing tunnel to set chocolate.

At this stage, each product is run through a metal detector before being individually wrapped and pack-aged. Even Colony Brands’ packag-ing equipment is specially designed for its purposes; the company has recently acquired a customized packag-ing machine to meet the growing demands of its production lines.

A safe step into the future In addition to implementing carefully

designed HACCP plans, Colony Brands has also earned ISO and GSFI certifications in order to ensure product safety.

The company’s ingredients buying department is rigorous in choosing suppliers, and each com-pany must meet the strict parameters defined by

GFSI before being contracted to provide ingredi-ents to the company.

Colony Brands is not only interested in ensuring the safety of its customers, but it is keen to protect its employees as well. Blask says that not only does malfunctioning equip-ment inhibit product safety, but it also creates unsafe and undesirable working conditions for employees. “We want to make [employees’] jobs more fulfilling by providing equipment that works,” he says.

And it seems to be working. Blask says the company employs several genera-tions of families, all of who have worked at Colony Brands for many years. Bakery Production Manager Bill Hermanson, for example, has worked for the company for 40 years.

“The people make Swiss Colony what we are,” says Blask. ◆

Sections of baked layer cake are conveyed toward a bricking station, where they'll be layered with butter-cream or jam.

The following companies have contrib-uted to the overall success of the Colony Brands Monroe, Wis., bakery facility:

• Advanced Detection Systems • CMC America• FANUC Robotics• METTLER TOLEDO Safeline• Quest Industrial, LLC • Raymond Corporation• SOLLICH KG


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12 TECH NICHE: DRIVES/MOTORS

June 2012 ■

Bearing Protection Ring Company’s line of Super-E motors with Internal AEGIS Bearing Protection Ring provides end-users with off-the-shelf availability of motors equipped with a pre-installed shaft ground. The addition of 98 ratings expands the existing 4 pole line of TEFC & ODP designs through 100 HP and adds an offering of 2 and 6 pole models, as well. While most shaft ground applications utilize a shaft ground on the outside of the motor, these units have the grounding ring factory installed internally on the motor. This internal design minimizes exposure to the outside elements and keeps the grounding ring from being damaged by external forces. Applications include heating, ventilation and air conditioning blower and fan motors, pump motors, and other general pur-pose applications using an adjustable speed drive. Baldor Electric Company www.baldor.com

Motor-To-Gearbox Online Configurator Tool The “motor to gearbox” option for Company’s online Product Configurator portal fills the gap between the popular online Product CAD Generator and the cymex® servo sizing soft-ware. The tool combines technical criteria in gearbox selection — for those designers who know their application requirements — and finishes with CAD and technical data options. This e-tool features:

Motor-to-Gearbox system configuration Application detail modification Database of over 7,000 motors Gearbox design selection

The tool is accessible at:http://www.wittenstein-us.com/tech-support/design-tools/product-configurator.cfm. WITTENSTEIN, Inc. www.wittenstein-us.com

••••

Drive Nut As a design alternative to screw-based linear drive sys-tems, the RS4 drive nut provides backlash-free linear motion and simplifies changes to linear pitch. The linear pitch of the nut is factory-set at one of five different linear pitch settings, determined by application require-ments. Pitch wedges between the drive bearings hold them at a specific angle relative to shaft. This angle de-

termines the linear pitch. Changing pitch is simply a matter of replacing the pitch wedges with a different set of wedges. Changing the pitch of this nut does not require any other compo-nents, machinery or controls, and no changes to system design are needed. Because there are no threads to clog or jam, the nut will not churn in the event of an overload. Instead, the nut simply slips until the overload can be corrected. This protects system components and helps prevent costly downtime for system repairs. Axial thrust is measured at up to 500 pounds and repeatable accuracy is to within ± 0.0004 inches depending on the type of controls used. Amacoil www.amacoil.com

Stepper Motor Drive System The DCM4826X stepper motor drive module is a bi-polar 2 phase chopper drive package rated for a 12-48VDC input voltage and a continuous output current rating of 2.6A rms (3.68A peak) per phase. The drive can be used with rotary stepper motors or stepper motor-based linear actuators and can be configured for full step, half step or microstep (1/4, 1/8, 1/16, 1/32, 1/64 step size). The unit is ideal in multi-axis stepper motor applications because less overall mounting real-estate is required due to the small size of the drive. In multi-axis motion systems, the space savings becomes greater as more axes are required. The mounting plate of the totally enclosed unit mea-sures a mere 64mm x 60mm (2.5-in x 2.4-in) with mounting hole center-to-center distances of 52mm x 38mm (2.0-in x 1.5-in) respectively. Total thickness of the unit from the mounting plate is 34.4mm (1.4-in). Through the interface, the desired values for Run Current, Hold Current, Delay Time and Step Size can be set. The pulse, direction and enable signals are optically coupled into the drive, providing electrical isolation between the signal and power circuits. Haydon Kerk Motion Solutions, Inc. www.HaydonKerk.com

FM1206_TechNiche.indd 12 5/23/2012 9:14:59 AM

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Bel-Ray, the leading specialty lubricants company to the Mining, Industrial and Powersports industries, launched its new package, label and enhanced product lines for 2012. Th e new package is unique to the lubricants industry and contains innovative labeling technology, which allows Bel-Ray products to be easily identifi ed, internationally compliant and multilingual for use around the globe. According to Bel-Ray’s Chief Operating Offi cer, Jennifer Liquori, the 2012 launch includes innovation at multiple levels. “Th e markets we serve have become more discerning and sophisticated, demanding not only highly engineered product technology, but also a package that’s more user-friendly. We are using the latest technology to create our new label design and we are thrilled to be ‘fi rst’, once again. Last year, we launched our new motorcycle line with a pull-out spout and multilingual packaging, also a fi rst. Now, our mining and industrial products have received a similar upgrade with labels that clearly identify the product, its application and grade; all color-coded for ease of selection and use,” said Liquori. Making the launch even more powerful are upgrades to Bel-Ray’s biodegradable technology and the industry-leading SF100 line of mining lubricants. Brand new motorcycle products for the V-Twin market and an all-new Marine line will also make their debut in 2012. “For more than 40 years, Bel-Ray has been making marine products for the US Navy and the largest marine equipment manufacturers in the world. We have taken our high performance marine related formulas and given them a technical upgrade. We have launched high-end, high performance racing fl uids, using revolutionary technology, off ering consumers the same Bel-Ray standard we’ve delivered for decades to the motorcycle arena, which has delivered champion aft er champion,” added Liquori. Located in Farmingdale, New Jersey, all products are made in the USA by the fi nest team of professionals in the business. For more than 65 years, Bel-Ray has stood at the forefront of lubrication technology.New products and new packaging. Same commitmentto innovation. Bel-Ray Total PerformanceLubricants.It just keepsgetting better.

Th e LABEL

World-renowned products require globally compliant labeling systems. Bel-Ray’s new Mining and Industrial labels feature the implementation of GHS (Globally Harmonized System of Classifi cation and Labeling of Chemicals) regulatory standards, as well as multilingual regulatory information. In addition to English, the labels include information in Spanish, French, Italian and German. Aerosol products feature regulatory information in 25 anguages for global distribution.

Bel-Ray has broken into the forefront of automation by introducing a Data Matrix Barcode, which allows the barcode to be scanned from up to 10 feet away and features the product number (SKU) and product lot number.

Maximizing compliance standards, Bel-Ray has included the NFPA symbol on the labels of their applicable Mining and Industrial package types (drums, kegs, pails and bins). Th e colored diamonds indicate diff erent hazard levels.

Innovations continue with Bel-Ray’s new, one of a kind, Viscosity Guide. Th is visual facilitates the use and selection of the appropriate ISO (International Standards Organization) viscosity grade.

Bel-Ray has made product identifi cation simple with color codes and iconography. Mining and Industrial products have been segmented to align with the following categories and colors:

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Krystal Gabert, Editor

Food safety and plant safety should be two of the biggest concerns for food manufacturers. Protecting the public is important, but so is protecting food manufacturing workers. Failure to do either can not

only bring great physical harm to those unlucky enough to be affected by unsafe business practices, but it can also bring great legal liability to operations that flout general safety practices.

Some of last year’s biggest food processing disasters can be attrib-uted to grave neglect. Others, though, can be described only as fluke accidents that could have been difficult to predict. What all have in com-mon, however, is that each incident was preventable.

In the aftermath of these disasters, food manufacturers can take away important lessons about what other manufacturers did wrong, and what they themselves can do better.

Incident Report:

AVERTING DISASTER

June 2012 ■

The Jensen Farms Listeria outbreak that began late last sum-mer and carried into the fall was the deadliest outbreak of any foodborne illness in 25 years, according to the Center for Disease Control and Prevention (CDC). At least 116 people were sickened, and 23 died as a result of the prolific Listeria contamination.

A n FDA investigation turned up multiple potential causes of the contamination, and while the agency identified the facility’s unsanitary conditions as the “root cause” of the

outbreak, the exact origins of the contamination may never be fully known. The FDA pinpointed several conditions that led to the out-break. The agency reported:

There could have been low level sporadic Listeria monocyto-genes in the field where the cantaloupe were grown, which could have been introduced into the packing facility. A truck used to haul culled cantaloupe to a cattle operation was parked adjacent to the packing facility and could have introduced contamination into the facility. The packing facility’s design allowed water to pool on the floor near equipment and employee walkways. The packing facility floor was constructed in a manner that made it difficult to clean. The packing equipment was not easily cleaned and sanitized; washing and drying equipment used for cantaloupe packing was previously used for postharvest handling of another raw agricul-tural commodity.

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Jensen Farms

Holly, Colorado

Listeria Outbreak:

Cantaloupe

Last year’s plant safety and food contamination incidents domi-

nated the news and shocked food processors into action. We review

the biggest disasters of 2011 and determine what could have been

done differently to better protect workers and consumers.

FM1206_Disaster.indd 16 5/24/2012 7:43:52 PM


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There was no pre-cooling step to remove field heat from the cantaloupes before cold storage. As the cantaloupes cooled there may have been condensation that promoted the growth of Listeria monocytogenes. All of these conditions are easily avoidable, and the existence

of all five in a processing facility suggests a culture of food safety neglect. It is, then, rather surprising that Primus Labs — an inde-pendent auditing company — gave the facility a “superior” rating mere days before the Listeria outbreak became public. Such a rating preceding a large outbreak is not unprecedented. Auditors cannot report on day-to-day conditions at a facility, but can only pass along information regarding the conditions on the day of the audit visit.

Antimicrobial tests are readily available and allow fruit pack-ers (and other manufacturers) to self-audit by performing sample tests before fruit leaves the facility. This kind of testing not only provides a real-time “progress report” for fruit packers, but it also serves to expedite the recall process if a positive test is found.

In order to prevent the need for such a recall, it is imperative for food manufacturers packaging fresh fruit to follow the recommen-dations for washing, drying and processing as laid out by the FDA. Such specialized equipment is readily available to processors, and could prevent the need for an expensive recall, not to mention the public health threat that a Listeria outbreak can cause.

On October 10, 2011, the FDA sent a warning letter to Jensen Farms, noting the death and illness linked to the farm’s outbreak and threatening further action if Jensen Farms refused to make changes to ensure the safety of its products. In addition to high-lighting the facility’s “poor sanitary practices,” the letter made three specific recommendations for improving food safety at Jensen Farms.

Using packing equipment designed to facilitate cleaning and sanitation of melon contact surfaces and constructed of materi-als that may be easily cleaned and sanitized. Validating and verifying that melon wetting and brushing opera-tions are not a potential source of melon contamination or cross-contamination. Cooling and cold storing melons as soon as possible after har-vest because delays in cooling when melons with netted rinds

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S hortly before the Jensen Farms outbreak stole the food safety spotlight, a meat giant was facing contamination troubles of its own. On August 4, 2011, Cargill announced

one of the largest meat recalls in U.S. history; the company was recalling 36 million pounds of ground turkey after a CDC investiga-tion pinpointed the company as the source of a salmonella con-tamination that would eventually sicken at least 119 people and kill one.

The facility was likely processing tainted meat as early as February of that year, and illnesses were reported starting in

(such as cantaloupe) are wet from washing operations may allow for multiplication of human pathogens on the rind surface. If followed, the FDA recommendations should help safeguard the

food supply from another recall of this magnitude. ◆

Cargill

Springdale, Arkansas

Salmonella Outbreak:

Ground Turkey

FM1206_Disaster.indd 17 5/24/2012 7:44:33 PM

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O n the heels of the Cargill recall, National Beef Packaging Company recalled 60,000 pounds of ground beef for possible E. coli contamination,

impacting some of the largest grocers in the country. In a news release announcing the recall, National Beef announced that, “The problem was discovered as a result of routine microbial testing conducted by the Ohio Department of Agriculture at a state-inspected facility that had purchased these products for further processing. A traceback investigation revealed that the slaughter facility, National Beef Packing Co. products were the sole source for the positive product sample.”

A combination of preemptive microbiological testing and plant sanitation procedures could have helped to prevent or mitigate this disaster.

Though the amount of product recalled was much smaller than in the cases of either Cargill or Jensen Farms, and no illnesses were reported in connection with the outbreak, the impact of the National Beef recall was primarily damaging to the meat industry itself. Coming only days after Cargill’s ground turkey recall, reports of this E. coli contamination served to undercut consumer confidence in the safety of the meat supply.

If there is a bright spot that exists in this story, it is that quick work by the facility and by state regulators meant that microbiological tests were able to detect E. coli in time for product to be pulled from shelves before any illness could occur. Proper supply chain management is imperative for this kind of quick action. ◆

AVERTING DISASTERincoming ingredients and outgoing product and every step along the process. When contamination is discovered, meat processors can use the tools built into supply chain applications to identify possible sources of contamination and to identify lot numbers of finished goods that present the risk of contamination.

By combining this kind of tool with careful HACCP planning and heightened sanitation standards, meat processors can combine prevention with containment to create a safe system to avoid out-breaks like the one at Cargill. ◆

June 2012 ■

Nation

al Bee

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Dodge

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E. Col

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Ground

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March. The company, along with regulators, offered little in the way of explanation for how such contamination could have gone unde-tected for nearly half a year, as consumers continued to get sick.

Making matters even worse, the salmonella strain identified in the Cargill contamination was Salmonella Heidelberg, which is largely resistant to antibiotic treatment. The day after the recall was announced, the Center for Science in the Public Interest said in a press statement, “The Center for Science in the Public Interest petitioned the U.S. Department of Agriculture in May to declare this and three other strains that have caused outbreaks and recalls as ‘adulterants’ under the law. That would trigger new testing for those strains and make it less likely that contaminated products reach consumers.”

Just over a month later, Cargill’s Springdale plant again recalled ground turkey confirmed to be contaminated by Salmonella Heidelberg. The facility again closed its doors for a deep clean.

Salmonella contamination is especially difficult in poultry prod-ucts. Because salmonella contamination is so common in poultry, the USDA allows small levels to exist in foods, and consumers are warned to cook poultry thoroughly. When antibiotic-resistant strains like Salmonella Heidelberg are present, however, the danger to consumers is greater.

Increased cleanliness standards in plants are always advisable in preventing salmonella contamination. Because of the relative com-monness — and acceptability — of salmonella, however, additional methods are necessary to protect the supply chain from adulter-ated products.

Supply chain management tools can help processors track

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2020 Incident Report:

June 2012 ■

AVERTING DISASTER

Food safety lapses aren’t the only disasters to strike the food processing industry. Last October, six workers were killed when an explosion ripped through a grain elevator in east-

ern Kansas. The official OSHA investigation was expected to take about six months to complete, and in April 2012, the company was fined $406,000 and cited for various workplace safety violations.

In a news release announcing the fine, U.S. Secretary of Labor Hilda L. Solis said that “The deaths of these six workers could have been prevented had the grain elevator’s operators addressed hazards that are well known in this industry. Bartlett Grain’s disre-

gard for the law led to a catastrophic accident and heartbreaking tragedy for the workers who were injured or killed, their families and the agricultural community.”

Dr. David Michaels, Assistant Secretary of Labor for Occupational Safety and Health has said that “OSHA standards save lives, but only if companies comply with them. Bartlett Grain has shown what happens when basic safety standards are ignored, and this agency simply will not tolerate needless loss of life.”

OSHA cited Bartlett Grain with various “serious” violations, which were primarily related to lax training and procedural standards. In addition, the agency noted five “willful” violations, which were:

When the workplace hazard assessment determined that haz-ards necessitating the use of personal protective equipment were present or likely to be present, the employer did not select and require the use of types of personal protective equipment that [would] protect the employees from the identified hazards. Fugitive grain dust accumulations were not removed whenever they exceeded 1/8” at priority housekeeping areas, pursuant to the housekeeping program. The use of compressed air to blow dust from ledges, walls and other areas was permitted when machinery that presented an ignition source in the areas was not shut down. Inside bucket elevator(s) were jogged to free choked leg(s). Equipment was not approved for the class of the location [or] for the ignitable or combustible properties of the specific gas, vapor, dust or fiber that [was] present. Had Bartlett Grain chosen to abide by existing safety standards,

and had its employees been properly trained to recognize danger-ous situations, this tragic loss of life could have been avoided. ◆

•

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22

Th e Food Manufacturing Brainstorm features industry experts sharing their perspectives on issues critical to the overall food industry marketplace. In this issue, we ask:

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BRAINSTORM

22

Th e Food Manufacturing Brainstorm features industry experts sharing their perspec-tives on issues critical to the overall food industry marketplace. In this issue, we ask:

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BRAINSTORM

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Th e Food Manufacturing Brainstorm features industry experts sharing their perspectives on issues critical to the overall food industry marketplace. In this issue, we ask:

What factors should food manufactures consider when choosing reduced packaging options that are appropriate for frozen applications?

BRAINBRAINSTORMSTORM

22

Ronald Cotterman, Executive Director of Sustainability, Sealed Air Corporation

Packaging plays a key role in delivering frozen foods to the market efficiently and without damage while providing safety and convenience for the consumer. When choosing packaging options for frozen appli-cations, it is important to consider the following factors:

1. Optimize with the full life cycle in mind. Packaging selected should meet the essential requirements for the product during distri-bution, sale, use and disposal. Therefore, packaging materials should be selected that balance the need to make efficient use of packaging materials, reduce overall product dimensions, effectively merchandize the product and provide protection during distribution. This balance requires optimization of packaging rather than minimization.

2. Package for product protection. Packaging ensures that the product reaches the consumer without damage while retain-ing product quality. This means that packaging must survive condi-tions that the product will likely experience, not simply the average. Performance considerations such as seal integrity, toughness and, potentially, barrier properties, need to be taken into account and not compromised. Product damage can have a much more significant impact than that of the packaging.

3. Design with consumer use in mind. Packaging that provides convenience, protection and efficiency enhances overall sus-tainability. Packages with strong seals that are also easy to open ensure consumers can safely access the product, while pack-aging that delivers portioned products can help reduce overall food waste.

Packaging is an essential part of the product life cycle and, with a few straightforward considerations, can enhance overall sustainability. ◆

FM1206_BrainStorm.indd 22 5/24/2012 8:21:57 AM

www.foodmanufacturing.com

23

Robert E. Hogan, Director of Global Marketing, Zip-Pak Food manufacturers are constantly looking for innovative ways to showcase their product through packaging while minimizing waste, reducing

costs and maintaining the quality of the product. Particularly in the frozen food aisle, packaging is critical in grabbing the consumer’s attention through the freezer door. Fortunately for retailers, CPGs and consumers, new packaging solutions and technologies offer the benefits of conve-nience while simultaneously minimizing material use.

With these factors in mind, Zipbox, an innovative new package format that combines both rigid and resealable packaging, is an ideal way to reduce packaging material and grab consumer’s attention. The package is a poly-coated paperboard carton incorporating an attached flexible film header containing a ZIP-PAK Press-to-Close™ solution and is designed for direct-filling, which eliminates the need for an inner liner. This is

an important innovation for products such as frozen waffles or meat products that typically require a rigid container with an inner liner. By removing the liner, the package style can hold up to 40 percent more product, maximizing the product-

to-package ratio and cube utilization to reduce transportation costs. Zipbox® also provides a unique shelf presence compared to lay-flat packages.

However, if a product doesn’t necessarily need the protection of a rigid container, then flexible packaging is the best alternative for frozen applications. Zip-Pak recently commissioned Franklin Associates, a U.S.-based, third party research firm, to conduct a Lifecycle Inventory (LCI) comparing flexible and rigid packaging. The study confirmed significant environmental benefits of flexible packaging, especially as they relate to the Wal-Mart sustainability packaging scorecard. Compared to bag-in-box alternatives, resealable flexible pouches received a Wal-Mart scorecard rating increase of 47 percent. Frozen food applications are diverse,

as are the packaging options. Ultimately for manufacturers, balancing waste

reduction, cost efficiencies, product protection, and

consumer convenience is paramount to a suc-cessful product and package. ◆

FM1206_BrainStorm.indd 23 5/24/2012 6:45:02 PM

24 EXCLUSIVE FEATURE

June 2012 ■

Mark Hoffman, PE, PMP, SSOE Group

G rowing consumer demand for a greater variety of high quality products requires that food processing facilities increase produc-tion and improve efficiency at every step, and the cleanliness of

production systems is an important component to any food processing facil-ity. What’s often overlooked, however, is that increased production can strain the systems responsible for keeping a facility clean, which compounds the already arduous task of ensuring that production machinery is clean.

Efficient dust collection systems at the measurement and mixing step and easy-to-clean production equipment at the sizing and agglomeration step are important factors to address to make sure production doesn’t outpace the clean-ing system and that the operability of the cleaning system doesn’t slow down production. Carefully designed upgrades to the cleaning systems and the production equipment can be technically sound, cost-effective, reduce downtime, and minimize capital cost. Here’s how.

Dust Risks and System Design Problems The measuring and mixing step of dry processing is a notorious dust

generator and facility owners recognize that dust is a health and safety issue. Preventing slips and falls, inhalation, as well as environmental and food contamination are normal concerns. The potentially fatal effects from combustible dust are of primary concern in a variety of industries.

Although OSHA’s 2007 Combustible Dust National Emphasis Program and the National Fire Protection Association provide standards that should be followed, combustible dust explosions continue to occur and sometimes with fatal outcomes; therefore, OSHA is redeveloping stricter guidelines to address explosion hazards from combustible dust.

All too often, dust collection systems are poorly designed to meet the urgent needs of increased production. Quick fixes lead to improper duct sizing, inconsistent velocity, and often additional technical problems.

For example, inconsistent velocity over the course of a run of ductwork — in particular, high velocity at the beginning of the run and low velocity at the end of the run before filtration — may cause heavier dust particles to settle out and accumulate in the system, increasing the risk of the com-bustible dust explosions the system is intended to prevent.

Similarly, inadequate deflagration venting or suppression systems also increase the risk of explosion, as does failure to address details such as bonding across gaskets to prevent static build-up.

Design inadequacies can also create logistical problems, for example, when routing of new ductwork collides with structural components such as building columns, or poor placement of new hoods creates obstructions that personnel must work around.

The optimal, cost-effective solution is one that avoids unnecessary replacement of an existing system which requires higher capital costs and longer downtime. Food processing facility owners should instead consider

Beyond The White Glove Test Efficient dust collection systems and easy-to-clean production equipment require a holistic approach to their design.

a system upgrade designed by an experienced process engineer whose work ethic is a teamwork-based, holistic approach.

Analyze the Whole System, Not Just the Parts In order to take a holistic approach to analyzing systems and processes,

extensive information must be collected. Direct observation of the process, as well as discussions with the team will surface many pertinent pieces to the puzzle, from site-specific issues and operator challenges, to the tem-perature and humidity of the interior environment, to the specifications of the product being processed.

Often overlooked are key operations personnel who always have valuable insights about their day-to-day challenges with minimizing dust. Their ideas and approaches to mitigate the dust problem should be thoroughly noted. Direct observation of the process by the engineering team also yields many clues that are not conveyed through the original as-built drawings.

Plan for Increased Production Carefully designed upgrades to existing dust collection systems are often

good technical solutions to increase production and improve efficiency; they are cost-effective, too.

In the case of a processed breakfast food owner, an increased volume of dust was generated as operators added major ingredients like flour to the mixers and put hand-weighed minor ingredients like baking powder into a bag-dump station. Not only was the increasing amount of dust in the working atmosphere creating a health risk to employees and an explosion hazard, but it also became a serious housekeeping issue.

After careful evaluation, it was deemed that just a few modifications, in lieu of a system replacement, would cost-effectively do the trick. Upgrading the current motor to one with more horsepower increased the fan speed to optimal levels without having to replace the existing filter. But while the filter’s air-to-cloth ratio remained suitable, a section of ductwork was replaced to accommodate the increased flow.

A little trickier was determining the location of pick-up points and hoods to assure proper coverage without interfering with operations. Proper placement in this case was one hood positioned at the back of the mixing table, another hood at the bag dump station, and a pick-up point was connected to the mixer itself.

One challenging aspect of the design was routing the new ductwork to avoid building columns, pipes, conduit, and production equipment, but 3D modeling expedited the location of optimal routes. Another challenge was strategically locating the dust filter to prevent explosions from build-up. An outdoor filter would not do because of exposure to humidity and condensa-tion, so it was determined that the best solution was to locate it in a room that was vented to the outdoors.

Only a holistic assessment of the issues and challenges surfaced the right solutions and served as the foundation to a solid design — from the characteristics of the product, to the process of ingredient measuring and mixing, to the interior environment and structure.

Another major processed food owner faced a similar dust collection challenge when it added a new snack product to its brand line that called for a significantly higher amount of dry ingredients. The owner’s initial hope

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was to tie new pick-up points at two mixers and tie existing ductwork to a bag-dump station, but the existing 60,000 cfm air filtration system was already operating close to capacity to support the increase to dry-process-ing. The system was upgraded with a new fan and filter to provide for proper air flow and pressure drop, as well as installation of additional pick-up points. To meet the new filter’s air-to-cloth ratio and function properly with the new pick up points, several sections of ductwork were replaced.

In both examples above, carefully designed upgrades to existing dust collection systems were technically sound, cost-effective, and minimized downtime.

Hinges & Clamps Another literal sticking point in dry

processing occurs at the sizing and agglomeration step due to equipment that is difficult and time-consuming to clean. Consider a size-reduction step with a mill or grinder that spouts to a conveyor, which goes to a sifter where fines and overs are removed and con-veyors take them back to the system or to waste.

Say this system is bolted up and is a nice tight system that works well. However, operators can’t get into it to clean the many corners and crevices without back-taxing tools that are required to unbolt myriad parts and pieces. Disassembly, cleaning and reassembly take far longer than they need to, increasing downtime.

In contrast, consider an effective design that streamlines this system, limiting transition points to reduce or eliminate unnecessary spouting and conveyors. Equipment is selected with accessibility in mind, reducing or elimi-nating bolted connections that require tools to disassemble and reassemble.

Since it is difficult to modify equip-ment installed years or decades ago, replacement is necessary. While equip-ment vendors have recognized that hinges and clamps offer easier acces-sibility, proper specification param-eters developed by qualified engineers prior to purchasing is a must. The additional step of a thorough vendor

submittal review will ensure the equipment meets the facility’s requirements and expectations of equip-ment accessibility.

As in all good process engineering, the best solu-tions in these two areas are developed through team-work among facility owners, internal and consulting process engineers, and key operation personnel. Designing cost-effective dust collection systems and easy-to-clean production equipment isn’t just about

passing the white glove test. These systems are criti-cally important to safeguarding workers, promoting food quality, and improving process efficiency.

Mark Hoffman, PE, PMP, is Engineering Manager at SSOE Group, an international engineering, procure-ment and construction management firm. He can be reached at 651.726.7660 or by email at [email protected]. ◆

FM1206_SSOE.indd 25 5/23/2012 9:14:23 AM

26SPOTLIGHT ON: FEEDING www.foodmanufacturing.com

June 2012 ■

Feeder Controller Designed for the management of up to 16 gravimetric screw feeders, weighfeeders and mass flow meters, the DISOCONT® MASTER Touch Group Controller to the North American marketplace. The DISOCONT® Master is applicable in processes using multiple feeders. The controller is designed for use in applications where feeders are controlled by a master gravimetric feeder and can be controlled or monitored from a single workplace, at a specific ratio as part of an overall group setpoint. Features include:

Touch screen operation Recipe management Displaying, analyzing and acknowledging events Resetting the totalizing counter Measurement value selection

Fieldbus, language translation and batch reporting are available options. Typical installations can be found in a control room or control cubicle where the system communicates with the feeders via a databus reducing cabling requirements. Schenck AccuRate www.accuratefeeders.com

•••••

Feeder For Canisters & Pouches OMNI-Feeder is a variable speed feeder for desiccant and oxygen absorbers that accommodates both canisters and pouches. In addition to inserting canisters or pouches into rigid bottles, the equipment can be adapted to dispense desiccants and oxygen absorbers into various packaging solutions. Capabilities and features include:

Can handle over 300 bottles per minute Multiple desiccant drops per bottle Ability to run differently sized canisters and pouches Less than five minutes for changeover Fully automatic servo operation Aluminum frame construction Small footprint Fixed inner belt assembly Adjustable outer rail assembly

Omega Design Corporation www.OmegaDesign.com

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Filling & Portioning Depositors The C-Frame Depositors deposit fillings for stuffed sandwiches, multiple layered prod-ucts, stuffed seafood, appetizers and rolled or wrapped product. These Portioning Depositors provide excellent portion weight control and clean, accurate filling placement down the line. 45,000 deposits per hour are attainable on cer-tain models. The design enables the equipment to fit right into existing production lines. The system uses a rotating spiral that gently moves the product to the rotary vane pump. Bridging and overworking are eliminated because the product is neither rolled nor tumbled. The 100% hydraulic system also minimizes maintenance, reduces downtime and lowers repair costs. NuTEC Manufacturing www.nutecmfg.com

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28 SPOTLIGHT ON: FEEDING www.foodmanufacturing.com

Sanitary Open Construction Weigh Belt Feeder The MWF-SGSP-OS Ultra-Sanitary Open Construction Weigh Belt Feeder can provide either a “closed loop” gravimetric control of material feed rate or an “open loop” control for precise convey rate output and totalization of an uncontrolled or intermittent material supply. Design specifications include:

Handling a wide range of materials and densities Having excellent accuracy and stability Sanitary processing due to its all stainless steel construction Positive belt tracking, without the use of mechanical devices, thanks to a unique belt tracking system Easy access, with a low-maintenance design and no tools disassembly Durability and stability under harsh conditions Fast belt removal due to a cantilevered frame

Belt velocity is measured from the tail pulley rather than the drive motor, providing a direct measurement of belt speed; this improves both measurement and control of material. The load cell assembly can be easily removed, then rein-stalled without re-calibration of the feeder. Thayer Scale www.thayerscale.com

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Hi-Speed Feeder The HS-8 Electromagnetic Vibratory Feeder with quick stop and high conveying speed capabili-ties is designed for improved efficiency in packaging, weighing, batching and bagging operations.

The feeder is ideal for use in conjunction with many weigh scale and packaging machines. New E-Z Tune™ technology enables customers who build their own trays to significantly reduce the time

spent tuning feeders. The unit features: A low profile design for easy installation A “wedge” shaped body for small diameter weigh scale systems An electromagnetic design for quiet operation

Units are equipped with rubber isolators and a threaded insert for easy mounting. For added convenience, the unit can be provided with all stainless steel hardware for wet environments. Eriez www.eriez.com

•••

June 2012 ■

FM1206_Spotlight.indd 28 5/23/2012 9:13:20 AM

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30 EXCLUSIVE FEATURE

June 2012 ■

David McCarthy, President and Chief Executive Officer, TriCore, Inc.

C IP stands for Clean-in-Place. A CIP system is usually comprised of one or more tanks for rinsing, washing and sanitizing your process equipment. Like your washing machine, a CIP system is generally

programmed with a variety of cycle types, depending on what equipment you are cleaning and what product you are making. Well, maybe not the spin cycle, but you will usually get cycles like rinse only, full wash, and sanitize. Like your washing machine, each cycle is comprised of a series of steps for things like filling the system, adding detergent, washing, rinsing and draining. There is generally some sort of recording device, to provide independent verification that proper temperatures, flow rates and chemical concentration levels are met.

The connection between a CIP system and your process equipment is through a series of pipes, valves and/or flow connection plates. These sys-tems generally circulate various cleaning solutions through your process equipment, while monitoring time, temperature and chemical concentra-tion levels to insure your equipment is properly cleaned. As the name implies, the CIP system and the equipment you are cleaning remain in place, and are generally not disassembled in any way as part of the cleaning regimen.

Compare this to a manual cleaning process. With this method your process equipment needs to be disassembled by hand; manually washed, rinsed and/or sanitized; then reassembled when complete. For larger items like tanks, this likely requires rinsing down the tank, manually scrub-bing the interior with a wash solution and brush, and then manually rinsing it off when complete. These methods are time consuming, and carry

some risk to product integrity if the manual cleaning is not performed properly. For very large tanks, a manual approach may not even be possible.

When the Same Thing Is Different

Let’s face it: time cleaning your process equipment is time spent not making your product. A well automated CIP system can make sure that you are protecting your product by properly cleaning and sanitizing all process equipment, while at the same time doing so in the most efficient manner possible. Let’s look at some automation options that can really get the most out of an automated CIP process by optimizing your CIP cycles based on how you are using your process equipment.

The old adage states that the only thing constant is change. This is very much the case in most modern food manufacturing plants. As an ever increasing number of SKUs are processed, what you make affects how

you should clean. In a food plant it is generally harder to clean a tank that made chocolate pudding than the same tank that made vanilla pudding.The same tank, running different prod-ucts, can have different optimized CIP cycles.

Different sets of pro-cessing equipment, mak-ing the same product, may also have different cleaning requirements. For example, you may

have a group of 10 tanks, all the same size, all capable of making the

same product. The tank nearest to the CIP system may be 300 feet closer than the farthest tank. The closer tank requires less cleaning solution to fill the pipe to and from the CIP system, will lose less energy than the father tank and will generally use less cleaning chemicals.

Another thing that can vary in your plant over time is the types and source of your CIP chemical solutions. A new sanitizer may be half the cost and require half the contact time as your old one. The same product, made with the same processing equipment, using different chemicals can

The Inside Dirt On CIP The Inside Dirt On CIP A CIP system is kind of like an automated washing machine connected to your food processing equipment. Do it right and you will save time and money, do it wrong and

you could have a real mess to clean up. Want the inside dirt on CIP?

Let’s talk about what you need to know.

(Photos/TriCore, Inc.)

FM1206_TriCore.indd 30 5/24/2012 8:23:19 AM

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have different optimized CIP cycles.

In Search Of CIP Nirvana

Not too long ago process and CIP functions were operated from industrial control panels with switches, buttons and status lamps used as the primary way for people to interact with the automated systems. Some plants still operate this way today. For CIP, usually a small group of cleaning options would be hard coded into a plant floor controller.You might get a selector switch optioning cycles like long wash, short wash and rinse only. Each cycle would be a fixed sequence; much like a washing machine cycle is still done today. With this method CIP cycles were generally programmed for worst case, to insure you adequately cleaned the process equipment.You could in no way optimize this process as we can today. Recording of key process parameters was done with chart recording devices.

The best contemporary CIP sys-tems are automated to allow for flexible cleaning cycle configura-tions. Today, with modern control systems the plant sanitarian can configure precise cleaning cycles specific to particular products made in particular pieces of equipment. Savings in energy and chemicals costs can be substan-tial. Significant reductions in clean-ing times can also be achieved, allowing for more time to make product. Recording is often done electronically allowing for easier dissemination and analysis of criti-cal CIP data.

The Complete CIP Approach

Innovation happens in tech-nology all the time. In our food manufacturing plants, new cleaning approaches such as Electrochemical Activation systems (ECA), show a promise of a green technology using significantly less

The Inside Dirt On CIP water, chemicals, energy and most importantly time required for a given CIP cycle. Modern automa-tion systems need to be agile and flexible to take advantage of new technologies such as these, while leveraging existing technologies to get the most optimal results out of existing systems and equipment.

A properly automated CIP system should allow you to eas-ily make adjustments to your cleaning cycles, without having to re-code or hardcode anything in the system, and without the assistance of specialty techni-cal resources. This will put the power into the hands of your

plant sanitarians, giving them the tools to precisely match cleaning cycles to products, equipment and chemical profiles. If done properly your CIP system should give you the most secure form of cleaning for your equipment, at the lowest possible cost, in the shortest possible time. ◆

FM1206_TriCore.indd 31 5/24/2012 8:23:37 AM

32

with Michael Antinone, Associate Director, General Mills Worldwide Innovation Network

Product development projects are often kept quiet by processors look-ing to protect their “secret recipes.” However, some companies such as General Mills are using open innovation to share their R&D projects with suppliers and others who may be able to help make the final product a larger success. Food Manufacturing spoke with Michael Antinone of the General Mills Worldwide Innovation Network (G-WIN) about the benefits of putting development projects out in the open.

Q:Q: A:A:

June 2012 ■

Interview by Lindsey Coblentz, Associate Editor

What is the X3 Process, and how does it work?

The X3 Process is a new approach that we developed at General Mills to provide a step-by-step roadmap for our open innovation projects. It encompasses three core principals of innovation — eXamine, eXpand, and eXplore — and facili-tates the process of innovation by helping make connections between unmet technical needs and actionable solutions.

Unlike some other innovation processes, the X3 Process provides a non-linear path to success, which means you use only the steps you need to effectively identify appropri-ate solutions. This is important to us because we realize that people approach innovation from various camps. For example, there are those who excel at defining needs or problems, but struggle to identify solutions. On the other hand, some people are great at generating solution paths but are less comfortable with problem definition. It is criti-cal that the X3 Process accommodate various approaches, so that anyone can use it to achieve success.

This non-linear approach is also important because not all projects are the same, and therefore, not every project will require every step of the process. Instead, the X3 Process allows you to right-size the solution for the task at hand, only doing what is necessary to get to the best solu-tion spaces. The X3 Process includes the following steps:

Ask the right question(s) – gather knowledge internally to gain alignment on your “true” knowledge gaps and technical needs

•

Get smart – build and develop new knowledge, including key insights and innovation opportunities Ask better questions – immerse your team in new knowledge to generate insights and new hypotheses Communicate needs – write, refine and finalize well-crafted briefs that clearly explain your needs Find smart people – use available tools and networking opportunities to identify potential solution providers Make connections – initiate relationships and kick off projects

How was this process developed?

Since formally launching G-WIN five years ago, we learned that our scientists were excited about the open innovation tools available to them, but they didn’t necessarily know how and when to use them most effectively. There was a need for a facilitator or roadmap for the entire open innova-tion process — something that would let our scientists be scientists.

Beginning in March of last year, the G-WIN team worked with a group of General Mills’ strategists and inno-vators to develop the approach, bringing together a number of best practices to balance the art and science of open innovation.

How have General Mills’ innovation projects been impact-ed by this new process?

The X3 Process has been instrumental in our recent inno-vation projects, which is why we decided to share our

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Open Innovation: Open Innovation: A Not-So-Secret Recipe A Not-So-Secret Recipe

Q:Q: A:A:

Q:Q: A:A:

FM1206_Q&A.indd 32 5/23/2012 9:10:52 AM

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insights externally in hopes that other businesses, organi-zations and individuals will find the approach valuable to their projects as well.

We first implemented the X3 Process at General Mills to guide a sugar-reduction project that kicked off in June 2011, and we intend to use the process for similar large platform projects in the future.

How has open innovation worked for General Mills? Have there been any unforeseen benefits or consequences?

Innovation is an important growth strategy for General Mills. We’re always looking for ways to bring even higher levels of taste, health and convenience to consumers. We can use open innovation as a lever to deliver these ben-efits to the consumer through introducing new products, improving our existing products and packaging or finding new ways to manufacture or market our products.

One recent example of how open innovation has driven performance is our new Fiber One 90-Calorie Brownies. General Mills’ Snacks division, which includes brands such as Nature Valley, Fiber One and Chex Mix, has embraced open innovation to advance several areas of its business, including new product innovation. While the Fiber One team created the idea and concept for a tasty, wholesome brownie, and our R&D department had the expertise to make the perfect dough, they recognized they didn’t have the existing internal expertise and baking

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manufacturing capabilities to bake it. In order to quickly bring the product to market, we decided to enlist an open innovation partner, which we found in a company with which General Mills had worked years earlier. That partner had the baking experience and pilot plant facilities needed to test and perfect the baking process to the Fiber One team’s exact specifications. The Snacks division estimates that the partnership saved nine to 12 months in terms of taking the prod-uct from concept to launch, and Fiber One 90-Calorie Brownies have already proven a terrific success, on track to reach $120 million in year-one retail sales.

One unforeseen benefit of open innovation that our experiences have shown us is the huge opportunity we have to better connect with suppliers with which we are already working. Prior to launching G-WIN, we used to be close to the vest about our future plans and projects, even with suppliers. We now see the value existing suppliers can have at the front end of innovation, as seen with the Fiber One 90-Calorie Brownies project.

Is open innovation a fluid process? Have there been any changes with the process as it has moved forward? Do you anticipate further changes?

Since launching our program, we’ve continuously refined and evolved our practices to become more effective and efficient in bringing the right outside technologies, processes and products to General Mills, which has accelerated the pace of our innovation and saved money, time and risk. A few of the notable evolutions of our program include the following:

In 2008, we expanded the G-WIN team to include more than a dozen Innovation Entrepreneurs who work with each of General Mills’ busi-nesses to identify and prioritize the solutions and capabilities that are the most important to each business. We realized that we needed to be more specific and transparent about the challenges we were looking to solve in order to get higher-quality sub-missions. For example, it’s one thing to say that we’re seeking “packag-ing solutions” as we may have done early on in our efforts, and another to say that we’re looking for ways “to use renewable content in flexible packaging films and rigid containers.” In the fall of 2009, we launched the G-WIN innovation portal, through which we publish technical chal-lenges and invite visitors to create and submit non-confidential proposals. During the first year of launching this more robust and clearly articulated site, we connected with more than 1,000 inventors from around the world and received more than 500 proposals. In 2010, we introduced a town hall meeting strategy to help efficiently make meaningful connections with potential partners around the globe. We hold these town hall events at times and locations that coincide with food industry or technology events to ensure we’re able to meet, greet and learn more about a large number of potential partners that are relevant to our business. Attendees are encouraged to familiarize them-selves with our current technical challenges by visiting our online portal prior to the town hall event. The meeting itself provides the opportunity for them to get to know us, network with each other, and share their core competencies and capabilities with us. After the town hall meeting, we then follow up individually with the attendees who were a best fit in terms of their abilities to solve our challenges. Last but not least, we’ve held two Supplier Summits to bring together our top suppliers to network, hear about the company’s business strate-gies and learn about specific partnership opportunities. In response to the Supplier Summit we held last summer, we’ve already received more than 120 proposals, more than 100 of which are continuing forward for further evaluation. ◆

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Q:Q: A:A:

Q:Q: A:A:

FM1206_Q&A.indd 34 5/23/2012 9:11:27 AM

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The HACCP Update section of Food Manufacturing is designed to offer our readers insight into the state of HACCP implementation and compliance across the Industry. We received hundreds of responses to this month's survey on juice processing.

HACCP36 UPDATEUPDATEJUICE PROCESSINGJUICE PROCESSING

June 2012 ■

Krystal Gabert, Editor This month’s survey on juice processing is the first targeted toward beverage

suppliers since the Food Safety Modernization Act (FSMA) mandated HACCP planning across all industry segments last year. Juice, along with seafood, poultry and meat, however, remains one of only a few industry segments for which specific HACCP considerations are mandated by the FDA.

Food Manufacturing asked its beverage processing readers whether juice facilities with mandatory HACCP plans have better plans than those in less regulated facili-ties. Readers responded:

Meat, poultry, seafood and juice producers have better HACCP plans. — 54.1% There is little difference between guided HACCP plans and non-guided plans. — 24.3% Facilities that use plans not set by federal guidelines have better HACCP plans. — 21.6% These results are noteworthy if not unexpected. Despite the industry’s general

resistance toward regulation, Food Manufacturing ’s HACCP surveys have consis-tently revealed an overall satisfaction with HACCP planning policies and mandates. This attitude manifests again in the reader response to subsequent question in this month’s survey, in which readers were asked, “The Food Safety Modernization Act has made HACCP planning mandatory in all food manufacturing segments, not just juice, seafood, meat and poultry. Do you think this is an appropriate change?” Responses to this question remained fairly consistent with last year’s figures, with 91.9 percent of readers reporting a belief that “all food segments should be required to write and implement HACCP plans” and only 5.4 percent of respondents believ-ing that “HACCP planning should not be mandatory for any food industry segment.”

When respondents were asked why they think juice is the only non-animal food product to have the distinction of mandated, industry-specific HACCP plans, one reader responded, “The microbiological considerations and toxins as a result of chemical contaminants (i.e. patulin, mycotoxins, etc.) for improperly handled/

processed juice make HACCP a critical component to production [with] consumer safety in mind. There were several juice issues in the 90s that perpetuated this decision.”

Last year, several readers pointed to the Odwalla and Sun Orchard juice recalls in the late 1990s — which many in the industry feel chipped away at public confidence in juice safety — as prompting FDA action in crafting juice-specific HACCP plans. As seen in the pie chart at left, sat-

isfaction in the resultant plans is fairly high and is, in fact, up 13 percent over the results of last year’s survey posing the same question.

This year, it appears as if juice processors are tweaking their HACCP planning procedures, likely in response to the FSMA. As displayed in the graph above, juice processors report seeking

guidance from various sources when crafting HACCP plans. The figures displayed here remain fairly consistent with last year’s survey, with a few notable exceptions. “Suggestions from plant-floor staff” is down about 5 percent from

last year, while “Consultation with equipment manufacturers” is up about 10 percent, “Advice from 3rd party regulators and government auditors” is up about 7 percent, and “The publicly available HACCP guidance pub-lished by the FDA” is up about 5 percent. These figures suggest a slight shift away from a “man on the ground” perspective in favor of guidance from professionals studied in food safety protocol.

Additionally, beverage manufacturers’ reported HACCP planning schedules have shifted from last year’s figures. While 12.5 percent of respondents last year reported updating HACCP documents semi-annually, this year none reported doing so. Those who consider HACCP plans a “living document” open to constant revision have dropped by over 10 percent, and the number of manufacturers performing annual audits has gone up. These numbers suggest that food manufacturers are opting for a more structured HACCP planning

process. Like other food industry segments, juice manufacturers are facing regulatory challenges by updating pro-

cesses and increasing food safety protocol. By doing so, they aim to make the regulations work for them and for consumers, creating a safer food supply chain along the way. ◆

••

•

What factors have been key to effective HACCP planning in your facility?

0 10 20 30 40 50 60 70 80

Internal QA/QC experts 68.4%Advice from 3rd party regulators and government auditors 50.0%

Outside advisors/consultants 47.4%Suggestions from plant-floor staff 44.7%

44.7%The publicly available HACCP guidance published by the FDA

Consultation with equipment manufacturers28.9%

18.4%Other

Yes

75.7%

No

24.3%

Do you feel that the FDA guidance for HACCP planning in juice processing facilities is appropriate to address the specific challenges and critical control points associated with juice processing?

FM1206_HACCP.indd 36 5/24/2012 8:25:29 AM

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Food & Beverage Tubing FB70-PVC tubing for food and beverage applications is made from FDA Title 21 approved in-gredients and is listed with NSF. Under NSF-51 requirements, the product has been certified for use in dairy, alcohol (less than 8%), acidic and non-acidic applications. The product is soft and flexible, making it ideal for typical appli-cations that require a tight bend radius and installation over barbed fittings. Custom sizes, straight-cut lengths, assembly operations such as fitting insertion and custom packaging are available. Grayline Inc. www.graylineinc.com

Multi-Piston Depositor The model 4P-16 filling machine is designed to take up less space than conventional systems in crowded food production plants. The system is ideal for integrating with horizontal vac-uum formers, tray sealing lines and automatic conveyors to ac-curately fill a wide range of pumpable products such as sauces and marinades, salsa, entrée items such as macaroni and cheese, gravy, or virtually any other pumpable product with or without particulates. The product features PLC control with color touch screen operator interface, positive shut off spouts with blow off and moving spouts. Sanitizing is quick thanks to the tilt hopper, tool-free piston removal and quick remove spouts. Hinds-Bock www.hinds-bock.com

Combination Filling System The combination filling system unites Company’s Servo 3600 Auger Filler with two Volumetric Cup Fillers. The system integrates two particulates and a powder within a single pouch at rates of up to 120 units per minute. A continuous motion Vertical/Form/Fill/Seal unit is utilized in place of a tradi-tional Horizontal/Form/Fill/Seal system to improve cycle times and minimize the amount of production space required for the manufacturing process. Applications include soup and baking mixes, pasta and other side dishes, cereal products, and a variety of other consumer convenience products. Spee-Dee® Packaging Machinery, Inc. www.spee-dee.com

FM1206_NewProducts.indd 37 5/24/2012 8:27:57 AM

June 2012 ■

38 PRODUCT REVIEW

Food-Grade Checkweigher The Quick Check ZQ375 is a checkweigher designed with food-grade, stainless steel construction. The system offers a robust, hygienic housing; highly visible, color-coded display; and multi-connectivity operation. Featuring NSF 3-A certification, the unit is specifically designed to meet the sanitation and hygiene stan-dards in food manufacturing applications. With a smooth, polished surface finish; curved corners; and easy-to-remove cover, the ZQ375 allows for fast and effective cleaning, minimizing the growth of microorganisms on the scale and limiting food trap areas where bacteria can thrive. In ad-dition to a hygienic design, the product employs a durable IP69K-rated enclosure with Gore-Tex® Vent technology to allow moisture buildup, a result of temperature change from and hot and cold washdown cycles, to escape and not be trapped inside the enclosure. This mem-brane is an industrial food grade technology that ensures the unit is completely resistant to dust and water in-gress in high pressure and heavy washdown applications. Avery Weigh-Tronix www.wtxweb.com

Can Drying Tunnels Can Drying Tunnels use a variable height plenum with a Y-shaped slot configuration. The systems can be readily supplied to cater to single- or multi-lane conveyors. The units rest on brackets attached to the con-veyor and feature specifically configured slots that direct air to remove the water efficiently while driving it downwards and out of the enclosed area. This enclosed environment ensures the dispelled water is contained and that the drying air performs more effectively than with conventional “open” alternatives. The unique design offers a custom solution to drying all sizes and areas of cans while producing less turbulence and noise than conventional Airknife technology. Air Control Industries www.aircontrolindustries.com

One-Yard Tilt Trucks The 1-cubic yard capacity Poly-Trux® P-405 Heavy Duty tilt truck is ro-tationally molded with a proprietary internal rib design in a single piece from high density polyethylene (HDPE) and set within a powder coated steel support frame and base that together safely accommodate up to 1,300 lbs. of material. The load bearing ability delivers up to 30% more strength than many 1-yard tilt trucks that rely on structural foam or blowmolding with polypropylene (PP). Developed for the collection and transfer of bagged refuse, office waste, recyclables, scrap and other ma-terials, the vehicle rolls and steers easily on two, hefty 10-in. rear wheels and two swiveling front, non-marking casters and is available with op-tional tow hitches, hinged lids and soft, nylon dust covers to hide the waste and help keep any odors inside. The unit comes in standard gray and in custom colors in quantity. MOD www.modroto.com

Portable Dust Collector The PCH Series of portable dust collection systems provides source-point collection of airborne contaminants and prevents contaminants from migrating throughout the facility to settle on equipment and fixtures, contaminate product, or present physical hazards to personnel. The PCH Series collection and filtration system is suitable for a wide range of particulate types. Collection efficiency is optimized, power consumption is reduced and operator obstruction is minimized due to the units’ E-Z Arm® High Flow Extractor arm design. The arm's close-profile, external arm support eliminates the air flow resistance common with internally supported arms. The series also includes a dynamically balanced, non-sparking, all-aluminum motor, designed and built to enable the compact, unit to collect contaminants directly at the source without risk of igniting volatile dusts. Several models are available. Airflow Systems, Inc. www.airflowsystems.com


The most trusted name in Stainless Steel ConveyorsSince 1974, Kamflex has engineered and manufactured quality stainless steel sanitary conveyors. Our engineering response time is the best in the industry and our quality has no equal.

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CIP Pump The Moyno® Sanitary Pump is available in a convenient clean-in-place (CIP) design for quick and easy cleaning. The suction housing is equipped with an additional sanitary connection to accept flow bypass piping and valves. During CIP operation, cleaning solution passes through the pump, washing the internal parts clean, while excess liquid is routed through the flow bypass line and back into the piping downstream of the pump. The unit meets sanitary require-ments and features standard mechanical seals. In addition, it offers clamp-style, DIN or ACME thread connections. The low-shear, non-pulsating flow enables the unit to transport shear-sen-sitive materials with a minimum of turbulence or stress. Other features include:

Flow rates to 325 gpm; pressures to 500 psi Handles solids up to 1 in. in diameter Easy, on-site maintenance Self-priming Low total cost of ownership Pulsation-less flow

Moyno, Inc. www.moyno.com

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Energy-Efficient Lighting The ECO-T™ LED Recessed Troffer is a cost-effec-tive, energy-efficient alternative to traditional fluorescent fixtures. Offered in 2’x2’ and 2’x4’ sizes, the product is designed for installation into T-bar grid (“drop in”) ceilings and offers a high-color rendering index (CRI) of 84. The system is offered in correlated color temperatures (CCT) of 3500K, 4100K and 5000K and comes standard with a dimming driver and prismatic clear diffuser for higher lumens; a translucent diffuser for softer illumination is also available. The 2’x2’ 45-watt model replaces a typical 2U32 fluores-cent fixture and exceeds 3,700 lumens; while the 2’x4’ 55-watt model replaces four F32T8/28W fluorescent lamps and exceeds 4,900 lumens. Designed with the look of a traditional fluorescent fixture, the unit offers a classic recessed housing with LED strips that resemble fluorescent lamps, but operate with the energy saving and long life (50,000 hours) benefits of LED technology. The housing features a room side access door for serviceability and for re-lamping the replaceable LED strips. A discreet, interior mounted Class2 UL-listed LED driver is housed inside the luminaire center cover, and maintains an IC-Rating for the fixture. MaxLite www.maxlite.com

Freeze/Chill Solutions For Meat Processing Company’s range of patented cryogenic freezing/chilling solutions can help meat processors obtain higher throughput and higher yields. Cryogenic technology uses high-efficiency liquid nitrogen or carbon dioxide. Models include:

CRYOLINE® CW CRYOWAVE™ IQF Freezer: Patented rolling-wave action and high-efficiency design provides significant cost savings vs. flight-ed freezers, eliminating CO2 snow carryover and improving cleanability. CRYOLINE® XF Crossflow Spiral Freezer: High-efficiency hygienic design doubles the heat transfer rate of standard spiral freezers, reducing freezing costs. ACCU-CHILLlTM Combo Chiller: Eliminates the back-straining handling and spreading of poultry and meat products and carbon dioxide (CO2) pellets in combo bins with automation.

Linde North America www.linde.com

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June 2012 ■

PRODUCT REVIEW www.foodmanufacturing.com

Screw Heat Exchangers The °Celsius screw heat exchanger presented is an indirect heat exchanger based on a transfer screw design and is used for cooling, heating and drying powders, granules and pastes. The heat is transferred via the trough wall, screw shaft, screw flight or a combination. All systems are custom designed and manufactured to suit individual heating, drying or cooling ap-plications. Kemutec www.KemutecUSA.com

Impeller Technology Company’s impellers are engineered to fit the most challenging application, from miscible and immiscible fluids blending to solids suspension and high viscosity fluid mixing. Models incude:

RL-3 impeller: Reduces maintenance costs and downtime caused by fibrous material buildup. Easily retrofits to existing agitators, provides safe and reliable operation and offers application versatility with a wide range of available sizes and materials. XE-3 axial flow impeller: Designed for heat transfer, blending and solids suspension applications. Smoothline impeller: Features liquid-shedding surfaces and concealed hardware for enhanced CIP performance. The Smoothline impeller enhances cleanability, ensures product purity and optimizes process efficiency. HE-3 impeller: Efficient in creating greater fluid motion with less energy. SC-3 impeller: Engineered for deep tank applications utilizing a rolled blade design.

Chemineer, Inc. www.chemineer.com

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Ultra-High Shear Mixer The X-Series Ultra-High Shear Mixer is designed for products that require great uniformity in a dispersion or emulsion. This inline unit is often used in processes where exceptionally narrow particle size distributions are desired within a single pass. The system delivers more vigorous mixing, greater size reduction and higher throughput compared to conventional colloid mills. In certain applications, even formulations that previously warranted a move to expensive, high-pressure homogenizers can now be successfully produced in an ultra-high shear mixer. Sample applications include flavor emulsions, salad dressings, sauces, spreads, condiments, gum dispersions, fruit pulps, syrups and beverages. The product consists of a precisely-machined stator with con-centric rows of teeth and a matching rotor turning at tip speeds more than 11,000 ft./min. Process fluid enters the center of the generator and acceler-ates outward through channels in the intermeshing teeth of the rotor/stator. This subjects the product to intense mechanical and hydraulic shear — and thousands of shearing events in a single pass. Charles Ross & Son Company www.mixers.com

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EQUIPMENT AND MATERIAL

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Sanitary Design Standards For Bakery Equipment Jennifer Frankenberg, Vice President, SAGE Food Safety Consultants, LLC

IndustryINSIDER

June 2012 ■

42

From 2008 to 2011 bakery product recalls due to unde-clared allergens have increased 360 percent. Over that same time span, microbiological recalls accounted for a quarter of total bakery recalls. These food safety statistics

highlight the importance that food processing and packaging equipment design and installation play, especially in the ability to control microbiological and allergen contamination. Sanitary food equipment design and installation should prevent niches for microbial harborage, as well as points for food allergens to accumulate. These areas must be readily and easily accessible for cleaning and inspection to prevent food safety issues that could result in costly recalls. In addition, the proper design and instal-lation should result in efficiencies that result in operational cost benefits.

In the early 2000s, the American Society of Baking (ASB) became the Secretariat for the Baking Industry Sanitary Standards Committee (BISSC) standard for the sanitary design of bakery equipment. This standard has been in existence for a number of years and needed to be updated and to become a consensus standard to become more acceptable to the indus-try. ASB converted the BISSC standard document to an ANSI standard. The document is now known as the ANSI/ASB Z50.2 American National Standard for Bakery Equipment – Sanitation

Standards. In late 2010, several trade associations including the American Bakers Association (ABA), AIB International and Bakery Equipment Manufacturers and Allieds (BEMA) retained SAGE Food Safety Consultants, LLC to work with the Z50 Committee and facilitate the process of reviewing and updating the ANSI Z50.2 docu-ment.

With SAGE’s facilitation, several working groups were formed, each tackling individual sections of the equipment standard. Initially, the working groups focused on revising definitions and basic design princi-ples. Next, the groups concentrat-

ed on specific equipment types within their areas of expertise. In total, there were 68 working group conference calls over the

span of nine months. Out of these conference calls, a document was generated with over 264 line changes. Obsolete sections were removed and another 50 sections were added to address new technologies and expand on what already existed in the document.

In February 2012, the revised draft of the standard was pre-sented to the Z50 Committee, which then voted on the sug-gested changes. The draft revision was approved and is mov-ing forward to the next step of public comment. During the public comment phase, individuals are welcome to review and comment on the document. All submitted comments must be addressed individually before the revised document can become an official standard. Jennifer Frankenberg of SAGE Food Safety Consultants, LLC commented, “This is a critical point in the pro-cess where we have the opportunity to improve this document through continued dialogue with the industry. I truly encourage everyone to participate by reviewing the document and submit-ting their comments.”

In the meantime, Jennifer says they are not sitting still – new working groups have already been formed to address different equipment types, such as robotics and control panels. One goal for the project is to encourage more bakers, sanitarians and regulatory officials to participate in the process to get a balanced perspective on what users need from equipment manufacturers to ease the cleaning process. “This is an ongoing process as we work with this 'living document' that requires constant updating to keep up with changing technology and industry needs. We have a lot of work ahead of us over the next couple of years. Our next goal is to submit another revision to the Z50 Committee early in 2013.” ◆

This month's topic:

BAKERY

With SAGE’s facilitation, several working groups were formed,

each tackling individual sections of the equipment standard.

FM1206_IndustryInsider.indd 42 5/24/2012 8:24:32 AM

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