Educating the Dietary Supplement Industry on What Goes Into Quality Audits and Auditor Quality

PLUS Environmental Controls ■ pH in Dairy Products ■ Cadmium: A Clandestine Threat

Volume 22 Number 1 FEBRUARY / MARCH 2015

Educating the dietary supplement industry on what goes into quality audits and auditor quality

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WWW.INVISIBLESENTINEL.COM CO V E R: © N omad_So u l / L e s Cu nli ff - Fotolia.com Food Quality & Safety is a proud member of: United Fresh Produce Association Folio Ozzie and ASBPE award winner for editorial and graphics excellence. POSTMASTER: Returns and address changes to Food Quality & Safety magazine, PO Box 986, Levittown PA 19055-0986 P. 215.966.6118 | [email protected] | www.invisiblesentinel.com Invisible Sentinel® and Veriflow® are trademarks of Invisible Sentinel, Inc, of Philadelphia, PA. February/March 2015 5 Contents FEBRUARY/MARCH 2015

Features Cont. Safety & Sanitation Manufacturing Columns 28 How to Fit Training Into & Distribution Your Production Schedule - Fotolia.com ry © P ict ur e-Facto 40 Keep Your Cool Washington Report providing food safety training automation technology played a 11 Food Safety Outlook for when new employees are for 2015 onboarded to a company critical role in Hill Country Bakery’s implementation of a temperature the U.S. food system’s New Year By Jennifer McCreary monitoring system at its distribution resolutions include working within and Marie Lefaive center government budgets, meeting inspection goals, and forming By Georgia H. Whalen © pixde s ign123 - Fotolia.com and Nick Hitchcock, PE better ties with China By Ted Agres Quality Food-Grade Lubrication 30 Sweet and Savory: 42 Popular Ingredients with Utilizing single point automatic Possible Lawsuits lubricators can increase both Industry Insights productivity and safety in the food FDA’s proposed rules and guidelines industry 13 Cracking the Case of a on the two most common food Multi-State Salmonella additives—sugar and salt— By Toby Porter Outbreak present a number of challenges for a look at the serious consequences manufacturers that occurred when a peanut butter company put their profits By Michael Gruver ahead of safety and Glenn Pogust Food Service & Retail 44 Floor Cleaning Eye-Opener By Darin Detwiler, M.A.Ed. mat - Fotolia.com © A a r on mat advanced cleaning techniques 33 Compression on soiled floors can eliminate the and Tension in Measuring direct/indirect contact areas that Physical Properties are sources of contamination Around The World Various types of fixtures can be By Robert Kravitz 15 oUt of Africa used to perform everyday QC tests for food and packaging materials Food safety and quality initiatives 47 Supporting a Store Brand are growing on this wildly diverse By Robert McGregor continent a manufacturer’s perspective on the fundamentals of choosing By Linda L. Leake, MS 35 Flow Behavior of Chocolate quality suppliers Melts: Working According to ICA Standards By Tom Boyd and Jim Jackson an application note on viscotesters Departments being used in QC applications for 8 From The Editor chocolate products 10 nEws & Notes By Klaus Oldörp, PhD Special Report 49 Cadmium: A Clandestine 52 New Products Threat to Food Safety 53 Events this poisonous heavy metal 53 Advertiser Directory is occurring at increasing Testing concentrations in agricultural 54 Scientific Findings 37 Determining pH During systems Cheesemaking By Nick Kim, PhD guidelines and considerations and Brett Robinson, PhD for measuring pH in dairy products By David Masulli Exclusive Online Content

To read this article, go to the © Ze rb o r - Fotolia.com February/March issue on www.foodqualityandsafety.com: facebook.com/FoodQualityandSafety • The Growing Global Milk Market

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Please note this is a COMMON SIZE mechanical file, you will need to center file using the center marks Job Name: WATR16748_A_QDa Corp_R_2015_DBmec.indd provided when placing ad in the publication page area. (common size = smallest live/smallest trim/largest bleed) SPECS APPROVALS Small Trim: 7.75” X 10.5” PUBS: Food Processing Pharmaceutical Discovery Large Trim: 8.375” X 10.875” AD: PM: American Laboratory Food Quality & Development Food Safety Magazine Pharmaceutical Manufacturing Bleed: 8.625” X 11.375” CW: MK: American Drug Discovery American Pharmaceutical Review Genetic Engineering News (GEN) Pharmaceutical Technology Live: 6.75” X 9.5” CD: PP: Bio Business Genome Technology Pharmaceutical Technology EUROPE Colors: 4C Bio IT World Genomics & Proteomics Pharmaceutical Executive ST: QA: BioTech World Jour of The American Soc for Pharm Form and Quality Scale: 100% BioTechnology Focus Mass Spectrometry Proteomics Journal Other: QDa ®, 2015 QR Code Check iPhone DROID BioPharm International Lab Asia Media Guide Scientific American BioProcess International Lab Business - Jesmar Scientific Computing & Instrumentation LCGC Asia Scientific Computing World RELEASE DATE 01-09-15 Chemical & Engineering News Drug Discovery and Dev LCGC N. America Drug Discovery News LCGC Europe Environmental Science & Technology Molecular and Cellular Protemomics Nature Methods Publisher Lisa Dionne, [email protected] Associate Publisher Ken Potuznik, [email protected] Editor Marian Zboraj, [email protected] Design Maria Ender, [email protected] From The Editor Production Claudia Vogel, [email protected] Christiane Potthast, [email protected] Elli Palzer, [email protected] MANAGER, DIGITAL MEDIA & STRATEGY Jason Carris, [email protected]

resident Barack Obama Advertising Sales Director is looking to consolidate Stephen Jezzard food safety. At press time, 350 Main Street Malden, MA 02148-5089 the President proposed (781) 388-8532 Pa bill as part of his 2016 budget [email protected] plan to create a single food safety Sales Office U.S./Canada/International agency by combining the respons- Ken Potuznik bilities of the FDA, USDA, and 29822 N 51st Place, Cave Creek, AZ 85331 (480) 419-1851 • fax (480) 718-7719 other agencies in order to better [email protected] protect the food supply. Editorial Office The proposed agency would be housed within the Depart- 111 River Street, Hoboken, NJ 07030-5774, USA Reprints: E-mail [email protected] ment of Health and Human Services (HHS) since food safety and foodborne outbreaks are public health concerns, falling in line Editorial Advisory Panel with the larger mission of this department. It would be independent from the FDA and be primarily responsible for food inspec- Betsy Booren, PhD Jennifer McEntire, PhD Chief Scientist VP and Chief Science Officer tions, outbreaks, and mitigation. American Meat Institute Foundation The Acheson Group Currently, most of the responsibility for food safety and in- Gerry Broski Mary Ann Platt Sr. Marketing Director, Food Safety President spections lies with the FDA and USDA. However, according to the Neogen Corp. CNS/RQA, Inc. bill, the current system’s “fractured oversight and disparate reg- Christine Chaisson, PhD Director Mike Robach ulatory approaches” have been known to cause confusion. The The Lifeline Group Vice President, Corporate Food Safety, Quality, & Regulatory bill states that consolidation “is an essential step to reforming the Virginia Deibel, PhD Cargill Director, Microbiological Consulting federal food safety system overall.” Covance Laboratories Bob Swientek Agriculture Secretary Tom Vilsack says a single agency would Caroline Smith DeWaal Editor-in-Chief, Food Technology Food Safety Director magazine expedite the sharing of information and ensure better coordina- Center for Science in the Public Interest Institute of Food Technologists tion, cutting down on delays that could prevent the government Sara Elhadidy Purnendu Vasavada, PhD Senior Food Scientist PCV & Associates and Professor of from acting—which he acknowledges sometimes occurs due to Unilever Bestfoods Food Science having multiple agencies. Ultimately, the proposed bill is meant Philip H. Elliott, PhD University of Wisconsin Food Safety, Global Quality Assurance to streamline inspections and eliminate unnecessary overlap. W.K. Kellogg Institute Patricia A. Wester President Of course there are skeptics. One of the main concerns of Daniel Y.C. Fung, MSPH, PhD PA Wester Consulting Professor, Food Science & Animal Sciences critics is housing the new agency under HHS. Many worry that Kansas State University Craig Wilson Vice President, Food Safety food safety won’t get the attention it deserves under this massive Steven Gendel & Quality Assurance Vice President, Div. of Food Allergens Costco Wholesale department because it’s already responsible for administrating IEH Laboratories & Consulting Group other important health programs. Tim Jackson Steven Wilson Director, Food Safety U.S. and Canada. Chief Quality Officer Meanwhile, groups like the National Consumers League are Nestle USDC Seafood Inspection Program praising President Obama’s new proposal. “Our current food systems are redundant and fragmented,” says Sally Greenberg, Printed in the United States by Dartmouth Printing, Hanover, NH. Copyright 2015 Wiley Periodicals, Inc., a Wiley Company. All rights reserved. No part executive director. “Consolidating USDA’s Food Safety Inspec- of this publication may be reproduced in any form or by any means, except as permitted tion Service and FDA’s food safety oversight will ensure cohesive under Sections 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the publisher, or authorization through the Copyright Clearance practices and superior response times in the event of an outbreak, Center, 222 Rosewood Drive, Danvers, MA 01923: (978) 750-8400: fax (978) 750-4470. All materials published, including but not limited to original research, clinical notes, ultimately keeping consumers and our food supply safer.” editorials, reviews, reports, letters, and book reviews represent the opinions and views of The group is urging Congress to support the creation the authors and do not reflect any official policy or medical opinion of the institutions with which the authors are affiliated or of the publisher unless this is clearly specified. Materials of the new food safety agency, but many believe the published herein are intended to further general scientific research, understanding, and discussion only and are not intended and should not be relied upon as recommending or President’s proposal will likely meet opposition in the Republican- promoting a specific method, diagnosis or treatment by physicians for any particular patient. controlled Congress… While the editors and publisher believe that the specifications and usage of equipment and devices as set forth herein are in accord with current recommendations and practice at the time of publication, they accept no legal responsibility for any errors or omissions, Marian Zboraj and make no warranty, express or implied, with respect to material contained herein. Publication of an advertisement or other discussions of products in this publication should Editor not be construed as an endorsement of the products or the manufacturers’ claims. Readers are encouraged to contact the manufacturers with any questions about the features or limitations of the products mentioned.

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NEWS & NOTES

Assessing Vulnerabilities Combating Illegal Fishing for Food Fraud The Presidential Task Force on Combating Illegal, Un- USP releases “Guidance on Food Fraud Mit- reported, and Unregulated (IUU) Fishing and Seafood igation” for the food industry and its regula- Fraud releases its recommendations to identify ways tors to develop and implement preventive for the government to prioritize actions to address management systems in dealing with eco- IUU fishing and to protect seafood and ecological nomically-motivated fraudulent adulteration resources. Some of the key actions recommended of food ingredients. The guidance allows in- include supporting legislation to implement the Port

dividual assessment of all the indicators and State Measures Agreement setting standards for port e -f o t lia. com e Natur © Cr e ativ factors known to contribute to fraud vulner- inspections to prevent IUU seafood from entering commercial markets; developing best prac- abilities and impacts, as well as qualitative tices for electronic systems to collect catch information, track data, and improve reporting from tools to make sense of the results. Contrib- all vessels involved in the fisheries supply chain, including Automatic Identification Systems uting factors included in the tool go beyond and low-cost technologies suitable for smaller vessels; and adjusting tariff codes to enhance fraud history and include economic and geo- identification of illegal species or seafood fraud. political anomalies, audit strategies, and supply chain and supplier characteristics. Final Guidance on Labeling of Certain Beers The U.S. FDA issues final guidance in assisting manufacturers in the labeling of bottled or otherwise packaged © i n du s tri e bli c k - Fo t o lia. com beers. Certain beers that do not meet the definition of “malt beverages” are not subject to the labeling provisions of the Federal Alcohol Administration Act. This refers to beers that are not made from both malted barley and hops but are instead made from substitutes for malted barley (such as

sorghum, rice, or wheat) or are made without hops. These particular beers are subject to the © h ose 69 - Fo t o lia. com Environmental Impact Statement food labeling provisions of FDA laws and regulations. The FDA’s Draft Environmental Impact State- ment examines the potential environmental effects of its proposed produce safety rule— Business Briefs entitled Standards for Growing, Harvesting, Listeria Awareness Packing, and Holding Produce for Human and Education NSF International partners with the IDDBA American Feed Industry Association Consumption. The draft focuses on four key This year, the Interna- to conduct audits for its Safe Feed/Safe areas in the rule: definition of covered farms, tional Dairy-Deli-Bakery Association is con- Food Certification Program. water quality standards, biological soil ducting a year-long food safety initiative amendments of animal origin (such as ma- campaign called Safe Food Matters! to build GFSI recognizes SQF against the Guid- nure and compost), and actions taken with awareness of safe food practices and serve ance Document Sixth Edition for the respect to domesticated and wild animals on as an industry resource for food retailers, scope of Storage and Distribution. farm lands. Only the water quality standards manufacturers, and their employees. The have been recognized as potentially having Initiative will focus on best practices for de- Mérieux NutriSciences acquires the a significant adverse environmental impact. creasing the potential for Listeria monocyto- Randolph Companies, which provide Draft identifies proposed supplemental genes growth and cross-contamination, par- technical services to the food industry. The Randolph Companies remain sep- changes that would allow time for potentially ticularly for deli ready-to-eat foods. Taking arate entities and will continue to be dangerous microbes in agricultural water to the proper steps in educating retail service operated independently of each other. die off, as the environmentally preferred op- associates on safe food handling, cleaning tion. The flexibility provided by this option is and sanitation procedures, equipment main- LECO Corp. broadens its accreditation the reason why most covered farms would tenance, and good employee practices can for Reference Materials under the A2LA not need to change their water source or treat help reduce the possibility of Listeria growth Accreditation Program for Reference Ma- their water with chemicals. in perishable service departments. terial Producers in compliance with ISO.

10 FOOD QUALITY & SAFETY www.foodqualityandsafety.com © Picture-Factory - Fotolia.com

ashington Washington A small businesses andoutlining activities clarifying definitionsofsmall and very to four ofthese rules, the first forexample, 2014 hadissuedproposed minorrevisions the endofOctober. TheFDA inSeptember Program, andthird-party accreditation by safety, theForeign Supplier Verification end ofAugust, andfinalrulesforproduce preventive controls foranimalfoodbythe preventive controls forhumanfoodand Act (FSMA). Theseinclude finalrulesfor of theFood Safety andModernization tions to implementfive major provisions year, theFDA willpublishfinal regula- ity forfoodsafety. Bythelatter halfofthis on theprivate sector to take responsibil questionable countries increase. frompands andimports Chinaandother challenging astheglobal supply chain ex best, thistaskpromises tobest, become more sources lagging orremaining modestat system. Butwithfinancial andother re- and securityofthenation’s foodsupply cessors inthedrive to improve thesafety forming better ties with China | within government budgets, meetinginspection goals, and The U.S.food system’s New Year resolutions include working Food Outlook for 2015 Safety All thiswillcontinue to putpressure growers, producers, andpro ing up theiroversight offood local governments willberamp unfolds, state, federal, and s 2015 - - - -

By & Safety comply withFSMA,” headds. Buttheywill lacking,” Dr. Acheson tells Unfortunately those resources willbe with different countries andindustries. the outreach thattheagency needsto do programs, theeducation strategies, and for FDA isbuilding theFSMA training Acheson says. “Whatwillget expensive FDA’s obvious lack ofresources,” Dr. sociate commissioner forfoods. The Acheson Group and a former FDA as David Acheson, MD, founderandCEOof chain controls, andproduct testing,” says around environmental monitoring, supply pected gaps inthepreventive control rules the re-proposals filledinsomeoftheex change inthefinalrules, particularly as time around. “We don’t expectto seemuch are likely to bevery similarthesecond comments from industry, thefinalrules changes hadbeentriggered byearlier tion andinspection. into afoodfacilitysubject to FDA registra- that would re-categorize farm atraditional tally clueless about what theyneeddoto food companiesmedium-sized will be to

Ted “The big challenge“The will be in2015 Because many oftheproposed new Agres magazine. “Many small- and Food Quality Food Quality Report - - - and “omnibus”) spending bill,FDA’s bud “cromnibus” (for“continuing resolution” locked into place. Under the $1.1-trillion and otherfood-related agencies federal are cal Year budgets 2015 forFDA, USDA, CDC, Appropriations (HR83) Act, 2015 , theFis of theConsolidated andFurther Continuing and thanksto enactment lastDecember’s The current 30, fiscal 2015 Sept. year ends Budget Status Quo should bewell positioned. most of them have been preparing, they the finalrulesare publishedbutbecause hand, have only oneyear to comply after room. Big food companies, on the other regulations andthushave somebreathing have two to three years to comply withthe regulations. ment agencies to implementmany FSMA sistance to state, federal, and local govern withandprovidepartner cooperative as the agency’s aging ITinfrastructure, and hire more andtrain inspectors, improve FSMA. Much ofthiswould beusedto next two to three years to fully implement mates itwillneed$300millionover the increase isvitalbecause theagency esti- come from userfees).Nevertheless, any lion, thelion’s share ofwhich would have inally requested an increase of $263 mil funding levels (theWhite House hadorig crease by only $27.5 million over the2014 these andotherFDA centers andoffices in $147 million.Food safetyactivities within Center forVeterinary receives Medicine plied Nutrition gets $903million andthe ical devices, andtobacco products. of prescriptioners andgeneric drugs, med user fees, imposedmostly onmanufactur ance comes from newandexisting industry House hadrequested. The$1.85 billionbal year and$4 million more than the White percent) more thantheagency received last public funding, which is$37 million(1.5 this total, about $2.59 billion comes from percent) increase over Fiscal Year 2014. Of get risesto $4.44 billion,a$96.7 million(2.2 FDA’s Center forFood SafetyandAp February/M arch 2015 (Continued onp.12) 11 ------WASHINGTON REPORT

(Continued from p. 11) The funding bill gives the CDC nearly interest to them or their constituents that “I don’t believe FDA will have enough $405 million to respond to the growing otherwise would not have been passed resources to pay the states all they need and threats of emerging and zoonotic infec- into law. One of these provisions bars the states will not have the funding to do it tious diseases. Of this amount, nearly poultry that is processed and cooked in on their own,” Dr. Acheson says. For exam- $48 million is dedicated to food safety, China from being used in the nation’s ple, state agencies have traditionally been an increase of $8 million for the agency to school lunch and breakfast programs, the responsible for inspecting farms while US- acquire “advanced DNA technology to im- Child and Adult Care Food Program, and DA’s Agricultural Marketing Service (AMS) prove and modernize diagnostic capabili- the Summer Food Service Program. FSIS inspects, certifies, and grades agricultural ties and enhance surveillance, detection, had previously granted approval to four and other farm products. Under FSMA, FDA and prevention efforts at the state and lo- Chinese poultry processing plans to ex- will have the authority to inspect certain cal levels.” CDC labs receive an additional port cooked chicken to the U.S. so long as food safety issues on larger farms, a respon- $7.25 million to “establish cutting-edge lab the birds had been raised and slaughtered sibility it would prefer to delegate. “AMS diagnostics to improve rapid identification in the U.S., Canada, or Chile. The decision inspectors are trained in food quality and and detection of emerging pathogens; es- raised red flags, so to speak, among U.S. in grading, not in food safety,” Dr. Acheson tablish an innovative e-pathology system consumer and other groups because of says. “Someone will have to pay for their to speed communication and establish China’s abysmal food safety record. training as food safety professionals.” virtual specimen sharing in real time; and Democratic Reps. Rosa DeLauro Last year, public health organizations increase research capacity and safety in of Connecticut and Chellie Pingree of including the Pew Charitable Trusts, the high-containment labs.” Maine, both members of the House Ap- American Public Health Association, and propriations Committee, had added the the Association of Public Health Laborato- USDA Inspections amendment to the Fiscal 2015 USDA ap- ries pressured lawmakers to increase FDA’s The funding bill also allocates slightly propriations bill last spring and congres- funding for FSMA. Expect to see similar more than $1 billion to USDA’s Food Safety sional leaders included the provision in actions this year especially because of and Inspection Service (FSIS). In order to the omnibus spending bill. “Banning worries that the fiscally-minded, Republi- counter economic fraud and improve the Chinese chicken from school meals is a can-controlled Congress may be reluctant safety of the nation’s seafood supply, FSIS, common-sense step to protect our kids,” to grant the agency significant additional in conjunction with USDA and FDA, “is en- DeLauro said in a statement. “China’s funding. Indeed, there already are signs couraged to support developing technolo- food safety record is atrocious, yet last year of congressional mistrust; the funding gies that will provide rapid, portable, and USDA deemed poultry processed in China bill gives the inspector general at the De- facile screening of food fish species at port to be as safe as poultry processed here. partment of Health and Human Services sites and wholesale and retail centers,” the Children are among the most susceptible (FDA’s parent agency) $1.5 million extra explanatory statement says. to foodborne illness. We cannot take un- to conduct oversight investigations of the As part of its emphasis on prevention necessary risks with their health.” China, FDA. The bill notes that FDA’s resources of foodborne pathogens, FSIS this year predictably, was not pleased. China’s Min- have increased by more than 60 percent hopes to encourage private facilities to istry of Commerce spokesman Sun Jiwen over the past five years as its responsibili- voluntarily develop food defense plans to urged the U.S. “to take effective measures ties have grown, but effective oversight has prevent intentional contamination, with to correct the erroneous practice and cre- not kept pace. the goal of achieving 90 percent compli- ate a favorable environment for the healthy The real reason appears to be more ance by September 30. FSIS also wants to development of Sino-U.S. economic and deep-seated. “During the past year, FDA develop new and enhance existing poli- trade relations.” has informed non-governmental stake- cies, procedures, notices, and directives Despite this, Washington and Beijing holders of important decisions and an- to industry to sample, test, and establish will continue taking steps to improve food nouncements before they informed the new Salmonella performance standards relations. Last November, Michael R. Tay- [congressional] committees,” according for raw ground chicken and parts, raw lor, JD, FDA deputy commissioner for foods to an explanatory statement of the fund- beef, and raw pork. It will also direct more and veterinary medicine and point person ing bill, which also carries the weight of than 80 percent of its investigative and en- on FSMA, met with food safety officials in law. “A collaborative working relationship forcement activities on food safety issues. Beijing to discuss improving collabora- between the committees and the agency is In July, FSIS is expected to finalize record- tion. “The legal, regulatory, and technical necessary to ensure efficient and effective keeping regulations that will require all gaps between our systems are challeng- implementation of Congress’s funding establishments and retail stores that grind ing, but we think they can be overcome decisions. These actions jeopardized this raw beef products intended for commerce with sustained effort,” Taylor told a food relationship. As such, FDA is directed to to maintain records of their suppliers. conference in Shanghai at the time. He ensure the committees are notified of ma- also announced that FDA hopes to triple jor changes to existing policies and any China Food Not Welcomed the number of full-time staffers in China significant developments in its operations The 1,600-plus-page funding bill has been who focus on food safety—from four to 12. ■ prior to providing non-governmental criticized because lawmakers inserted Agres is a freelance writer based in Laurel, Md. Reach him stakeholders such information.” a number of amendments of particular at [email protected].

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B the ground, unable to stand. Tony drove years, andtheirsonTony, foundhimon day morning, Shirley, Pete’s wifeof45 withvomitingcramps - anddiarrhea.Mon complaining of excruciating abdominal soft-spoken man was unable to avoid ence severe dizziness. Byday’s end, this Sunday Pete began in2008, to experi- Editor’s Note: food safety crisis. part account ofa2008-2009 nationwide a peanut butter company put theirprofits ahead of safety A look at theserious consequences that occurred when a Multi-State of the Case Cracking Outbreak B y Darin Detwiler, M I glove mill.On alate November ing formore than30years ata had recently retired after work obby Ray “Pete” Hullet, age 67, ndustry ndustry This is the first inathree- isthefirst This . A .Ed. Salmonella - in North Carolina, where doctors immedi - his father to thehospital near their town a short-term care facilitynearherhome. tion. Her doctor recommended shestay in Minn., contracted infec aurinary tract widow Shirley MaeAlmerofPerham, Pete asdeceased. fore Thanksgiving—doctors pronounced third day inthehospital—and theday be- in Pete’s body was shutting down. Onhis the doctors told hisfamily thatevery organ and stool specimensforthelab to analyze. tibiotics. Theyalsocollected urine, blood, ately puthimonIVfluids, oxygen, andan At about this same time, 72-year-old As hiscondition continued to decline,

I nsights

- - pancreatitis asa iner identifiedthe apparent cause ofher autopsy,Shelander’s themedicalexam- began suffering from extreme nausea and to North Carolina. OnDec.27, Betty 2008, various television shows—before retiring in Los Angeles andNew York—even on as aprofessional actress/singer/dancer even herdoctors. Christmas, caught everyone bysurprise— goodbye. death, four days Shirley’s before family to gather byherbedsideto say mas was halted as doctors called for the ly’s planto bring Shirley homeforChrist to handlethesenewinfections. Thefami- mune system was nownotstrong enough lung cancer tumor, andabrain herim- strength to survive herearlierfights with stomach anddiarrhea. cramps infectionwas latertract complicated by treatment ofherurinary dren. Thestaff’s visits from herfive children andgrandchil imurium cases from 16states of PulseNet stafflearnedof 35 separate In early the CDC’s December 2008, GrowingThe Investigation Salmonella of herdeath.Shirley Mae Almerdiedfrom Almer andhissiblings learnedthecause Several days after burying theirmother, Jeff monella results camein.Pete Hullett diedfrom formed Tony Hullett test thathisfather’s cause ofdeathaspancreatitis. shortly after herarrival. Doctors listed the gency room. She was declared asdeceased her unconscious onthefloor and called911. found husband, Albert, Betty’s afternoon, prescribed somemedicinefor relief. That vomiting. doctor Thenextmorning, Betty’s an ambulance brought herto theemer Shirley made the best of it, evenShirley madethebestofit, enjoying field gel electrophoresis (PFGE) pattern. Betty Shelander,Betty age 53, performed Although Shirley had the will and the On Dec. 23, 2008, health officialsin- On Dec.23, 2008, Betty had no signs of life by the time hadnosignsBetty oflifebythetime

—all withanunusualpulsed- Typhimurium

Typhimurium Salmonella February/M arch 2015 : “Heavy Growth.” Salmonella (Continued onp.14) . During Betty . During Betty infection. infection.

Typh Sal 13 - - - - - INDUSTRY INSIGHTS

(Continued from p. 13) STOP Foodborne Illness, a non-profit food Soon, CDC, state, and local investigators Through the collabora- safety organization. STOP convinced FDA had their hands full with a second group tion of CDC and health officials to meet with him in January 2009. of 41 cases from 17 states displaying similar officials from Minne- The organization also connected Kendrick PFGE patterns as the first. with a reporter at The New York Times and a By the beginning of 2009, investiga- sota, Connecticut, and producer from ABC’s Good Morning Amer- tors declared that the clusters shared the Michigan, investigators ica show. same DNA fingerprint and made up a sin- linked all of the infec- Texas officials had no idea that the gle-strain outbreak. Through the collab- tions to peanut butter. Plainview facility even existed. Parnell had oration of CDC and health officials from not registered his Texas peanut facility as Minnesota, Connecticut, and Michigan, a food processing plant with the state. As investigators linked all of the infections to a result of Kendrick’s whistleblowing, fed- peanut butter. these illnesses and deaths: dirty condi- eral authorities and the Texas Department When CDC officials asked Pete Hul- tions in the food processing plant, such of Health investigated the Texas plant as lett’s wife about the foods he ate, she as mold and grease–along with bird drop- another source of the outbreak. His infor- shared that his favorite treat was Aus- pings, rats, and roaches. They also noted mation helped prove that peanut products tin-brand peanut butter crackers. “He ate leaks in the roof. In addition, inspectors were being shipped between PCA facilities it as a snack two or three times a day—usu- found that the PCA plant did not apply in different states–contrary to what Par- ally just a few before he went to bed.” high enough roasting temperatures to kill nell had told the public and investigators When Minnesota State health officials any Salmonella in their product. throughout the outbreak. asked Shirley Mae Almer’s family about Though the FDA shut down PCA’s On Jan. 28, 2009, Texas authorities or- what she ate while in the long-term care fa- Georgia plant, Stewart Parnell, PCA’s dered PCA to stop distribution and recall cility, one of her daughters mentioned that owner, continued operation of his Suffolk, their product out of the Texas facility. At during a family visit she served her mother Va., plant. He stated early on that products the time, its peanuts were ingredients in some toast with peanut butter. According were not shipped back and forth between more than 3,500 products produced by to Shirley’s son, Jeff, “She was picky about PCA’s various facilities in different states. numerous companies, such as King Nut what she ate, but she liked peanut butter This statement proved to be false. and Austin. on toast.” Unbeknownst to investigators, PCA Federal authorities identified PCA as An investigation into the foodborne ill- also had a peanut processing plant in the cause of the multi-state Salmonella ness that took the life of Betty Shelander tied Plainview, Texas, where Kenneth Kend- outbreak that sickened 714 consumers in her Salmonella infection to the consumption rick served as assistant plant manager for 46 states and caused the deaths of nine of a contaminated peanut product. several months in 2006. Back then, Kend- people between September 2008 and rick observed numerous problems in the March 2009. Traceback to the Texas plant, including rat infestations, Victims’ families, including those of Unsuspected Source bird nests, and a roof leak—all of which Pete Hullet, Shirley Mae Almer, and Betty Minnesota Department of Health deter- triggered his concern for feces in the prod- Shelander, would wait almost six years to mined that the common denominator uct. According to Kendrick, “particularly see Parnell and other executives from PCA between the individuals infected was with water leaking off a roof, bird feces can brought to justice. Though the U.S. Depart- King Nut creamy peanut butter. FDA of- wash in and drip onto the peanuts.” ment of Justice indicted four executives ficials would soon identify the Peanut Kendrick sent anonymous emails and from PCA in February 2013 on 76 criminal Corporation of America (PCA) as the only letters to the Texas Department of Health charges including the sale and distribution company that produces King Nut brand and to companies that purchased prod- of adulterated food, none of the charges peanut butter. ucts from his plant—but he never received would technically involve PCA’s sickening Simultaneously, the Connecticut a response. or killing of their consumers. ■ Department of Public Health completed In 2006, after only a few months on the Detwiler is the senior policy coordinator for food safety at numerous tests on containers of King Nut job, Kendrick chose to leave his position STOP Foodborne Illness. He has over 20 years of involvement peanut butter, findingSalmonella in each with PCA because as he stated, “I knew it in food safety reform, including having served two terms as a USDA regulatory policy advisor on meat and poultry container. The CDC conducted a second was a train wreck and something unethical inspection. Detwiler teaches the Regulatory Affairs of Food study, finding prepackaged peanut butter and bad was about to happen.” at Northeastern University where his is also a Doctoral Candidate in Law and Policy. Reach him at ddetwiler@ crackers as another link in the illnesses. When Kendrick learned that the wide- stopfoodborneillness.org. Contributing to this article were Austin and Keebler brand prepackaged spread Salmonella outbreak in 2008-2009 Wendy Maduff, PhD, a food scientist, and Pamela Crawford, peanut butter crackers, produced at a traced back to PCA’s Georgia plant, he a food industry student of the author. North Carolina facility, obtained their pea- spent “hundreds of hours” trying to con- nut butter paste from PCA. tact the media and federal food or health COMING IN APRIL/MAY ISSUE… The Federal inspections of PCA’s Blakely, agencies to get attention placed on the next article in this review will focus on Ga., processing plant in 2009 revealed Texas plant as well. The only response he the PCA scandal from a whistleblow- problems that would seem to cause all received was from the Chicago office of er’s point of view.

14 FOOD QUALITY & SAFETY www.foodqualityandsafety.com © Ekler - Fotolia.com

“I of contrasts, says Lucia Anelich, PhD, this adage, Africaisdefinitely a continent lion Africansshare theimplicationsof safety. Whileitcould besaidthatall1.1 bil Editor’s Note: of eachcontinent. food quality, safety, issues andregulatory part series ofarticles that will showcase diverse continent | Food safety and quality initiatives are growing onthis wildly Around Around proverb associated withfood dance.” goes So theAfrican stomach, itdrums foryou to f you give badfoodto your This isthesecond inasix-This Out of Africa Out ofAfrica

By Linda L. Leak -

well-developed manufacturing andretail crop management companies, andalso industries such asfertilizer, seed,and commercial farms and associated support formalized agriculture, withfirst world oped invarying degrees. Only afewhave “Other African countries are more devel their populations,” Dr. Anelich begins. dominantly street foodvending to feed lying onsubsistence farming andpre- Africa. South principal ofAnelich Consulting, Pretoria, , “We have anumberofcountries re- MS The The Worl - farming, food manufacturing, and retail tion interms offoodsafety. as thecontinent’s mostadvanced legisla- supporting regulations shecharacterizes ufacturing, and food retail system, with production, foodprocessing andman - ture, andawell-established formalfood boastingcan continent, asolidinfrastruc is themostdeveloped country ontheAfri- ety offoodproducts.” sectors offering the consumer awide vari- sector that caters to thedomestic,regional, more involved in regional and interna - Tamale, Ghana. versity forDevelopment Studies(UDS) in crobiology andfoodsafety withtheUni- Saba,Setsoafia PhD, alecturer infoodmi- can countries, according to Courage Kosi commoditiesport from anumberofAfri- normally raw produce, are somekey ex yams, mangos, andbananas, which are economic growth, Dr. Anelich says. food isbecoming ofthat anintegral part food economy and international in trade African economies are growing, andthus Growing Economies pia asitsheadquarters. on June with Addis 26, 2001, Ababa, Ethio Africa’s states except Morocco was formed consisting a 54memberfederation ofall nent’s countries, theAfricanUnion (AU), cooperation and peace among the conti - rope combined. Offering hopefor greater than theU.S., China,Japan, India,andEu ond-most-populous continent is larger of theworld’s second-largest andsec 11.7 millionsquare miles, thelandmass of 54very diverse countries. Covering most developed inthisregard.” can countries, Africaremains butSouth the erate foodproduction plantsinmany Afri- There are multinational companies thatop and international markets,” sheelaborates. “South Africa has a well-established Africahasawell-established “South According to Dr. Anelich, Africa South “Countries in Africa are becoming To that end, cocoa, coffee, cassavas, The continent of Africa consists February/M arch 2015 d (Continued onp.16) 15 ------AROUND THE WORLD

(Continued from p. 15) “These developments should, however, go and Certification Systems; and Methods tional trade in order to generate foreign hand in hand with harmonization of food of Analysis and Sampling. currency,” Dr. Anelich relates. “To that standards at regional and international In addition, says Dr. Anelich, large end, a certain level of food safety must levels, in order to facilitate trade.” countries and blocks such as the U.S. and be achieved before food trade can occur. Most countries in Africa are members the European Union (EU) are now wishing Moreover, when countries can supply of the CAC and WTO. “It therefore follows to have discussions with African delegates safe and nutritious food for their domestic that Codex Alimentarius standards are the the day prior to the Codex meetings to dis- markets, they are better able to ensure ade- minimum standards that these countries cuss various matters on the agenda. “This quate health and growth of their respective should comply with,” Dr. Anelich contin- level of interest in African positions was populations so citizens can then contrib- ues, “not only for conducting international not apparent before this program started ute in a meaningful way to long-term eco- and regional trade, but also for providing a few years ago,” she notes. nomic growth of that country.” safe and nutritious domestic food. To The AU is currently spearheading All countries in Africa have food stan- that end, Africa is in this development an African food safety authority. In early dards, Dr. Anelich points out, but they trajectory.” stages of development, the initiative is range from very few and rudimentary stan- projected to set safety standards for and dards to antiquated standards developed monitor the African food supply, much like during colonial times to more modern the European Food Safety Authority does standards reflecting the spirit of the World for EU member states. In October 2014, Trade Organization (WTO) and the Codex organizers met to investigate developing Alimentarius Commission (CAC). a Rapid Alert System with the following Consequently, projects exist within objectives: 1) Quick exchange of informa- Regional Economic Communities to har- tion about food and feed-related risks to monize existing food standards, Dr. An- ensure coherent and simultaneous actions elich relates. “However, many existing by all network members with the view of food standards are not based on scientific protecting consumer health from eminent principles as per the WTO Agreement on public health risk, and 2) Contributing to the Application of Sanitary and Phytosan- economic development by maintaining

itary Measures and the Technical Barriers C o ur age K s i Set oa f ia Sa b a consumer confidence in the food system Street vendered cow skin, locally called “wele,” in to Trade Agreements (SPS and TBT),” she tomato sauce for sale in Ghana. and providing a sound regulatory founda- says. “Rather, these may be either too le- tion for trade in food. nient, allowing for easier importation of As part of its capacity building pro- unsafe foods into those countries, which gram, the AU has set up a number of ex- What About HACCP? may pose a risk to human health, or the pert committees that “mirror” certain Co- “Hazard Analysis and Critical Control standards may be stricter than Codex stan- dex committees. “These consist of experts Points (HACCP) programs are imple- dards, which may then constitute a barrier within that field that meet once per annum mented in many countries, particularly to trade (as per the WTO Agreements) if the in Nairobi at the AU-Inter-African Bureau amongst multi-national companies op- stricter standards are not scientifically jus- for Animal Resources offices and develop erating in African countries,” Dr. Anelich tifiable. Because of all this, it is clear that a response document to the items on the says. “However this is not necessarily the further development of science-based food Codex committee agenda,” Dr. Anelich re- case with small domestic businesses and standards is required.” lates. “This document becomes a common even larger, less-developed domestic busi- For this to occur, Dr. Anelich says, ca- African position that is then sent to all the nesses. HACCP-based systems are imple- pacity building is required in those African National Codex Contact Points in Africa for mented widely in South Africa and South countries that do not possess scientific those countries to use as a response to that Africa has the most companies certified to expertise relative to conducting risk as- Codex committee. This is certainly bearing HACCP-based systems by third party au- sessments and incorporating the results fruits, as we are seeing more meaningful dits from accredited certification bodies of those risk assessments into appropriate participation from African countries in than any other country in Africa.” food standards. Codex meetings.” “HACCP programs are implemented Easier said than done. Capacity build- Dr. Anelich, a microbiologist, serves occasionally in the larger manufacturing ing requires political will as a first step, on the AU’s Food Hygiene Expert Commit- companies in Ghana, especially if there followed by policy development and long- tee. Other expert committees include Food are problems with their products, but the term strategies for maintaining that capac- Contaminants; Food Additives; Food La- small-scale producers don’t implement ity in a particular country. beling; Pesticide Residues; Nutrition and HACCP,” Dr. Saba says. “Companies are “This is vital to enable effective par- Food for Special Dietary Uses; Residues of monitored by the food regulatory bodies ticipation in relevant regional and in- Veterinary Drugs in Food, Fish and Fisher- in the country but the enforcement is ac- ternational forums such as the Regional ies Products; and Fresh Fruits and Vegeta- tually very weak, coupled with inadequate Economic Communities and the CAC, bles. New proposals for expert committees expertise. Food safety auditing is virtually respectively,” Dr. Anelich emphasizes. are Food Import and Export Inspection none existent here.”

16 FOOD QUALITY & SAFETY www.foodqualityandsafety.com safety, and inadequate funding for continental food safety organizations, Dr. Saba mentions.

Looking Forward Dr. Saba says the African populace is becoming more aware of food safety issues than ever before. “This makes it easier for most consumers here to take on manufacturing companies for their actions or inactions,” he purports. C o ur age K s i Set oa f ia Sa b a Street vendered fried chicken and guinea fowls sold in an open stall in Ghana. Aside from the many challenges that face Africa, there are also a number of opportunities, Dr. Anelich emphasizes. “Africa Dr. Saba emphasizes that he speaks only for his own country, is clearly on a growth trajectory, with an average growth rate of but he says that Ghana’s situation in food safety is likely the norm five percent per annum, which it has maintained over the past few in many other African countries. years, with some countries showing a higher growth than five per- For example, implementation and enforcement of food reg- cent,” she says. “There are definitely opportunities being grasped ulations is a big challenge in many African countries, Ghana in- to exploit the agricultural and food producing potential of Africa. cluded, says Dr. Saba. “The major food safety issues in Africa are Thus, there is no better time than the present to ensure that food foodborne illnesses and inadequate food hygiene practices,” he standards are developed and/or revised in keeping with WTO, stresses. “Compounding this, some people don’t believe illnesses SPS, and TBT Agreement principles. This approach will facilitate are caused by unwholesome food.” harmonization of food standards, and consequently food safety There are an estimated 2,000 food safety-related deaths in standards, at regional and international levels.” ■ Africa each day, according to the United Nations Food and Agri- Leake, doing business as Food Safety Ink, is a food safety consultant, auditor, and award- culture Organization and the World Health Organization. An es- winning journalist based in Wilmington, N.C. Reach her at [email protected]. timated 700,000 deaths occur in Africa each year due to diarrhea associated with contaminated food and water, according to Dr. An- For bonus content on food safety in Africa, go to February/ elich. Reported foodborne disease outbreaks in Africa show that March 2015 issue on www.foodqualityandsafety.com and the majority are caused by Salmonella spp., Shigella flexneri, Shi- click on “Out of Africa.” gella sonnei, and Shigella dysenteriae; plus Bacillus cereus, Staphy- lococcus aureus, and Clostridium perfringens. Various types of par- asites are also a significant cause of foodborne illnesses in Africa. FQ1502 “The presence of illegal levels of food additives such as E110, E102, E104, and E124 in local and imported products, especially in children’s foods and drinks, without any indication about their possible adverse effects written on labels, is a problem in Africa, and there is virtually no equipment here to test food for recommended levels of additives,” Dr. Saba says. “Inadequate testing laboratories is another quagmire to food regulation in Africa that makes it difficult for regulators to take swift action when problems occur,” he continues. “Many labs have inadequate testing equipment and expertise. As a result it can take months or years for some analyses to be done, and some samples have to be sent out of the countries for analysis. Our local food and drugs authority (FDA) doesn’t have adequate capacity and has to send their samples to Accra, Ghana’s capital city, which is about 373 miles away, and Accra only has one lab serving the country’s FDA.” Currently managing the UDS faculty laboratory complex, Dr. Saba helps the FDA in his geographic region to test certain locally produced products that are striving to meet the Ghana FDA standards for the certification of products. This testing includes prox- imate analysis and microbial analyses of locally produced beverages like sobolo, which is made from dried sorrel flowers flavored with sugar and ginger, and also milled cereal/legume products, including Tom Brown (roasted-maize porridge), a traditional weaning food and dawadawa (a.k.a. sumbala), a condiment made from néré (Parkia biglobosa) seeds or soybeans that is traditionally sold in balls or patties. Other weaknesses in food safety and quality initiatives in Af- rica include low literacy rates, governments not prioritizing food

February/March 2015 17 Lessons on Supporting Claims of Quality in Supplements Educating the dietary supplement industry on what goes into quality audits and auditor quality

By Daniel Fabricant, PhD and Corey Hilmas, MD, PhD

herever you travel around this country—and When you look up the word quality, you will find that it is an at- even internationally—you will likely hear the tribute or defining characteristic that has become the standard as same rhetoric from dietary supplement manufac- measured against other things of a similar kind. In a world where turers. Firms claim they have quality, something we group according to the buckets of good, better, and best, quality that their competitors do not, and they are doing it the right way is the degree or extent along the scale to that asymptote we call despite not allowing an external audit for quality and compliance perfection, an impossible point we can never reach. Many may by a third party. When one of us hears this from a company, we not be familiar with the teaching of W. Edwards Deming and his 14 typically respond by asking how they know this to be true, and we points for continuous process improvement, but they are quality are left feeling surprised that more dietary supplement firms do concepts that have passed the test of time. Deming was a U.S. stat- not use a quality audit from a third-party certification organization istician of mathematical physics, and a pioneer of modern quality to demonstrate the adequacy of their quality systems, considering management. He developed the founding principles of Total Qual- its benefits to benchmark continuous process improvement and ity Management and the System of Profound Knowledge. Deming

relatively low cost. introduced the DMAIC and PDC(S)A acronyms, which have been FQU / f otolia.com(3) montage:

18 FOOD QUALITY & SAFETY www.foodqualityandsafety.com quoted in every quality seminar since the 1980s. DMAIC stands (cGMPs), but there is quality and, therefore, value in the services of for Define Measure Analyze Implement and Control and PDC(S) an audit. The results of a third-party quality audit provide a bench- A stands for Plan Do Check (Study) and Act. These acronyms and mark assessment of the adequacy of the existing program as it sits Deming’s 14 points of quality management gave birth to Six Sigma statically in the present, and an assessment of weaknesses to drive by Bill Smith of Motorola, many of the concepts of ISO9000 series continuous process improvement into the future. and the ANSI Q90 series standards issued today for quality im- The Natural Products Association (NPA), formerly the National provement, and Lean training of the ‘90s. Nutritional Foods Association, created the first GMP standard for performing quality audits as well as certification in the dietary Keeping Up to Standard supplement industry. NPA is committed not only to advocating Intrinsic to demonstrating quality for any firm is implementation for the rights of manufacturers, suppliers, and retailers to have a of an external quality audit and certification to an industry stan- marketplace in which to sell products but also to consumers hav- dard. Given the choice available to the industry, there is no short- ing access to quality products in order to maintain their health age of auditors for part 111 current Good Manufacturing Practices (Continued on p. 20)

February/March 2015 19 COVER story: Lessons on Supporting Claims of Quality in Supplements

Associations will typically develop self-regulatory programs or initiatives which demonstrate industry transparency and maturity, and provide the consumer valuable information that can be used to evaluate products.

Microbiology Testing by Dietary Supple- ment and Nutraceutical Companies

By Tom Weschler In June 2010, the FDA’s Final Rule on Dietary Supplement cGMPs became effective and all companies that manufac- ture, package, label, or hold dietary supplements and nutraceuticals, as well as products imported into the U.S., were expected to be in compliance. cGMPs require a comprehensive system of process controls, and document each stage of the manufacturing process, in order to minimize and detect problems early if they arise. It’s difficult to know the types and extent of product quality and safety testing by dietary supplement and nutraceutical (DS/N) companies prior to the FDA’s Final Rule. In interviews conducted for Strategic Consulting, Inc.’s (SCI) latest report, “Industrial Microbiology Market Review” (IMMR-4), however, many companies reported needing to move quickly to comply with the microbiological testing required by the FDA Final Rule. The regulations required DS/N companies to demonstrate that the microbiological levels in products are below target levels and that no “ob- jectionable organisms” are present in view of the product’s intended use. S CI (Continued from p. 19) According to IMMR-4, and well-being. NPA has developed a long and diverse array of DS/N companies conducted approximately 35 million mi- self-regulatory initiatives and programs, all of which were firsts for crobiology tests in 2014. While this represents significant the natural products and dietary supplement industry. change for these companies, it accounts for just two percent of the micro testing conducted in the entire industrial To advocate both consumer and industry concerns, associa- market, which covers the food, beverage, personal care tions will typically develop self-regulatory programs or initiatives products/cosmetics, environmental water, and industrial which demonstrate industry transparency and maturity, and processes sectors. provide the consumer valuable information that can be used to A good number of DS/N companies chose to go with a evaluate products. The public and private benefits of industry system that combined versatility and ease-of-use, and that self-regulation are numerous, and they typically outweigh the enabled them to quickly comply with FDA’s micro testing costs incurred to industry. First, self-regulatory programs and requirements. The BioLumix system was a preferred choice initiatives may lead to the establishment of product or ingredient early on, with the Soleris system gaining share in recent standards to ensure quality and safety. In turn, these standards years. In total, these two systems, both of which are now may facilitate the emergence of markets by establishing baseline owned by Neogen, have an estimated combined installed base of more than 500 systems in the DS/N segment. SCI levels of product quality and safety; result in improved consumers’ research shows good adoption by companies in the U.S. as understanding; impart brand recognition through seals/marks well as in Asia. representing third-party certification; induce brand loyalty; and garner trust of new products. Weschler is president of Strategic Consulting, Inc., which provides business strategy Standard setting and implementation can be a further bene- and market intelligence for industrial diagnostics companies. Reach him at 802-457- 9933 or [email protected].

fit to manufacturers by lowering production costs, which can be FQU / f otolia.com(3) montage:

20 FOOD QUALITY & SAFETY www.foodqualityandsafety.com COVER story: Lessons on Supporting Claims of Quality in Supplements

Increased Awareness of Nutraceuticals GMP regulations and passed it to the FDA in late 1995. This model served as the basis for the 1997 FDA proposed GMPs in the Published in January 2014, Markets- trients. Manufacturers are also taking andMarkets’ “Nutraceutical Ingredi- in consideration the convenience fac- form of an advanced notice of proposed ents Market by Type & Application— tor for consumers and providing them rulemaking. Global Trends & Forecasts to 2018” re- with healthy nutrients in the form of Rather than wait for the FDA to finalize port covers five major applications of food and beverages instead of supple- the proposed rule, the association began nutraceutical ingredients: functional ments. developing its own GMPs to ensure quality. food, functional beverages, dietary Different types of nutraceutical in- The NPA GMP audit program was launched supplements, animal nutrition, and gredients covered in the study are in January 1999, with the first certifications personal care. According to report, prebiotics, probiotics, amino acids, issued in July of that same year. NPA’s GMP the aging population and an increas- peptides and proteins, phytochemi- education seminars were also rolled out in ing number of chronic diseases gen- cals and plant extracts, omega 3 and 1999. The program has awarded certifica- erate health concerns in the consum- structured lipids, fibers and specialty ers’ mind, which are major factors that carbohydrates, vitamins, proteins, cation to more than 106 member companies, push the nutraceutical product and rotenoids and antioxidants, and oth- ranging from some of the largest manu- nutraceutical ingredients market. Con- ers. The overall nutraceutical ingredi- facturers to the smallest in the industry, sumers are shifting their eating habits ents market is expected to experience including both domestic and foreign firms, from hunger-satisfaction to the intake growth rate of 7.2% from 2013 to representing more than 45,000 finished of healthy food in order to either fulfill 2018, whereas Asia-Pacific is expected products and thousands of raw materials. the nutrient deficiency in the body or to grow at a rate of 7.4% for the same When the program was first launched, to prevent the deficiency of major nu- period.—FQ&S the goal of the GMP Certification program was to ensure that all elements of the passed on to the consumer. For example, a nation which could potentially render a manufacturing process are reviewed so standard can be established to assist man- product adulterated. NPA in conjunction that products meet their intended quality. ufacturers in producing interconnecting with some of the other industry trade orga- Third-party on-site inspections of manu- or interchangeable parts. Especially in nizations helped develop a model for the (Continued on p. 22) high-tech industries, standards assure a manufacturer that if its product conforms, the product will interconnect with comple- mentary or rival products of similar specifications. But most important in the days of the global marketplace is that industry self-regulation helps consumers evaluate products and services by providing information about the qualities and characteristics of the seller’s products.

Filling a Need In 2014, NPA’s GMP Certification Pro- gram entered its 15th year of verifying for consumers that dietary supplements are manufactured according to the highest standards. Prior to the GMP final rule roll out in 2007, dietary supplement manufacturers were only required to adhere to GMPs for foods (21 CFR Part 110), which were largely enforced by local and state health departments. The association recognized that while food GMPs are certainly significant in regards to controlling general sanitation practices and monitoring sink log records, they did not address product quality with regard to specifications including identity, purity, strength, and composition, as well as incorporating process control and quality control features to prevent mix-up and contami-

February/March 2015 21 COVER story: Lessons on Supporting Claims of Quality in Supplements

(Continued from p. 21) ities to determine whether specified performance standards on a number of measures—including quality control, cleanliness, re- More on Industry Education ceiving, and testing of raw materials—are being met. A member supplier must receive an “A” rating in order to be certified. Those NPA’s GMP education sessions usually take place at in- who receive either a “B” or “C” rating must correct deficiencies and dustry events and tradeshows in the U.S., they have also been conducted for firms onsite domestically and in Asia, submit for a re-audit. Europe, and South America. The education seminars have taught over 1,000 industry stakeholder firms as well as Continued Improvements FDA regulators. NPA also holds monthly webinars in its The NPA GMP program was amended in 2008 to incorporate the “Wednesday Webinar” series on a variety of issues of in- requirements introduced in the long awaited FDA cGMPs Final- terest to industry stakeholders—from GMP compliance, ized Rule for dietary supplements (21 CFR Part 111). The program NDI notification, and adverse event reporting require- holds great value for the industry for a number of reasons but none ments, to didactic approaches on how to write and qual- more significantly than reducing exposure to regulatory vulner- ify structure/function claims. The organization is ensuring ability. It is important to note that a product failing to meet the that the industry is properly trained and is manufacturing FDA cGMPs is considered a technical adulteration. FDA will not the best possible ingredients and products for consumers. provide help to a manufacturer or distributor to prepare for the NPA employs two of the FDA’s former top heads in dietary supplement regulations and combines its experience in GMP inspection, nor will it offer certification. training the FDA field offices with the safety and quality The objectives of the GMPs from the FDA’s perspective are to record of the UL company.—D.F. & C.H. provide the general public with unadulterated products that are not misbranded and meet their respective label claims. Thus, those manufacturing firms and distributors that seek to evaluate facturing facilities cover such areas as filth control and cleanli- their state of compliance, have an expert third-party review their ness of equipment, facility, and grounds, establishment of a qual- facility in preparation for an FDA inspection, or need very skilled ity control unit, test methods, expiration dating, and procedures and detailed assistance with their quality system to bring it to a for storage and distribution. The third-party certification program state of compliance can use a third-party certifier to address that includes inspections of dietary supplement manufacturing facil- regulatory need. To assist firms and present the 815-page GMP Final Rule in a more condensed, palatable form, NPA offers GMP education and training alongside the certification program. The seminar education has expanded to incorporate claims training to highlight Get the Metal Out! the differences between permissible structure/function claims and unauthorized disease claims, New Dietary Ingredients, and ProtectProtect youryour eequipmentquipment and keekeepp yoyourur pproductroduct ppure.ure. requirements of various business models to the GMP Final Rule by former top agency officials. Cartridge Style NPA has recently partnered with UL, which has more than 100 Magnetic Liquid Trap years of experience in the testing and certifying of products. Its • designed to remove ferrous tramp name is recognized universally by retailers, consumers, and sup- from liquid processing and conveying pliers of U.S. products, materials, components, and systems. NPA lines and UL are developing education to train both quality auditors and • provide dependable protection against tramp iron contamination the dietary supplement industry. One problem with third-party au- • equipped with powerful, high-energy diting and certification bodies is the lack of transparency displayed Neodymium magnets so firms can know the true quality of their auditors. NPA and UL are developing unique training in GMPs, Safe Quality Foods, and meatLINE™ 07 new changes with the Food Safety Modernization Act designed Metal Detector specifically for auditors. The process in how auditors are qualified • Detects and separates any type of to perform quality audits will provide much needed transparency metal, encapsulated or free and enable auditors to better think like agency investigators. • Fits all commercial vacuum fillers Third-party quality audits are a tool that should be used more • Fast and easy to clean in a few steps without tools in the dietary supplement industry as a management tool for deter- • Pressure washer safe mining the effectiveness of one’s quality systems in place. There is no excuse for failing to meet FDA cGMPs. A plethora of resources is available to ensure firms are compliant. Don’t risk falling victim to an avoidable mistake—take advantage of resources that have regulatory experience to help navigate your way through compliance. ■

Dr. Fabricant is the executive director and CEO of the Natural Products Association. Reach +1 316-284-2020 buntingmagnetics.com him at [email protected]. Dr. Hilmas serves as senior vice president of scientific and regulatory affairs. Reach him at [email protected].

22 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Non-GMO Verification in Dietary Supplements Supplement companies seeking non-GMO designation are steadily catching up with the food and beverage sectors By Kelly Mae Heroux

ity, segregation, that the substrate with which the micro- and the testing organisms were cultured was non-GMO. of high-GMO Other common GMO-risk ingredients risk inputs, found in supplements include solvents, vary by country, enzymes, carriers/standardization mate- region, and state. Some are rials, and gel caps/animal derived gelatins. onsumer demand for process-based and investigate in- Adding to the inherent challenge of non-genetically modified organ- puts and processing aids, while others are verifying long lists of ingredients as non- ism (GMO) products is rising glob- based on the finished product. The com- GMO is a lack of transparency in supply Cally, alongside the emergence and growth mon feature across all countries with la- chains and subsequent difficulty in proof both mandatory and voluntary non- beling laws is a requirement that products curing the necessary documentation from GMO labeling initiatives. The benchmark with GM-derived content that is not sub- ingredient suppliers. These documents for these new programs was set in 2004 stantially equivalent to its conventional include: disclosures of formulation per- by Europe’s GM labeling regulations, BC counterpart be labeled. For companies in centages (for high GM-risk ingredients); 1829 and 1830, which gave rise to the Ohne the dietary supplement industry, meeting process flowcharts to identify raw ma- Gentechnik, Nourri Sans OGM, and Gen- the core requirements of any non-GMO terial sources; non-GMO declarations of tchnik-Frei programs. North America’s scheme can be very challenging. Accord- enzymes and fermentation organisms; non-GMO verification program is imple- ing to Kiren Israelsen of the United Natu- country of origin information for raw ma- mented and managed by the Non-GMO ral Products Alliance, “The supplement terial sources and production processes; Project (NGP). industry lags behind the food industry on and traceability and segregation practices. Global sales of non-GMO products are being non-GMO.” Acquiring this level of detail from what is projected to increase dramatically over Unlike the majority of food and bev- oftentimes a large international manufac- the next five years to encompass fully 15 erage products, supplements commonly turer with proprietary processes can be a percent of all global food and beverage re- include long lists of ingredients. The bulk stretch for supplement producers. tail sales in a market currently valued at of these ingredients are high-GMO risk, However, many efficient pathways over $800 billion. According to the Natu- being highly processed, animal derived, or through verification have been developed. ral Marketing Institute (NMI), the package sourced from high-GMO risk crops. Thus, For example, FoodChain ID, the founding claim “No GM ingredients” plays a major demonstrating compliance for just one of technical administrator to NGP, has devel- role in consumer purchasing decisions. In this type of ingredient can be laborious. A oped guidelines, ingredients forms, and fact, that claim was concluded to be more manufacturer seeking NGP verification for absence declarations, and, in addition important to North American shoppers a product containing lanolin derived D3 provides consulting to help participants than “great tasting” and “nutritious.” Due (cholicalciferol), for example, would have in the evaluation of supplement products. to this sharp increase in consumer inter- to secure documentation from their sup- In tackling the requirements of com- est, NGP Verified has become one of the plier that the sheep from which the lanolin plex ingredients and supply matrices, the fastest growing labels in the natural prod- was derived were not fed GM feed, which supplement industry has been encouraged ucts industry. To date, more than 20,000 requires review of feed ration statements. by single-attribute label trends. Single-at- products have been NGP verified, repre- Vitamins B12, B2, beta carotene, and ascor- tribute label claims commu- senting $7 billion in annual sales. bic acid among other vitamins, amino acid nicate transparency, are ex- Along with national and global inter- and enzymes may also be manufactured planatory, and build consumer est in non-GMO products comes an un- using GM microorganisms, in which case, confidence by being third- even playing field for non-GMO product evidence that the microorganisms used to party based. NMI reports manufacturers. Non-GMO standards and produce these ingredients are non-GMO that shoppers are increas-

February/March 2015 23 N on-GMO Verification in Dietary Supplements

(Continued from p. 23) plement Working Group was launched in Consult with a qualified technical ingly seeking specialized consumables to an effort to even the playing field and assist administrator or verifying body prior to meet their lifestyle and dietary needs. In any supplement company in becoming eli- joining the non-GMO scheme to identify doing so, they look to front-of-package sin- gible for non-GMO verification. Cofounded risk, foresee obstacles, and get practical gle attribute claims to avoid the burden of by MegaFood’s CEO Robert Craven and solutions. This reduces costs and fosters having to read the fine print on the back. FoodChain ID, the Working Group con- awareness of what to expect once enrolled. Some believe that these claims surpass sists of industry professionals who share Collect supporting documentation brand loyalty. knowledge of ingredient suppliers, refor- prior to enrolling. Use a standardized data Though NGP verification is achievable, mulation strategies, and general guidance collection tool for all ingredients, such as it’s not always easy; some products have in preparing for verification. The following forms used by a technical administrator. taken more than a year to demonstrate are some examples on how to prepare for Relevant data includes disclosures of addi- compliance. The Non-GMO Dietary Sup- non-GMO verification. tives, carriers, enzymes, microorganisms, fermentation media, raw material sources, and non-GMO manufacturing systems. Stage the enrollment of products by FREE! beginning with bestsellers or product formulas that capture a range of the high- GMO risk ingredients in your product line. A staged enrollment helps familiarize QuEChERS Sample staff with what’s required from ingredient suppliers; eases severity of the learning curve and lessens workload of your qual- Consumable Kit ity department; and determines the level of transparency and open communication channels from ingredient manufacturers. Appoint staff with adequate resources and education to accommodate the additional workload. Non-GMO designation for a product is not a one-time effort. Stan- dards evolve, GMO approval and commer- cialization statuses change, and GMO testing requirements and tolerance thresholds change due to new GMO events. Team with an accredited non-GMO scheme approved testing laboratory if testing is deemed a requirement for verifying high-GMO risk inputs. Testing and sampling requirements vary according to differing ingredient matrices. Identifying the most efficient point in the supply chain for capturing qualified representative samples is crucial to keeping costs down. Develop new products with a consideration toward demonstrating compliance with your chosen non-GMO scheme(s), and then consult with a technical administrator prior to enrollment to pre-evaluate the new formulation for eligibility. Manu- facturers who do this can have their new products successfully verified in less time If you do pesticide analysis in your lab, this kit will while avoiding costly missteps. ■ provide all you need for QuEChERS extraction. Visit http://info.teledynetekmar.com/QuEChERSkit_FQS Heroux has served as technical consultant for prospective participants in the Non-GMO Project Product Verification Pro- * One kit per location. Offer valid only in the USA. gram, and is currently a manager for FoodChain ID, which is part of the Global ID Group family of companies. Reach her at [email protected].

References Furnished Upon Request

24 FOOD QUALITY & SAFETY www.foodqualityandsafety.com AIB

S T in affected products, and diminishmarket breaks undermine consumer confidence kill thousands. Additionally, theseout outbreaks affectmillionsofpeopleand and concern. Each year, foodborneillness as early as possible aspossible as early that is capable of detecting signs of microbial contaminants How to design aneffective environmental monitoring program Environmental Controls Improving afety &S major public health challenge, food supply systems remains a organisms to gain entryinto ability ofpathogeniche micro |

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Lakshmikantha Channaia - - the specificenvironmental conditions and collects informationabout (EMP) gram for theproduction ofsafefood products. environment inthefoodprocessing facility ical to maintainandmonitor thehygienic controls and/orhygiene practices. It iscrit outbreaks results from poorenvironmental demand. A substantial amount of these demand. Asubstantialamountofthese Environmental M An environmental monitoring pro monitoring program. an effective Figure 1: onit anitation omponents of Components of environmental environmental oring

- - training programs. Also, corporate man - rective actions, and to reinforce employee ing frequency, to initiate appropriate cor pathogens to determine sanitation clean- on target indicator microorganisms and tives. team shouldhave The EMP clarity It to isimportant clearly objec state EMP Commitment Objectives andCorporate CFR). turing Practices (GMPs) (21 ing frequencies, Manufac and other Good cused onvalidating cleaning andsanitiz and sanitizing methods, butismore fo to validate theeffectiveness of cleaning is not designed gienic practices. The EMP evaluate theeffectiveness ofaplant’s hy a timely manner. Additionally, will EMP microorganisms as well as pathogens in provides vitalinformationabout indicator EMP team andmayEMP include the plantqual concern inafacility. Thisgroup willbethe help identifypotential areas ofriskand dividuals to familiarwiththeoperation an effective is to bring EMP together in- taskintheimplementation of The first TeamEMP corrective actions, andmapping (Figure 1). and shipping, baseline/target, trends and microorganisms, sampling tools, labeling selection ofindicator andpathogenic tal monitoring team, zones, sampling, are anenvironmen of theEMP be apart - ping. key Some components thatshould finished products, packaging, andship ing, raw materials, pathogens ofconcern, evaluating thefacility, thetypeofprocess shouldbecarefullyAn EMP designed after Components ofanEffective EMP itoring team. the employees mon- oratleastto theEMP should be properly communicated to all risks, and associated corrective actions of thefoodsafetyprogram. Theobjectives, sources to ensure thatitisanessentialpart bysupplyingthe EMP alltherequired re- agement needsto andsupport understand February/M arch 2015 (Continued onp.26) 25 ------SAFETY & SANITATION Environmental Monitoring

(Continued from p. 25) units, etc.). If zone 3 is contaminated with ity manager, the plant or corporate micro- a pathogen, it could lead to contami- biologist, line supervisors or operators, nation of zone 2 through employees’ and sanitation supervisors or workers. actions or movement of machinery. If the facility does not have a food safety Zone 3 monitoring will indicate if microbiology expert experienced in the there is a weakness in building development and implementation of an design or poor employee sanitary EMP, it is strongly recommended that the practices. Areas of concern might facility contact an experienced outside include buildup in overheads, expert for guidance. Once the team is as- around extraction units, around sembled, the process flow should be eval- ventilation fans, or floor areas, uated to include the zones posing the most and handoff between sanitation microbiological risk to the finished prod- and production, maintenance and uct. The team should walk the plant floor production, employee entrance and to identify areas where the product may be production, or storage (freezers/coolers/ vulnerable to contamination. dry) and production. The total percentage of testing from Zones zone 3 would be around 30 to 40 percent. Some benefits of using indicator microor- The best way to identify sampling points is Zone 4 refers to the areas remote ganisms include: to use the zoning concept, which divides from product processing areas (e.g., of- • Non-pathogenic and sophisticated facility operations into four zones based on fice areas, locker rooms, maintenance containment facilities or labs (e.g., the levels of risk. It is vital for the environ- rooms, etc.). If zone 4 is not maintained Bio Safety Level-2) are not needed for mental monitoring team to define zones 1 in a good sanitary condition, it can lead sample analysis, to 4. Once the zones are determined, care- • Low concentrations of pathogens in fully consider which specific tests are going the environment make them difficult to to be used before beginning sampling. An EMP should be detect using current testing methods, Zone 1 refers to all direct food-con- carefully designed after • Indicator microorganisms are tact surfaces in the plant (e.g., blenders, evaluating the facility, high in numbers and can be easily conveyors, utensils, work tables, etc.). It enumerated, is not recommended to swab for patho- the type of process- • They are valid representation of pathogens in zone 1 because it is not an effective ing, raw materials, gens of concern since they use nearly way to capture product contamination. pathogens of concern, the same pH, nutrients, temperature, Non-pathogen or indicator microorganism water, etc. as pathogens, and swabs should be used on product surfaces finished products, pack- • Laboratory tests are generally faster that are not always cleanable, like the un- aging, and shipping. and less expensive. derside of a conveyor or a filling chute that Examples of indicator microorganisms is stationary. that can be used to monitor hygienic con- Total percentage of testing from zone 1 to cross-contamination of zones 1, 2, and ditions in an EMP are total aerobic plate is normally 10 to 20 percent. 3. Zone 4 is not considered a high risk of count, total coliforms, fecal coliforms, and Zone 2 refers to nonfood-contact areas potential cross-contamination. Enterococcus spp. of fecal origin. Indica- that are closely adjacent to product-con- Apart from zones 1 to 4, periodic air, tor microorganisms are not a substitute tact surfaces. In general, this is the area office areas, water, and plant employee for testing pathogens. A positive result where environmental contamination is hand swab samples should be monitored indicates conditions for pathogen con- most likely to affect the safety of the prod- for indicators as well as pathogens. Zone 1 tamination and a risk of foodborne illness uct (e.g., equipment framework, mainte- could also be tested for pathogens. How- is plausible. nance tools, drip shields and chain-guard ever, if zone 1 is tested positive for patho- housings, etc.). The focal point of zone 2 gens, then the product made on that line Sampling and Frequency testing will be to validate sanitary design must be held until further confirmative test Environmental information or data is of the equipment. These are the areas results are available. If the final confirma- obtained using a vast spectrum of ap- in the framework that collect food parti- tive results are positive, then it is likely a proaches, ranging from a simple settling cles, but are not easily broken down for recall situation. plate (sedimentation), to sophisticated proper cleaning. indicator swabs that forecast the pres- Total percentage of testing from zone 2 Using Indicator Microorganisms ence of specific pathogenic bacteria in a is normally 40 to 50 percent. Indicator microorganisms are routinely given establishment. There are a number Zone 3 refers to nonfood-contact sur- used to determine the potential presence of methods and tools that can be used for faces that are not close to zone 1 surfaces of pathogens and to assess the effective- environmental monitoring. The choice

(e.g., walls, floor, drains, air handling ness of cleaning and sanitation practices. of methods/tools depends on the type of © mjak - Fotolia.com

26 FOOD QUALITY & SAFETY www.foodqualityandsafety.com facility, type of food products, pathogen for a baseline higher than 125 percent of employee traffic patterns and practices, of concern, etc. The common sampling the mean (e.g., seasonality adjustment) collect more swab samples, initiate cor- tools that can be used to evaluate the should be documented. The EMP and rective actions, verify the effectiveness of overall sanitary condition of the facility the target/baseline are unique for each corrective actions, and monitor the results. includes sterile swabs, sponges, air sam- plant and for each type of product. Also, Most environmental monitoring programs pling units, RODAC plates, ATP (adenos- it is different for different zones. Since the do not consider the corrective action to be ine triphosphate) bioluminescence assay reasons for a positive finding are likely to successful until there are at least three con- kits, etc. More sampling and testing does be plant-specific, the corrective actions secutive negative results from the affected not necessarily mean more safety. Al- will differ from plant to plant based on area after it has been verified that some- ways follow hygienic procedures (e.g., thing was changed to address the micro- wear sterile nitrile gloves) while collect- bial contamination. ing environmental samples. Determining Indicator microorganisms frequency of sampling (daily, weekly, bi- are routinely used to Mapping weekly, monthly, quarterly, etc.) and the Every facility has several areas to map, time of sampling (at what time during the determine the potential and within each area, there will probably shift) are the most vital parts of the EMP. presence of pathogens be two or three different zones. For exam- Once the EMP is fully implemented it and to assess the effec- ple, a plant might have a couple of raw should be verified for its effectiveness. If areas (coolers, blending rooms), fully pro- the current sampling plan and frequency tiveness of cleaning and cessed areas (oven exit, cooling tunnel), fails to meet the expected result, then sanitation practices. and packaging areas (baggers, form-fill, the frequency and number of samples packing tables). A map of all sampling lo- per zone should be modified to achieve cations should identify each area and the the target. final food products. The environmental specific zones within each area that will monitoring team needs to consider vari- be tested. This can be an effective way to Labeling and Shipping ables that can impact the baseline (e.g., identify hot spots to take appropriate cor- The environmental monitoring team seasonality, geographic differences, and rective actions. Map the locations of nega- should receive proper training on sam- supplier sources). tive results (green flag), increasing trends pling. Microbial supply companies or ac- (orange flag), and positive samples/results credited laboratories will often come to Trends and Corrective Actions (red flag) on a facility design diagram to your facility on an annual basis to train The results of environmental monitoring help define the scope of the problem. Map- and calibrate sampling tools. Once the en- samples should be tabulated in a way ping helps identify harborage niches and vironmental samples are collected, write that they can be compared with previous hot spots in a plant that may act as a source the sampling date, location, device used, results in order to highlight trends. It is of contamination. sample size, list of testing requests, date important to compare sampling results submitted to the lab, etc. on the sampling against a target level or a baseline. Any Summary bag for easy identification. Always submit increase in indicator microorganism or An effective EMP is an essential compo- a negative control swab (i.e., a swab not pathogen numbers should be addressed nent of a food processing system. FDA’s being used). Also, it is important to ship by corrective action, since these results Food Safety Modernization Act advocates the collected samples as soon as possible are a signal that there is a deviation in the importance of implementing an effec- (overnight shipping) in a sterile the sanitary conditions. A suitable cor- tive EMP in food manufacturing facilities plastic bag with ice packs in it, rective action (e.g., identification and as a preventive measure to detect areas but keep the ice from directly elimination of the source of contami- of pathogen harborage and to verify the contacting the outside of the nation) should be initiated to bring effectiveness of cleaning and sanitation sample bags. It is important to the values close to or below the programs. It is critical for food manufac- keep the samples cool (less than target/baseline. turers to develop a science-based environ- 40 degrees Fahrenheit) to pre- If a positive result (or mental sampling, testing, and verification vent microbial growth. repeatedly high numbers) program that effectively monitors the over- is found in any sampling all hygiene quality of the facility. An unsci- Baseline/Target zone, reassemble the team entific and improperly designed EMP can Historical data (e.g., consecu- and initiate a root cause in- be expensive and wasteful. Every product, tive sampling results/data from vestigation. Restrict traffic in process, employee training, raw material, the previous six to 12 months) is the affected zone(s) as much GMP, and pathogen of concern is different. needed to establish a baseline/target. as possible. Examine the area thoroughly EMP is specific to the individual food facil- For example, if a site tests less than 50 cfu and use the team’s findings to improve ity and to the individual operations within (colony-forming units) for a year with only operations, including: increase cleaning the facility. ■ two/three spike readings, then a 50 cfu and sanitation frequencies, conduct re- Channaiah is director, microbiology, at AIB International.

February/March 2015 27 SAFETY & SANITATION Training

included. For those with more direct food safety job responsibilities—for example HACCP (Hazard Analysis and Critical Con- trol Points) team members or CCP own- ers—training must include topics such as monitoring, corrective action procedures and risk assessment. A word of caution: Do not overload your new hires. Trying to cover every detail of every practice or procedure in a company’s arsenal is counter-productive. New employ- How to Fit Training into ees are in a stressful situation, which means they are not optimally primed to learn new things. When they are bombarded with Your Production Schedule information, they will not be able to take Providing food safety training for when new employees it all in. It’s most likely that, by the end of are onboarded to a company training, new hires will have forgotten most of the information that was presented. The By Jennifer McCreary and Marie Lefaive following actions can address this problem. Start as early as possible. Send out any introductory food safety material, either online or printed, before the new hire Editor’s Note: This is the first in a five-part new employees clearly understand their even begins work. This serves the dual pur- series of articles that will explore each responsibilities is crucial. pose of introducing the person to concepts concept behind the five moments of need It is a lesson that was learned the hard of food safety and ensuring that the impor- in training. way by a major bakery facility. The com- tance of this topic is quickly underscored. pany decided it was unnecessary to invest Provide a blend of training channels. hen it comes to workplace in food safety training for temporary hires Classroom training is important, but when learning, Conrad Gottfred- as they were only employed in the pack- it is teamed with peer coaching, virtual dis- son, PhD, and Bob Mosher, aging room. The day the company found a cussion boards, or an online information two well-known perfor- temporary worker with a pocketful of pea- portal, the effectiveness of training in- Wmance support experts, have defined five nuts and had to destroy the full shift’s pro- creases dramatically. Remember that train- distinct moments of need: duction is the day it revisited that decision. ing is not just about teaching someone new 1. When learning for the first time, Contrast this to a company that has information; it’s about showing them how 2. When learning more, developed a full complement of onboard- to find answers when they have questions. 3. When remembering and/or ing programs, from food safety training for Scatter the training over several days applying what’s been learned, contractors and visitors, to introductory or weeks. This will allow new hires time 4. When things go wrong, and food safety training for all staff, to spe- to become competent in one learning area 5. When things change. cialized streams for supervisors and line before moving onto the next. It may mean When you know these five moments, it personnel. Simple, to-the-point programs a slightly slower time to competency, but is easier to see how you can fit training into delivered by trained internal staff has en- the savings in terms of retraining costs is your production schedule. We’re starting sured that the food safety awareness is wo- worth it. this series with the need for training when ven into every person’s DNA the moment people are learning for the first time, and they enter the facility. Importance of Consistency in the coming months, we will take a closer and Context look at each of the other moments. What Must Be Included If your onboarding process is haphazard, The classic example of this type of Basic Good Manufacturing Practices it lacks quality control. Some sessions will learning is onboarding training for new (GMP) training for all employees is critical. be excellent, others will be dismal. Any hires. The goal is to help employees ac- It remains the best line of defense against new hire who happens to arrive on a dis- quire the necessary knowledge, skills, and the introduction of unnecessary hazards. mal day is guaranteed to have significant behaviors to become productive workers. GMP training covers the daily activities as- learning gaps. Schedule food safety train- In the food industry, we can include an sociated with food safety programs: health ing along with other job-specific training, additional goal: helping them become safe and hygiene, cross-contamination avoid- as well as general company onboarding. food workers. There’s no need to reiterate ance, sanitation, tools, and equipment. If your onboarding programs lack why you do not want your company to suf- Your company’s food safety policies, context, you are probably checking off the

fer through the misery of a recall. Ensuring standards, and expectations must also be training box without realizing any true be- © pixde s ign123 - Fotolia.com

28 FOOD QUALITY & SAFETY www.foodqualityandsafety.com havior changes. Telling employees that they must not walk between the raw and processed sections of the facility is a good directive; not telling them what could happen if they do and why it is so important to the business is a bit like telling people not to go swimming in the lake without telling them that there are leeches in the water.

Who Should Deliver the Training If it is in your budget to hire professional trainers, then by all means do so. For those whose budget is less generous, onboarding training can be done in-house or in combination with professional trainers. Two keys to success are as follows. 1. The training must be properly designed with attention paid both to the accuracy of the content and the pace of the program. It should be built following adult learning principles that provide active learning opportunities and plenty of time for practice. Lec- tures were rarely successful at teaching us in our school days. They are no more successful today. 2. The training must be delivered by competent people. This means people who are not only knowledgeable of the topic, but who have had some grounding in the craft of training. Expertise in a subject is not enough—in fact, experts are often very poor onboarding trainers because they simply cannot chunk the information into simple, easy-to-understand lessons. It is not an understatement to say that the success of a training program can rest with the quality of the trainer.

Determining Competence The proof of training is in the doing. When an employee demon- strates proper food safety practices, you know the training has been successful. There are, however, levels in the assessment process that can help determine competence. • Level one is a check for understanding: Has the employee learned the information? Most companies use quizzes to test for this, though a one-on-one discussion is often more useful at uncovering misconceptions. • Level two looks at ability: Can the employee perform a task as demonstrated? Watching someone do the work in their natural work setting is the best test for this level. • Level three assesses attitude: Does the employee believe what you have taught and recognize its importance? This can be evaluated by listening to a new hire explain concepts or, as in level one, by having a conversation. Think of when you learned how to drive. The first step was the written exam to prove you knew the rules of the road. The second was a road test to show your skill behind the wheel. The third is one you demonstrate each time you choose not to drink and drive. And of course, it goes without saying that any training must be fully documented. After all, if it isn’t written down, it didn’t happen. Finally, a successful onboarding program requires frequent follow-up to make sure new employees understand their jobs, know where to go for help, and are integrating with the team. It takes a long time to become a part of a new culture. Be patient, and give your new hires the support they need over the first few months on the job. ■

McCreary is technical manager, training services, for NSF-GFTC. Reach her at jmccreary@ nsf.org. Lefaive is manager of program development, training services, for NSF-GFTC. Reach her at [email protected].

30 F cessing. Given thiscombination ofutility unpalatable flavors associated withpro to otherflavoring agents while masking also serves to reduce cost incomparison known for thousands of years, but salt The preservative effect ofsalt has been adding bulkandcolor to processed foods. example, allowsforlonger shelf-life while useful to foodmanufacturers. Sugar, for popular, bothingredients are extremely in conjunction withUSDA. More thanjust of Healthpartment andHuman Services lines forAmericansissuedbytheU.S .De- those recommended intheDietaryGuide- sugar every day, amounts well inexcess of 3,400 milligrams ofsalt of and110grams Indeed, theaverage Americanconsumes present anumber of challenges to manufacturers two most common food additives—sugar and salt— FDA’s proposed rules and guidelines onthe Lawsuits Possible IngredientsPopular with Sweet and Savory: by

Michael FOOD consumers, than sugar and salt. or more popularwithAmerican mon inAmericanfoodproducts, ew ingredients are more com - QUALITY Gruve Q & S AFETY and uality Glenn Pogust Flav ors& texture - near future may holdanumber ofchal presence intheAmericandiet. both sugar and salt maintain a constant ers, there shouldbelittlesurprisethat for industry andpopularitywith consum- packaged food,including of thepartition changes to theNutrition Facts Panelon 2014 theFDA proposed anumberof Act, orFSMA,Modernization inMarch Following thepassage oftheFood Safety Will Sugars to Lead Litigation? and litigation across theindustry. lead to an environment ofincreased cost claims against foodmanufacturers, could lawyers to labeling pursue andingredient creased willingness ofplaintiff onthe part cating sugar combined andsalt, within- In particular, recent U.S. FDA action impli lenges where sugar andsalt are concerned. For foodmanufacturers, though, the s

- - Facts panel,92 percent ofconsumers were Shown different ofthe versions Nutrition Facts panelto make purchasing decisions. gated howconsumers usetheNutrition sugars, and added sugars, and investi- relationship between total carbohydrates, 2014, tested consumer perceptions ofthe fusion. One study, published in August consumers, orjust likely to cause con- tion onAdded Sugars istruly helpfulto obesity disease. orheart the direct contribution ofaddedsugars to that inadequate evidence exists to support other mandatory nutrientsto date,” and “is different fromrationale our to support ing addedsugars amandatory declaration FDA acknowledges formak itsrationale what isactually being added.Indeed,the is addedappears more than important corn syrup. To theFDA, thefactthatsugar thesized ingredients such as high fructose such asfruitjuice, andmodern,highly syn curring sugars from whole foodsources ucts, common refined sugar, naturally-oc the additionofraw untreated sugar prod preparation, failing to distinguish between sugar addedto foodsduring processing or Sugars includes any typeoramountof one, asproposed, thecategory ofAdded number ofquestionsandconcerns. For additional nutrientvalue…” the premise thataddedsugars “provide no much hasbeenaddedto theproduct” with much sugar isnaturally occurring andhow will “help consumers understand how consumers how understand will “help cording to FDA, including Added Sugars “maintain healthy dietarypractices.” Ac Nutrition Facts Panel to help consumers Cosmetic Act thatallowschanges to the authority provided intheFood Drug and In proposing this change, FDA relied on It isalsonotclear whether informa- The Added Sugars proposal a raises category termed “Added Sugars.” total “Sugars” withaseparate information onsugar into www.foodqualityandsafety.com - - - - -

© Mike / gena96- Fotolia.com able to correctly determine how much are involved. While the FDA notes that Salt: Lower Levels or Else? sugar was contained in the product when certain products such as soda will contain In June 2014, a few months after FDA pre- using the current Nutrition Facts panel, only added sugars, its simplistic Added sented its Added Sugars proposal, the Ad- while only 55 percent and 66 percent of Sugars model makes no mention of how to ministration announced its intent to issue consumers were respectively able to de- sort between multiple ingredients that all voluntary guidelines for food producers to termine total sugar content when shown a contain some type of sugar. reduce sodium levels. While FDA has not panel with Added Sugars information. Ac- Consider a hypothetical juice product put forward any timeline for these guide- cording to researchers: “34 percent believe made from 90 percent grape juice and 10 lines to be released, the public was told to [Added Sugars] simply means more sugar percent pineapple juice. The manufac- expect them “relatively soon.” has been added to the products, 28 per- turer, not unreasonably, considers sugar in The impending new guidelines raise a cent think the line distinguishes between the grape juice inherent in the production number of potential issues for food man- added sugars and sugars that are naturally process and sugar from the pineapple juice ufacturers. First and foremost is the ques- occurring in the other product ingredients, tion of whether a manufacturer should try [and] about one in five (19 percent) just to comply with the guidelines, given that don’t know what it means.” The Added Sugars they are not mandatory. While reducing From a litigation perspective, the declaration could sodium content would likely enamor a most troubling aspect of the Added Sugars also lead to litigation manufacturer to the public community panel is the potential for this new labeling and regulators, a significant drawback to requirement to provide fodder for food la- against manufactur- voluntary sodium reduction is the poten- beling lawsuits. Given the lack of reliable ers of food products tial to fall behind in the marketplace. So- evidence on the health effects of Added that contain multiple dium plays a key function in many foods, Sugars as opposed to total sugar intake, improving texture, color, and controlling it is unsurprising that the FDA has thus sweetening agents... for microbes. Maintaining those qualities far declined to provide guidance to food while reducing sodium is a significant ob- manufacturers on the proper protocol for stacle for a manufacturer, and consumer measuring and establishing which sugars to be Added Sugar, and the labeling reflects reaction to reduced sodium levels is often are “added.” What is more, FDA acknowl- this view. In a case like this, however, the negative. For example, a 2010 initiative by edges: “[T]here are currently no analyti- FDA provides no standards as to how the Campbell’s Soup to reduce sodium content cal methods that are able to distinguish manufacturer should determine which was well-received by public health advo- between naturally occurring sugars and are the inherent sugars and which are the cates but fared poorly with consumers. In those sugars added to a food.” Added Sugars. A skilled plaintiff attorney 2011, Campbell’s added the salt back. In lieu of reliable analytical meth- is free to file suit claiming that the product If consumers do not generate demand ods for measuring added sugar content, is mislabeled, either on a theory that the infor sodium reduction in their purchasing the FDA proposes new mandatory re- herent sugars should actually be reported preferences—which has the effect of pun- cord-keeping procedures that would allow as Added Sugars, and vice versa, or that ishing manufacturers who voluntarily regulators to verify that the Added Sugar all of the sugars in this product should be reduce sodium in their products—what content reported on the label matches up reported as Added Sugars. reason is there for a manufacturer to make to the sugars added according to a food This problem is even more pronounced a meaningful reduction short of an FDA manufacturer’s production protocols. if one considers another hypothetical juice mandate? One significant motivation for FDA could, in theory, take action against product made from equal parts of 10 differ- voluntary compliance is the potential that a food manufacturer who fails to maintain ent types of juices, similar to a number of industry-wide refusal to comply with the adequate records, even if there is no affir- currently popular brands. Which of the 10 new guidelines—or the refusal to at least mative evidence that the product in ques- potential sources of sugar are Added Sug- make a serious attempt to comply—could tion was mislabeled. Such an approach, ars? Likewise, imagine a cereal in which give FDA no option short of issuing man- in turn, leaves plaintiffs free to file suit by sucrose is added to the cereal flakes, and datory sodium reduction regulations. arguing that the manufacturer misled the then later in the production process apple It seems apparent from both the Added public in reporting a specific Added Sugar juice is added for flavor. Is the fructose Sugars initiative and the forthcoming so- content, when in fact the manufacturer from the apple juice an Added Sugar, or is it dium reduction guidelines that the current could not verify that the reported amount only the sucrose? If the manufacturer fails environment at FDA is one in which food was accurate. Under this approach, FDA’s to include the fructose as an Added Sugar, manufacturers will not be granted the ben- record-keeping policies potentially turn have they mislabeled its product? The only efit of the doubt, and initiatives favored by manufacturers into defendants. certainty is that the FDA has thus far given “consumer advocates” may be adopted by The Added Sugars declaration could no indication to manufacturers how to FDA even if the science behind them is not also lead to litigation against manufactur- handle this issue, leaving manufacturers yet well-established. Given this regulatory ers of food products that contain multiple to guess on the right approach and plain- climate, industry may be wise to avoid sweetening agents, particularly if natural- tiffs free to argue that a different approach putting FDA into a position where it is left ly-occurring sweeteners such as fructose should have been followed. (Continued on p. 32)

February/March 2015 31 QUALITY Flavors & Textures

(Continued from p. 31) with no choice but to mandate sodium Potato chips, for example, reduction. are an obvious high It is also worth noting that the FDA has more than one way to force manufacturers sodium food where the to lower sodium levels. While a direct man- salty taste is at the heart date identifying maximum allowable so- of consumer appeal. dium content is the most obvious course, FDA could also pursue indirect methods, such as modifying or eliminating sodium’s GRAS status. When FDA first formulated the GRAS list in 1959, it did not formally list salt as a GRAS ingredient. The reason was that FDA judged it “impracticable” to formally list all GRAS substances, and named salt, along with pepper, vinegar, and baking powder as examples of “common food ingredients” that were considered safe and presumed to be GRAS. From a regulator’s perspective, then, the GRAS status of sodium has always been presumed, never scientifically established. Indeed, a 1979, a report by the Select Committee on GRAS Substances concluded that: “The evidence questionable use of limited resources both low potassium intake in the U.S. In other on sodium chloride is insufficient to deter- among regulators and industry. Accord- words, the problem is not that Americans mine that the adverse effects reported are ingly, the two sides could work together eat too much salt, but that they eat too few not deleterious to the public health when to identify this and other obvious high-so- fruits and vegetables and other foods high it is used at levels that are now current and dium foods for exemption to sodium reduc- in potassium. This may explain why, on in the manner now practiced.” The frame- tion standards, perhaps including notice or average, people in countries such as Italy work exists, then, for FDA to undertake a warning that the sodium level in that prod- experience fewer cardiovascular problems review of sodium’s GRAS status, and elim- uct exceeds the amount recommended in than Americans do, even though its aver- inate that status if so inclined. While strip- the government’s Dietary Guidelines. age salt intake is significantly higher than ping sodium of its GRAS status represents There are also commercial advantages in the U.S. It also highlights the inherent something of a “nuclear option” for FDA, to treating the voluntary sodium reduction limitations of regulating ingredients in it is nonetheless an option available to the guidelines as if they presage a mandate. isolation, and ignoring the potential that Administration to reduce sodium levels Manufacturers who investigate lower so- health effects associated with specific in- in processed foods. Accordingly, some dium alternatives to their current products gredients may also depend on the balance amount of cooperation with the FDA on will have the advantage of using this time of those ingredients against other sub- sodium reduction would seem an ideal to develop products that consumers will stances in the human body. path for food manufacturers rather than find more palatable despite their lower so- Political realities, and public relations, risking the imposition of new regulations dium content. When lower sodium levels may make it easy to pursue regulation of entirely from above. are mandated, a manufacturer who is pre- certain ingredients and industries. But if Working with FDA could lead to novel pared could enjoy considerable advantage the FDA is truly concerned with promot- approaches that benefit all parties. From a over the competition if its low-sodium lines ing a “balanced” diet, it should remember health and regulatory perspective, one con- are store-ready while competitors are still that balancing involves evaluating all of cern for both sugar and salt are the levels working to comply with the new standards. the variables against one another simulta- of each ingredient found in foods not typ- neously. Picking at ingredients one-by-one ically associated with them. One potential FDA’s Isolated Approach without keeping the entire system in mind way for industry to address this concern One thing that should not be lost in focus- may ultimately increase the risk that con- while protecting its own interest is to focus ing on the FDA’s sugar and salt initiatives sumers will develop the poor health con- regulators on a narrower field of products is the fundamental question of whether ditions that FDA is attempting to curtail. ■ where sodium reduction would be most an ingredient-by-ingredient approach beneficial. Potato chips, for example, are to food regulation is most beneficial for Gruver is a senior associate in Kaye Scholer’s complex commercial litigation department and is a member of the firm’s an obvious high sodium food where the consumers. A significant amount of re- Product Liability Group. Reach him at michael.gruver@ salty taste is at the heart of consumer ap- search suggests that high blood pressure, kayescholer.com. Pogust is special counsel in the firm’s complex commercial litigation department and is also a peal. Mandating reduced sodium levels typically associated with Americans’ high member of the Product Liability Group. Reach him at glenn.

that would apply to products like this is a sodium diet, is more a result of the overall [email protected]. - Fotolia.com © A a r on mat

32 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Brookfield Engineering Brookfield Engineering

T T Brookfield CT3 distance, measures theresistant force, pushes theprobe into thebread adefined The TPA test isatwo-cycle procedure that to measure thefirmness ofsliced bread. texture analyzer withcylinder probe used The image above showsanexampleofa Food Products Analysis or“TPA.” a standard test knownasTexture Profile instrumental measurements basedon that relate peoples’ sensoryproperties to search have resulted inasetofdefinitions evaluate foods. More than65 years ofre- way thathumanbeings usetheirsensesto QUALITY exture Analyzer. correlates thesefindings to the properties offoodproducts and that measures themechanical exture analysis is the science

Flav ors& Texture s item mightit beandhow difficult about thisis how sticky thefood item. Anotherway ofthinking theprobe extract from thefood the amountofwork required to white bread. “Adhesiveness” is the probe compared to the sliced significantly more resistance to with acrustyexterior willgive der compression. French bread how firmisthe object thatisun- is exactly what itsounds like— and “adhesiveness.” “Hardness” characteristics are “hardness” texture analyzer. The two primary a tified withmeasurements from fined properties thatcan bequan- “chewiness.” bread, such as“springiness” and Table 1 on page 34 lists the de time isonthex-axis. Note thatthe the two-cycles; force isonthey-axis, the graph offorce versus timefor compression cycle. Figure 1ashows then repeats the same pulls back out, to perform.Figure 1bshowsanalter generally takes lessthan30seconds sured throughout theTPA which test, position andtheforce loadismea- texture analyzer records theprobe recover to itsoriginal position.The during thefirst cycle, itdoesnotfully cycle. Once the bread compresses than thepeakloadP2insecond peak loadP1inthefirst cycle ishigher fine properties of the sliced fine properties ofthesliced QC tests for food and packaging materials Various types of fixtures can be used everydayto perform Physical Properties Tension in Measuring Compression and cal calculationsthatde- are usedinmathemati- These measurements the probe) ontheX-axis. of data using distance (position native way to present the same B y Robert McGregor - texture profile analysis test. Figure 1b: Graph showing force load vs. distance for profile analysis test. Figure 1a: Graph showing force load vs. time for texture - of hardness, corrected cohesiveness, and Table may seemcomplex—the product mathematical calculationshownin the that you instinctively butthe understand, ness” ontheotherhandisanexpression back after being compressed. “Chewi- think—how much doesthebread spring “springiness” isexactly what you might “chewiness” are calculated. Note that suchparameters as“springiness” and and adhesive force measurements, other able resistance. but forsaladdressings there canbenotice- no resistance when probe the extracted, is is to pulltheprobe away. For bread there is Using thedata related to thehardness

February/M arch 2015 (Continued onp.34)

QUALITY Flavors & Textures

Table 1: Table of sensory parameters used to characterize food items.

One of the more popular fixtures for general purpose testing using the tension mode is the dual grip assembly. This general-purpose device has two separate clamps that fasten the sample material and pull it apart. The bottom clamp is fixed to the base table while the top clamp attaches to the probe drive on the instrument. The top clamp moves upward at the start of the test and the instrument displays the measured force as the material stretches. The test objective is to measure the maximum force that a material can withstand when in tension mode. A sliding friction test can also be performed on packaging materials in accordance (Continued from p. 33) strength needed to remove the lid from a with ASTM D1894. The objective is to mea- springiness. Rest assured that food scien- sealed container. Tests like these are per- sure how easily two materials slide over tists have successfully used the various formed at different angles to simulate the each other. The instrument measures the terms in Table 1 to characterize food items approach taken by customers around the force needed to pull a weight robed in one for years. world. The preferred orientation for taking material across the surface of a second the lid off may be explained by the man- material. The rate of travel for the weight is Packaging ufacturer in the information on the side usually between 1 mm/second and 10 mm/ Exploding QC interest in the use of texture of the container. Peel strength needed to second. When there is too much resistance analysis to certify the physical properties of open the container can be adjusted to ac- between the materials, the friction may food products coming out of the manufac- commodate the user group for which the cause damage to one of the materials. This turing process is now spilling over into re- product is intended, such as senior citizens is an important test because it confirms, for lated industries, like packaging materials and children. example, that boxes of a specific food item, for these same products. Texture analyz- Film materials are used extensively such as cereal packaged in a large con- ers, as explained above, are nothing more to package all kinds of food items. The tainer, will arrive at their destination with than simple instruments that compress or ability of film to stretch without tearing the printed information on the outside of pull apart an item and measure the force is one of its important properties. A film the box in tact. Customers often judge a and energy required to make it happen. support fixture makes it possible to eval- product by appearance on the shelf, so this They mimic the consumer who uses the uate the tear strength of the film. The tex- test confirms that the surface of the pack- sense of touch when evaluating a food item ture probe has the shape of a punch that age withstands the rigors of shipment. by hand or when popping the food item pushes down on the film sample, which The field of texture analysis has prolif- into the mouth and taking bites. Texture is clamped in place during the test. The erated over recent years with the advent of analyzers can also qualify the integrity of rate of travel for the probe can vary from many fixtures that can measure the firm- the packaging used to ensure that the food 0.01millimeter (mm)/second to 10 mm/ ness and robustness of packaging materi- item survives transit from the manufactur- second and is usually selected according als. The objective is to ensure survival of ing plant to the supermarket shelf to the to the packaging process on which the both the food item and its container from end user who consumes the item. film will be applied. R&D labs may con- the production plant to the end user’s Simple examples of tests on packaging duct tests at different speeds to simulate kitchen, as well as to insure that the cus- materials include actions that consumers multiple ways in which the film might be tomer use of the item is optimized for ease use everyday when opening items like used. The test results not only qualify the and acceptability. ■

yogurt containers with lids that must be film for use in packaging processes, but E nginee r ing McGregor is general manager, global marketing/high-end peeled off. A peeling jig can be used with a also provide guidelines for choosing films lab instrument sales, at Brookfield Engineering Laboratories,

texture analyzer to measure the adhesive with specific tear strengths. Inc. Reach him at [email protected]. B r ook f ield

34 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Thermo Fisher Scientific

T CC25 DINTi measuringCC25 geometry hasbeen cotester iQ. Peltier temperature control unitof theVis are preheated to 40degrees Celsiusinthe cup andbob ofthemeasuring geometry tween 45 and60minutes. Meanwhile, the in anoven at52 degrees Celsiusforbe- sealing thecontainers andleaving them chocolate pieces into glass containers, according to ICAmethod46byputting and adarkchocolate, have beenprepared Two chocolate samples, a milk chocolate Method ataPreparation A Look tion methodslike theCassonmodel. of yield stress calculations with extrapola- sensitivity, which enhances the reliability rates are accessible due to the improved Also, smallershear and cleaning effort. ume, time for temperature equilibration, ing geometries, which reduces samplevol makes itispossibleto usesmallermeasur HAAKE Thermo Scientific Viscotester iQ ier andmore reliable. For example, the able to make viscosity testing inQCeas chocolate-coated cookies. chocolate fortheirownproduction, e.g. company producing chocolate orusing of thestandard QCtest methodsforany viscous behavior. feel, are directly related to thechocolate’s late, like thelookofitssurface oritsmouth Likewise, theproperties ofthefinal choco a well-defined viscosity andyieldstress. ping, coating, anddosing steps dependon V Scientific HAAKE The QUALITY iscotester iQ. iQ. iscotester hermo Thermo For the thetests done forthisreport, There are various instrumentsavail Testing theviscosity istherefore one tion, the transport, filling, dip tion, the transport, many reasons. During produc olate isacrucialparameter for he flowbehavior ofmolten choc

Flav ors& Texture s ------model andthe modern Windhab model a chocolate Casson thetraditional melt, RheoWin. To calculate theyieldstress of is performedautomatically byHAAKE be performedat. reach thetemperature the test isgoing to the sametime,whole sampleshould ometry shouldrelax completely while at by sampleloading andclosing thege- this timeany mechanical stress caused already inmeasuring position.During of themeasuringupper part geometry sample iskept atrest withthecylindrical results. During the conditioning the part which improves the reproducibility ofthe and always performed in the same way, itself to ensure thatitisnotforgotten should always ofthetest bepart method evaluation. Thesampleconditioning parts: sample conditioning, testing, and shown inFigure 1. RheoWin job. Theshearrate profile is lated into HAAKE aThermoScientific the Peltier cylinder temperature control. only 16.1 milliliter samplevolume fitsinto selected. Thissmallcylindrical system with ICA method 46. Figure 1: Shear rate profile applied according to In the final part, thedata evaluation In thefinalpart, HAAKE RheoWin Job consists ofthree The ICAtest method46hasbeentrans in QC applications for chocolate products An application note on viscotesters beingused to ICA Standards Melts: Working According Flow Behavior of Chocolate B y Klaus Oldörp , PhD -

yield stress. Ifthismethodispreferred, a use theshearstress value at51/s asthe to Servais hasbeencalculated. Results of indicate where theinterpolation according The sent the Casson fit. greenvertical lines the flowcurves rateto ashear of0 1/s repre two viscosity curves. with significant differences between the shows apronounced thixotropic behavior chocolate. the milk chocolate In contrast, arerate ramp almostidenticalforthedark andthedecreasing shear rate ramp shear tor oftwo ormore. chocolate hasthehigher viscosity byafac shear stress. It clearly showsthatthemilk pict theviscosity andtheblue curves the in Figure 2onpage 36. Thered curves de- a test according to ICAmethod46isshown A typicalrepresentation oftheresults from ResultsThe rate applied. can bedirectly correlated withthe shear independent of the instrument used and viscosity isthebestchoice because itis parison ofviscosity data,the steady-state Forthe slopeofshearrate ramp. com - effectand pendent from time-dependent ramps, thesteady-state viscosity isinde- viscosity transient datafrom shearrate corded forbothsamples. Compared to curve at40degrees Celsiushasbeenre - RheoWin willdothejob. simple interpolation calculationinHAAKE in nation ofChocolate Viscosity” published els. Inamore simpleapproach, “Determi- can beselected from along listoffitmod Journal of Texture Studies Green parabolic curves extrapolating The viscosity curves fortheincreasing In addition,asteady-state viscosity February/M arch 2015 (Continued onp.36)

suggested to 35

- - -

QUALITY Flavors & Textures

Nothing escapes (Continued from p. 35) the different methods to determine the yield stress of the two choc- Romer Labs. olate melts have been summarized in Table 1. The first and probably most important result from Table 1 is the insight that even from the same data, different models give different results. Therefore, only yield stress values calculate with the same mathematical model can be compared. Independent of the model chosen, the milk chocolate in this example shows the higher yield stress, the higher viscosity, and the stronger thixotropy.

Figure 2: Test results for a milk chocolate (open symbols) and a dark chocolate (filled symbols). The milk chocolate shows higher viscosity values (red curves), stronger thixotropy, and a higher yield stress. The extrapolation of flow curves (blue curves) to 0 1/s has been calculated according to Casson. The green vertical line at 5 1/s represents yield stress according to Servais.

Table 1: Determination of yield stress based on the data from Figure 2 using different models.

Figure 3: Viscosity curves of milk chocolate and dark chocolate at 40° C. The milk chocolate shows a significantly higher viscosity.

Summary In QC, the rheological characterization of chocolate mainly fo-

FIND OUT MORE ABOUT ROMER LABS TESTING SOLUTIONS cuses on its viscosity and yield stress. Using an instrument that AND CONTACT: combines sensitivity and strength, like the HAAKE Viscotester iQ, can help to successfully test chocolate melts over a wide range of ROMER LABS INC. 130 Sandy Drive shear rates. The commonly accepted test method according to ICA Newark, DE 19713, USA method 46 can easily be performed using only a small sample. The Tel: 302 781 6400 same is true for steady-state viscosity curves. ■ RI¿FH#URPHUODEVFRP ZZZURPHUODEVFRP Dr. Oldörp is a senior application specialist at Thermo Fisher Scientific in Karlsruhe, Germany. Reach him at [email protected].

References Furnished Upon Request Th e r mo Fi sh Scienti f ic

36 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Hanna Instruments

M nance, andpractices formeasuring the will discusselectrode design, mainte- surement canbeachallenge. Thisguide determining best practices for pH mea- care guidelines, andelectrode designs, of different sampling methods, electrode of adairyproduct. As there are amyriad method to estimate theaciddevelopment icals while alsoproviding aconvenient of contamination from bacteria orchem- worldwide foritshigh nutritional value much broader range ofdairyproducts. cheese, the guidelines can be applied to a pH ofdairyproducts. Whilethefocusison in dairyproducts Guidelines and considerations for measuring pH During Cheesemaking Determining pH B y David Masulli Cheese isaversatile foodthatisvalued The pH offers an indication anindication The pHoffers duction ofdairyproducts. a criticalQCstep inthepro easurement of pH presents Testing D - airy formulated to measure thehydrogen ion. termined by pH glass, which isspecially on hydrogen ionactivity; this activity isde electrodes generate amVpotential based (mV) readings from the electrode. ThepH values are assigned to incoming millivolt adjustsbe calibrated. Calibration how pH Prior to pHmeters must measurement, Calibration batches remain consistent. to ensure thedesired flavor is achieved and involves multiple pHqualitycontrol steps dairy product. Thecheesemaking process tion, cheese isthemost diverse formof this variance andcomplexity inproduc ing compositions andtechniques. Dueto cheese varieties, allprepared withdiffer and long shelflife.There are hundreds of (58.33 / 59.16) x 100 = 98.6% slope 175 mV / 3 pH units = 58.33 mV/ pH unit 160 mV – (-15mV) = 175 mV and +160 mV in pH 4.01 buffer pH electrode generated -15 mV in pH 7.01 buffer Sample

Calculation:

- - - tion. Based on this equation, a theoretical onthisequation,atheoretical tion. Based pH andmVisdefinedbythe Nernst equa- incorporated forhigher precision. are pH4.01 and7.01; athird buffermay be pH 5.0 and6.7, standards idealcalibration cheese typically hasapHvalue between pected pHrange ofthesamples. Because per day withstandards thatbracket theex sults, calibrate thepHmeter atleastonce termine theaccuracy ofdata.For bestre- procedurescalibration willultimately de- in theglass; thequalityandfrequency of tion ofthemeter corrects forthesechanges time due to normalwear andtear,- calibra As pHglass breaks downandchanges over than 7being basic,andpH7being neutral. and other buffering salts present. Values to thepresence ofphosphate, citrate, typically intherange of pH6.5 to 6.7, due be tested for quality. Milk is slightly acidic, cheesemakingBefore begins, milkmust Production result ininaccurate measurement. cent; anything outsideoftheseranges may slope percentage is85 percent to 105 per Acceptable ranges for offsetis±30mVand oretical slope of 59.16, and multiply by 100. age, divide theelectrode slopebythe- To convert thisto electrode slopepercent by thenumberofpHunitsbetween buffers. tween thetwo andthendivide buffers this slope, calculate thedifference inmVbe- such aspH4.0. To determine theelectrode measure themVvalue ofasecond buffer, 7.0 buffer; Next, thisistheelectrode offset. measurefirst and record themV value inpH form anelectrode offsetand slope check, check electrode offsetandslope. To per the mVmodeonapHmeter to periodically condition, butitisrecommended to use indications ofelectrode condition orslope ment is affected. Many meters will have much before theaccuracy ofthemeasure - relationship, butcanonly correct forso of electrode behavior from thistheoretical corrects Calibration fordeviations pH unit. will have aslopeof-59.16 mVperchange in value ofwhich isknownastheoffset),and electrode will read 0mVinpH 7.0 buffer (the less than7being acidic,pHvalues greater scale ranges from 0to 14, withpHvalues tribute to how basic a sample is. The pH a sampleis, while hydroxide ionscon- Hydrogen ionscontribute to howacidic The theoretical relationship between February/M arch 2015 (Continued onp.38) 37 - - - - TESTING Dairy

(Continued from p. 37) pedance. An offset outside of the accept- allows for direct measurements of cheese above this range may suggest illness in able range of ±30 mV usually indicates the samples, thus saving on preparation time the cow; values below this range may indi- pH glass bulb is dirty or coated. Cleaning and eliminating a potential source of error. cate that lactic acid fermentation has be- solutions are effective at both disinfecting Conversely, for other dairy products such gun. Although lactic acid fermentation is and removing oil and protein deposits. It as milk or cream, the spherical tip may be commonly performed as part of the chee- is also recommended to store electrodes in more suitable due to its wider area of con- semaking process, it is undesirable in the storage solution when not in use. This en- tact that permits a faster stabilization time. raw milk because potentially pathogenic sures that the sensing glass stays hydrated Ultimately, selection of the tip should be bacteria, rather than the starter cultures, and ready for measurement. based on the nature of the sample matrix. are performing the fermentation. The production of cheese begins with The Design Temperatures the metabolism of milk by microbial cul- Conventional pH electrodes have a ce- A wide temperature range is covered in the tures. These cultures ferment the milk un- ramic frit reference junction that allows cheesemaking process; pH measurements der controlled conditions, producing lac- the internal reference electrolyte to come may be taken in refrigerated conditions or tic acid from the sugars that are naturally into contact with the sample. In dairy conditions as hot as 85 degrees Celsius, present. Fermentation causes a decrease in products such as milk and cheese, pro- which is seen in the production of ricotta. pH and allows for flavors to develop. Next, teins and other colloidal solids can par- This presents a measurement challenge the milk is separated into solid and liquid tially or completely clog this ceramic frit, since hydrogen ion activity, and therefore components through the use of rennet, an resulting in slow electrode response or pH, changes based on temperature. Tem- enzyme complex that is responsible for inability to take a reading. For dairy, it is perature compensation allows measure- the curdling of proteins in milk. The re- recommended to purchase a pH electrode ments at high and low temperatures by sulting solid component is known as curd with an open junction rather than the comparing the measured pH to a reference while the liquid component is called whey. traditional single ceramic junction. The temperature. Automatic temperature com- Once the milk is coagulated, the curd is open junction design utilizes a gel refer- pensation is available on most pH meters fermented until it reaches a pH of 6.4. It ence electrolyte that comes in direct con- so users do not have to consider their tem- is subsequently separated from the whey tact with the sample; because there is no peratures during measurement. and left to form into a mat. At this point, the physical junction, clogging is no longer a Temperature also changes the be- mat is cut into sections and layered to ex- potential issue. The open design also of- havior of the pH sensing glass. As tem- pel more liquid. Fermentation continues in fers an added benefit of a faster response perature increases, the impedance of this layered form until the pH reaches pH time due to a higher flow rate of electrolyte the glass decreases, and vice versa. This 5.1 to 5.5 and is then salted or brined. Addi- into the sample. Other types of electrode relation means that while a reading may tional treatment may be performed based junctions exist, including PTFE junctions, stabilize more quickly at higher tempera- on the desired style of the cheese before the triple ceramic frit junctions, and ground tures, the glass degrades at a faster rate. product is stored, aged, and packaged. glass junctions; these designs confer their Conversely, readings may take a long time It is best practice to measure pH fre- own advantages, but are more suited for to stabilize under low temperatures due quently throughout the cheesemaking other applications. to the higher impedance. Manufacturers process from raw milk to finished product, Conventional pH electrodes have a minimize these measurement difficulties as pH influences the microbial community spherical sensing bulb that provides an by producing different glass formulations that contributes to flavor and texture devel- increased surface area for the sample to specifically designed for high or low tem- opment. If pH during cheese processing is interact with the sensing glass; this bulb peratures. In short, if measurements must too low, the cheese may be prone to a brittle shape is ideal for measurement in aque- occur in both hot and cold samples it may or pasty texture, and can potentially har- ous solutions. However, other tip designs be desirable to have an electrode dedi- bor the growth of mold after packaging. If exist on the market, and each shape offers cated for each of these extremes. However, pH is too high, the cheese may become too an advantage in certain applications. For if measurements are normally taken under firm, and can be dangerous for consump- example, conical tipped pH electrodes are standard conditions and only rarely under tion due to risk of pathogen formation. pointed so that they may easily penetrate extreme conditions, it may be best to per- When pH is measured in dairy prod- semisolid objects, such as cheeses. form measurements with a general-pur- ucts, electrode fouling is a common chal- If measuring the pH of cheese with an pose electrode. lenge. Electrode fouling occurs when fats electrode constructed of a spherical bulb Details for when and where to moni- and proteins obstruct the reference junc- and ceramic reference junction, a homog- tor pH can change depending on specific tion or attach themselves to the sensing enized slurry of cheese and deionized wa- product, but in all cases, proper electrode glass of the electrode. ter must be prepared. A slurry is necessary care and design selection is key for reliabil- Electrode fouling can be minimized because the flow rate of electrolyte into a ity of measurement. When implemented with proper maintenance, storage, and solid or semisolid cheese alone is too slow properly, pH measurements can ensure cleaning. Buildup on the sensing glass to enable a direct measurement. An elec- safe, consistent, and quality products. ■ causes inaccurate and sluggish measure- trode utilizing a conical tip shape in com- Masulli is application engineer at HANNA instruments. Reach ments, as it directly affects the glass’ im- bination with an open reference junction him at [email protected].

38 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Strengthen Your Chain.

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Keep Your Cool Automation technology played a critical role in Hill Country Bakery’s implementation of a temperature monitoring system at its distribution center By Georgia H. Whalen and Nick Hitchcock, PE

as well as no tracking of corrective actions in the event that a temperature issue was found,” explains Nick Rendon, maintenance manager for Hill Country Bakery. “We approached Patti Engineering with our desires for a reliable system as well as t Hill Country Bakery, production center located in San Antonio, Texas a system to resolve some of the issues that tion processes and monitoring for a number of reasons. we had seen with the antiquated system. is a major priority to ensure The distribution center stores both in- Their solution was a cost effective, reli- product quality. The company gredients for manufacturing and finished able, wireless solution that would address Ais proactive in investing in technology and products for distribution to retailers and all our needs and satisfy the requirements automation to meet its quality goals. Hill food service distributors. The bakery refor SQF. They worked expeditiously to Country Bakery’s commitment to produc- lies on temperature monitoring and logs successfully delivery our system in time for ing the highest quality baked goods has to ensure the highest standard of product our audit.” earned the company its coveted SQF2000 quality for customers and to meet SQF Patti Engineering’s solution included level 2 Certification. monitoring and reporting requirements. elimination of hard-wired temperature Achieving Safe Quality Food (SQF) The distribution center had multiple sensors, and the addition of a powerful Level 2 Certification requires establish- refrigeration zones with hard-wired tem- supervisory control and data acquisition ment of a Hazardous Analysis and Crit- perature probes to collect and monitor (SCADA) for automated data collection ical Control Points (HACCP) food safety temperature data. The problem was the and real-time monitoring. The ability for plan that is benchmarked by the Global connecting wires were prone to damage by remote monitoring and alarm notification Food Safety Initiative (GFSI). Preventing forklift trucks which could temporarily in- via mobile devices such as smartphones potential problems from occurring is the terrupt the continuous collection of data. completed the plan for improvements. paramount goal underlying a solid HACCP In addition, the method for data collection Freshloc wireless temperature sensors plan. Companies reaching this level of cer- was inefficient, temperature readings had were provided by Patti Engineering to elim- tification must pass SQF audits and contin- to be manually logged into a database for inate the recurring problems associated uously show improvement of rigorous and reporting; a time consuming task with in- with damage prone hard-wired sensors. credible food safety management systems. herent risk of human error. InduSoft Web Studio was chosen for de- A key part of every successful food Hill Country Bakery hired Patti En- velopment of the human machine interface manufacturer’s safety program involves gineering to assist with the engineering, and SCADA because of its open platform, refrigeration of ingredients and finished design, and implementation of a more ad- large library of drivers, and flexibility for products. Temperatures need to be mon- vanced and automated temperature mon- customization. itored and kept within a narrow range to itoring system. “We had a huge gap that Patti Engineering’s team customized ensure product quality and safety. Hill needed to be filled before our SQF level 2 Indusoft Web Studio to meet Hill Country Country Bakery was not satisfied with its audit. The continual degradation of our Bakery’s specific needs. Real-time mon- temperature monitoring system for its previous monitoring system continued to itoring of all temperature zones can now

55,000 square foot cold storage distribu- put us in a bind. There were gaps in data be viewed from the SCADA at the plant or © I deenkoc h - Fotolia.com

40 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Patti Engineering

any specifiedperiodoftime. from this database quickly and easily for ture andalarmreports canbegenerated recorded into anSQLdatabase. Tempera- ture zonesandalarmsare automated and eliminated. Alldatacollection fortempera problems. Manually generated logs were vent compromised qualityand/orsafety when atemperature issuearisesto pre- notifications of alarms are sentviaemail remotely onamobile device. Immediate Register Today atwww.UnitedFreshShow.org REGISTER TODAY! - gineering development timefortheproject. Hill CountryBakery hardware cost anden- andSCADAthe sensors system. Thissaved logic controllers orothercontrol between the engineers to cutoutany programmable perature probes viaModbusTCP, allowing municate directly to thegateway ofthetem system completed, Hill Country Bakery grammed theIndusoftgrammed software to com- With thenewtemperature monitoring In addition,PattiEngineering pro screen from T emperature history report emperature history report system. SCADA system. - - effectiveness. monitor and improve overall equipment lection from themanufacturing linesto settings. Another option is to add data col but to actually control/adjust temperature not only remotely monitor temperatures, tionality in the future, such as the ability to will allowHillCountryBakery to addfunc by hand. thatemployeeshours spentlogging data the reduction in the excessive amountsof with theautomated datacollection with cost savings benefithasalsobeen realized ing process ismuch faster thanbefore. A functions andmoving through theaudit proved thanks to the automated recording pliance foraudits. Dataintegrity isim- assurance to customers andqualitycom- can easily generate reports forquality engineer forPattiEngineering. Reach [email protected] that seeks toadvancetheindustryofcontrolsystemintegration. association professional non-profit global a (CSIA), tified member of the Whalen isdirectorofmarketingforPattiEngineering,acer The flexibilityofInduSoft WebStudio ■ Control System Integrators Association Control System Integrators Association February/M arch 2015 41 - - - - MANUFACTURING & DISTRIBUTION preventative maintenance K lü b e r Lubr ication

Quality R&D within the lubricant industry has advanced in recent years. Products available today now cover applications that were thought to be possible only from non-H1 materials. Many organizations are now realizing it is not just about the decision to go to a food-grade program, but to ensure

K lü b e r Lubr ication that the application of these products is done in a controlled manner. Using a SPAL can help improve food safety by avoiding improper mixing with non-food-grade ma- Food-Grade Lubrication terials and contamination coming from an Utilizing single point automatic lubricators can increase open system and/or lubricant container. both productivity and safety in the food industry With these units, quality managers can be confident that the NSF H1 (food-grade) By Toby Porter lubricant is being used in the location identified as a potential food contamina- hen it comes to enhance- optimum lubricant, this can reduce the option risk. ments in food safety from erating temperature of a component and A number of SPALs are available in a lubricant perspective, avoid other issues that can occur due to the marketplace, but it is important to previously unknown terms under-lubrication. By enabling best-prac- understand that the proper lubricants are Wsuch as NSF H1 and CFIA have become tice preventative maintenance routines, being used to handle a specific applica- common place. Now, food industry pro- it eliminates much of the hassle of plan- tion while also providing adequate food fessionals have a myriad of options when ning and scheduling manual lubrication, safety properties. It’s equally as important choosing products that help achieve helping to reduce labor and enhance plant to ensure the lubricants are being applied targeted levels of food safety for their fa- safety. It is important to understand the in a manner that continues along the food cility. Even ISO 21469, which refers to the benefits that can come from a SPAL, not safety path in which they were manufac- hygienic manufacturing process for a food- only from a maintenance and safety stand- tured. This is where the use of a SPAL can grade lubricant, is becoming well known point, but also from a quality and reliabil- become vital to maintenance and quality throughout the industry. It accounts for the ity standpoint. programs. For example, one system can lubricant and its ingredients, as well as the provide grease from one reservoir to multi- manufacturing process, handling, packag- Maintenance ple bearings—another can deliver oil from ing, and storage. The goal of this holistic The use of a SPAL can lead to increased one tank that can feed different drip noz- approach is to ensure the lubricant is not uptime for machinery by offering contin- zles for a baking oven chain. SPALs may be only manufactured in accordance with uous, uninterrupted lubrication for vari- recommended to provide a slow but con- the standards, but that it is also delivered ous components. These units can work to tinuous and defined volume of lubricant to intact and free from outside contaminants. avoid common issues, such as cross-con- an application point to minimize outside One aspect of these programs that tamination with incompatible materials, contamination. is often overlooked is the application of ingress of water into a lubrication point, The use of a SPAL combined with food-grade and ISO 21469 certified lubri- missed or over-lubrication of key com- NSF ISO 21469-certified lubricants en- cants once the grease cartridge and/or ponents, excessive downtime for main- sure the holistic approach to quality and oil pail is inside a facility. One option to tenance, and increased labor costs from safety has been continued beyond the consider is the use of a single point auto- manual lubrication. production walls of the manufacturer and matic lubricator (SPAL). A SPAL delivers These issues can significantly impact straight through to the application point of the correct amount of lubricant at the the bottom line by reducing productivity a component. ■ appropriate interval over the lifetime of and can also lead to unexpected and/or Porter is the food market manager at Klüber Lubrication the applicator. When combined with the premature machinery failures. North America L.P. Reach him at [email protected].

42 FOOD QUALITY & SAFETY www.foodqualityandsafety.com YOUR FOOD QUALITY & SAFETY TEAM DESERVES AN AWARD.

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F 44 P and safety. cleaned improve floors health, traction, unhealthy, anddangerous butproperly soils which canmake slippery, floors and restaurants, mopsandmopbuckets ities, including hospitals, schools, hotels, restaurant cleaning. inmany Infact, facil food service. all typesoffacilities, including thosein secret canhave for seriousramifications is to protect humanhealth, thenthislittle the ultimate goal of professional cleaning up to theC-suite regarding mops. And,if does notappear thattheword hasspread known orsuspected thisfordecades, but it professional cleaning industry have either sources of contamination | eliminate thedirect/indirect contact areas that are Advanced cleaning techniques onsoiled floors can Floor Cleaning Eye-Opener

Cleaning workers inthe andothers The useofmopsisstillprevalent in ood S FOOD on a little secret: Mops spread on alittlesecret: spread Mops quality control professionals in facility managers, operators, and erhaps it’stimeto letfoodservice QUALITY & S AFETY B y - Robert ervice &Retail facility, including foodservice. ings cananddoapply to any commercial conducted inahospitalsetting, thefind used to “wet-mop” or clean floors: mops, concerntral were all the tools customarily can bespread through cleaning. Ofcen- germs and bacteria that may cause disease Applied Microbiology in a hospital sanitation study published in service facilities. Thiswas made first clear contamination andhealth risksforfood bucket thatcanpotentially cause serious mops and the cleaning solution in the mop kitchen areas. itistheongoing But, useof to helpprevent accident aslip-and-fall in moisture buildup atbuilding entries, both They are perfectforcleaning upspillsor for certain tasksinafoodservice facility. ers, sprayers, andcleaning cloths. are ascommonly usedasvacuum clean- The researchers wanted to findoutif In all fairness, mops are recommended Kravitz Cleaning & Sa nitizing in 1971. Whileitwas

- bacterial counts occurred counts bacterial if mops were not effective decontamination, butbuild-up of provided andadequateLaundering drying decontaminated by disinfection. chemical high levels andcould notbeadequately wet, growth supportedbacterial tovery of control. Itwas foundthatmops, stored contamination andtoinstitutemeasures were undertaken todeterminethesource of ping techniques inuse, quantitative studies throughout thehospital by thewet-mop sive spread contamination ofbacterial what theyreported: buckets, andthecleaning solution. Here is they encountered are reasons why the tal study discussed earlierandtheissues day—cross-contamination ispossible. is often thecase during the ofthe course floor. And, if that floor is contaminated—as everyday from thewash-water. changed was dailyorifdisinfectant omitted 50 direct andindirect contacts withfloors Homeland Security, we have asmany as ner, formerly withtheU.S. of Department people realize. According to MarkWar many more contacts than most with floors reason isactually quite simple.We have ant to keep floors hygienically clean? The fair questionto askiswhy isitsoimport potentially harmfulcontaminants. pens, themopbeginsto spread soilsand bacteria—begins to diminish.As thishap disinfectant—its ability to killgerms and what isreferred to astheefficacy ofthe solution become more andmore soiled, ever, asthemop, bucket, andcleaning a disinfectantcanhelpprevent this. How nated. Thestudy didnote thattheuseof cleaning solution alsobecomes contami- builds upover timeandasitdoes, the becomes soiledandcontaminated. This used, literally from itsfirst application, it we have come in indirect contact with the an example,thathasalsotouched afloor, Following thedemonstration ofmas This was thekey concern inthehospi - Before exploringBefore thistopic further, a In otherwords, assoonthemopis . Every time we tie a shoelace, as www.foodqualityandsafety.com (Continued onp.46) ------

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NeoFilm_FoodQuality_0115.indd 1 1/19/2015 1:37:31 PM FOOD SERVICE & RETAIL Cleaning & Sanitizing

(Continued from p. 44) food service industry should prioritize ad- dressing these risks. Later, we will discuss how food service managers can address this problem.

Other Cleaning Culprits While the “wet mopping” process is probably highest on the list of cleaning tasks that can spread soils, germs, and bacteria, instead of remove them, mops and buckets are not the only culprits. Another key culprit is cleaning cloths, whether traditional terry cloth, which is often found in food service operations, or microfiber. Soils and microorganisms build up on them as they are used and ac kai v eventually can move from one surface to another, potentially spreading harmful or higher, which is then pressurized to being cleaned. Allowing for a few minutes germs and bacteria. about 60 pounds of pressure per square of dwell time—enough time for the chem- For instance, it is not uncommon for inch (psi). The steam vapor can be used to icals to effectively loosen and suspend custodial workers to clean restroom fix- clean floors, surfaces, restroom fixtures, soils—the same areas are then high pres- tures with a cleaning cloth that is then and other areas. And, according to Ben- sure rinsed. The final step is vacuuming used to clean high-touch (frequently and jamin Tanner, PhD in microbiology and the just cleaned areas with the machine’s commonly touched) areas, such as light immunology from the University of Ari- built-in wet vac system. While the process switches, door handles, ledges, railings, zona, steam vapor provides “a nontoxic, seems like it may be time consuming, ISSA etc. One very simple way food service man- environmentally friendly way to both clean reports in its book, 540 Cleaning Times, agers can prevent this is to incorporate a and disinfect at the same time.” spray-and-vac systems can be as much as color-coding system. A typical color-coded In a commercial kitchen, steam vapor two-thirds faster than traditional cleaning program for cleaning cloths looks some- can be an excellent tool because it melts methods, whether used to clean floors or thing like this: away grease and oil. However, the key restroom fixtures. • Red: restrooms and restroom fixtures, drawbacks with steam vapor cleaning are • Blue: kitchen area surfaces, counters, that it can be a rather slow process and, Testing for Results etc., when used on floors, it may require damp The use of adenosine triphosphate (ATP) • Yellow: high-touch areas, and mopping after use to remove residue from monitoring systems is certainly not new • Green: office desks, office equipment, the floor. Because our goal is to not use to the commercial food service industry. chairs, office counters, etc. mops, this can be a problem. Further, con- However, in most commercial kitchens, Taking this a step further, some facili- siderable care must be taken when using they are used to test cooking surfaces, ties now use what are termed “smart tow- steam vapor machines due to the very high tools, and equipment. As we know, while els.” “Smart” because not only can they heat generated. these devices do not indicate specifically be used in a color-coded cleaning system, There are also different types of hard that germs and contaminants are present but they can also be folded into numbered surface equipment—some use a combi- on a surface, a high ATP count can serve as quadrants. For instance, if sections 1, 2, nation of steam or very hot, pressurized a warning that this might be the case. and 3 have been used, the cleaning worker water. Advanced equipment features a Since we now know that soiled, con- can fold the towel to quadrant 4, using a vacuum system to recover cleaning solu- taminated floors have the potential to clean piece of the towel for each new clean- tion as the machine is used, while others spread disease, it is wise for food service ing task. use a squeegee to move chemicals into a managers to also begin using ATP moni- floor drain. Unfortunately, this squeegee tors to evaluate their floors. A good prac- Making Floors Hygienically Clean process can be problematic because it can tice is to test the floor before cleaning and While it is relatively easy to prevent the spread contaminants from one area to an- then after cleaning. This can evaluate the spread of contaminants using cleaning other when performed. effectiveness of the cleaning process used cloths, it gets a bit more complicated when Another option is to use what the In- and if you are still using mops and buckets, it comes to floor cleaning. However, there ternational Sanitary Supply Association conducting an ATP test after cleaning may are ways and means possible. (ISSA), the worldwide cleaning associ- prove to be a real eye-opener. One option is the use of a new genera- ation, refers to as spray-and-vac or no- Kravitz is a frequent writer for the professional clean- tion of steam vapor machines. These sys- touch cleaning systems. These systems ing and building industries. Reach him at Robert@ tems heat water to 240 degrees Fahrenheit inject chemicals onto the floor or surfaces alturasolutions.com.

46 FOOD QUALITY & SAFETY www.foodqualityandsafety.com Trailblazer Foods

P of choosing quality suppliers | A manufacturer’s perspective onthefundamentals Supporting a Store Brand safety orqualityissues. To minimize risks, associated withproduct recalls due to marketing andshelfspace. to bumpup prices to cover theircosts of than nationalbrands, which often need ity products could behadatalower cost many discovered shoppers thathigh qual stretch theirlimited dollars. Indoing so, begrudgingly, turnedto store to brands Recession. Consumers, perhaps even ally began to findfavor during theGreat been around forsometime,buttheyre- topears behere to stay. Private labels have What was once thought to beafadap Staying Power ofStore Brands cific needsas well aspricing limitations. deliver thegoods interms ofmeeting spe- will need to find manufacturers who can quality andfoodsafety. Inaddition,buyers can demonstrate a commitment to food chasers to withmanufacturers partner who forretailersit’s important andproduct pur FOOD SERVICE & number ofrisks, including those ters, butthey’ve alsointroduced a a chance to create newprofit cen- rivate labels have given retailers RETAIL

PARTNERING - - - B y of paramount importance. Productof paramount recalls ture, or packaging of aproduct. Safety is But qualitydoesn’t endwiththetaste, tex of thebestways to building start loyalty. brand—at a cost savings—is certainly one ity product thatrivals thatofanational regular salesandprofits fardownthe road. inturn,haspotentialalty to that, supply now haveers to anopportunity buildloy second-highest level at55percent. Retail Xreportingbrands, withGeneration the post-Millennials are high ofstore users shows that63 percent ofMillennialsand brands. Consumerresearch byMintel ment ofthepopulationhasadopted store outlets have grown five percent annually. across theboard, private labels across all three percent onanannualbasis, and store insupermarkets brands have gained shares rose ingrocery stores. Since 2011, Privatenual Label Yearbook Label Manufacturers Association’s label continues. According to thePrivate seemingly passed, the growth of private Tom What’s more, a relatively young seg While broad economic hardship has Providing consumers withahigh qual T railblazer Foods audits local strawberry farm. Boyd and

Jim Jackson

, unit and dollar , unit and dollar 2014 An ------highest qualityoffinalproduct. risks offoodsafetyhazards and assure the otherwise produced inorder to minimize under which ingredients are grown and a clear understanding oftheconditions and orchards, it’snecessary to develop that rely onfresh produce from farmfields manufacturers—is critical.For products ners—from growers to processors and selectiveBeing about production part Get to theSource safety ofafooditem? product purchasers assure thequality and tion chain today, howcanretailers and study to2010 be$152 billion. impact to theU.S. alonewas foundinone and effort to execute, andtheeconomic cost companies significant time,money, itation, maintenance, waste management, are upforreview, such aspestcontrol, san Points (HACCP) plan. Numerous programs Hazard Analysiser’s andCriticalControl programs are inplace to asuppli- support toportunity verify thatproper pre-requisite best flavor. whether it’sbeing picked atitspeakforthe the care withwhich fruitisgathered and at which pointthecompany canobserve well, visitsmay coincide withharvest, the safestmannerpossible.Whentimed produced, packed, handled,andstored in practices andverify thatingredients are a supplier to assess for best agricultural and qualityrequirements. selected ingredients meetstrictfoodsafety inorder operations to ensureer’s thatits volve touring acurrent orpotential suppli regular, in-person supplieraudits thatin- as well asproprietary items, carriesout blazer Foods, which produces store brand should berigorous. For example,Trail ing theselectionofasource. source aswell asdocumentationsupport maintain strictcriteria forconsidering a ods forsourcing ingredients. Theyshould that provide transparency into theirmeth- their suppliers. Work withmanufacturers own success dependsonthereliability of vested interest process: in a retailer’s Their Manufacturers and co-packers have a Given themany players intheproduc In addition,anaudit provides theop Audits viewof provide anup-close A suppliercompliance procedure February/M arch 2015 (Continued onp.48) 47 ------FOOD SERVICE & RETAIL Partnering

(Continued from p. 47) ous, credible food safety management sys- stable of suppliers for any given commod- recall and withdrawal, and Good Manufac- tem.” With the recent passage of the Food ity. If one is unable to fulfill a contracted turing Practices. Safety Modernization Act, all parties in the amount, another may be able to make up Just as important as dedication to cre- food supply chain will be required to pay the balance. Most processors allow for ating a quality product is a sense of pride heed to additional food defense measures. multiple suppliers, ensuring a higher as- in operations. Visiting a site provides the When evaluating along the supply surance that end demand can be met. chance to speak with key personnel. Not chain and assessing farms, consider Good only does engaging in dialog offer insight Agricultural Practices (GAP). Following Stay on Top of Special Requests to the product but it indicates whether at- GAP may involve delving into farm sanita- Consumers are increasingly seeking out titudes are positive and that there is a true tion or spray records. In essence, by taking foods with specific qualities: certified -or desire to be a part of a larger team. the time to verify production, handling, ganic, kosher, vegan, and gluten-free are Finally, the atmosphere and care on packaging, and storage practices, the just a few of the overriding buzzwords on a farm must extend beyond the fields and farm’s ability to produce safe, quality food grocer’s shelves. For some consumers, on the road to the processing plants. Farms will become evident. their selections have a real impact on their must put thought into logistics for trans- During the evaluation process and overall health and well-being, so it is criti- porting their fruit, ensuring that prod- facility or farm tours, request supporting cal to find vendors and suppliers with reli- uct is handled appropriately and kept at documentation of an operation’s commit- able and traceable sources. Maintain any proper temperatures. Plans should be well ment to safety and quality. Documents relevant certifications, in addition to those thought out and economical. may include policies, procedures, a HACCP for food safety, to provide customers with plan, audit schemes, and results, as well as documentation if requested. Adhere to Stringent Examinations any pertinent certifications. Be sure docu- Traceability is an essential part of the With private label products, retailers risk ments are up-to-date, and be prepared to manufacturing process. The ability to fol- their reputations on the quality contained invest significant time in researching a po- low a material or product through all stages within. And it’s not just quality that is a tential supplier or vendor. Depending on of the supply and distribution chain is vi- concern. Food safety is critical, and many the supplier, the produce, and any unique tal to consumers’ safety. A fast response to retailers with their own labels are requir- parameters for ingredients or handling, food safety issues not only helps protect ing certifications from all members within the process could take anywhere from sev- public health and safety, but is instrumen- their supply and manufacturing chains. eral days to a couple of months. tal in protecting the viability and longevity In the last five years, for instance, sev- A supplier evaluation program does of an organization and its reputation. eral national grocers began to require all not end with the initial approval. Rather, For retailers of private label products, of their suppliers adhere to Global Food each supplier should be evaluated contin- traceability also provides important in- Safety Initiative (GFSI) standards. Meeting uously to ensure that standards are main- formation on the quality aspect of the fin- such standards provides a “high degree tained. Consider requiring annual updates ished good. If a particular product receives of confidence” in the design, implemen- of audit records and certifications. Also, rave reviews, manufacturers can pinpoint tation, and maintenance of food safety revisit farms and facilities several times the farms and their specific varieties that management systems. After fully and con- a season for greater assurance that safe, contributed to its superiority, allowing sistently implementing the requirement quality ingredients are received. manufacturers to refine their recipes. Like- across all private label suppliers, the re- wise, products that underwhelm consum- tailers are seeing a significant decrease in Price Drives Decisions ers can be evaluated down to the suppliers, the number of recalls. Price is a critical factor in any arrange- and recipes again can be tweaked to make When selecting a manufacturing partment, but it is typically considered last a more palatable finished product. ner, develop an evaluation process that in- in a three-tiered deal. Once suppliers are corporates a review of documents and certi- vetted for the volume of product required Quality From Farm to Fork fications. Such a step ensures that suppliers and quality standards are met, price must Fundamentally, choosing a supplier will be in line with a retailer’s commitment fit into a company’s model. comes down to need, availability, quali- to providing quality, safe food products. As For private labels, price can be a sen- fications, and price. Within these param- there is no overarching, governing body sitive issue. National brands tend to set eters, there is room for implementing that certifies vendors and suppliers, it’s up pricing, and private labels typically sell practices that can help protect the integ- to retailers and their manufacturing part- at a 25 percent to 30 percent discount. If rity of a sourced product and, ultimately, ners to establish guidelines for those inter- farmers are facing a difficult year, costs the final product delivered to consumers. ested in doing business with them. may be driven up. Retailers may need to Evaluate all partners closely and maintain For processors and manufacturers, accept reduced margins, consider offering a commitment to frequent audits to ensure GFSI standards are common and provide their consumers less of a discount relative quality from farm to fork. ■ assurance of safe food management pro- to major brands, or find a cheaper source grams. In addition, the Safe Quality Food for their ingredients. Boyd is FSQA manager of Trailblazer Foods, which produces co-pack, private label, and branded products. Reach him at (SQF) certification program is recognized To secure greater flexibility in pricing [email protected]. Jackson is director of purchasing worldwide among those seeking a “rigor- and availability, consider developing a for Trailblazer. Reach him at [email protected].

C riod iscapable ofcausing acute poisoning a sufficientdoseofCd timepe over ashort effective poisonatlowdose.Exposure to toxicity ofCdrefers to itscapacity asan if thatwere possibleto arrange. Thehigh it appears that we could live without Cd, toxic inmammals. At abiochemical level population. Cd absorbed ofthegeneral bymembers usually accounts forover 90percent ofthe and occupationally exposedgroups, food in food.With theexception ofsmokers Cd thatwe take ineach day isdelivered concentrations inagricultural systems This poisonous heavy metal is occurring at increasing Threat to Food Safety A Clandestine Cadmium: B y Nick Kim,hD P Cd is both non-essential andhighlyCd isbothnon-essential low concentrations. ofthe Most normally present inourbodiesat curring chemical elementthatis admium (Cd) isanaturally oc and Brett Robinson,hD P - - Report creases withage, from anestimated 1mil retained in a person’s body gradually in- tobetween 40years, 20 theamountofCd source, andlossofeach daily dosetaking substance. With foodasaconstant daily we have ofabiologically cumulative mulative exposure. late to thelong-term consequence ofcu the risksare notimmediate re butrather - perday,in millionthsofagram and egory entirely. Here dosesare measured food safetyrisksofCdare inanother cat 24 to hours two weeks later. However, this cause occurring isnotrapid, between tle as0.35 byingestion. grams Deathfrom acute lethaldoseto humanscanbeaslit with or withoutsubsequent fatality. The Cd is one of the best examples that Cd isoneofthebestexamplesthat - - - -

50 year olds. function may bestarting to occur inpost- the earliestonsetofachange inkidney essentially represent thepointatwhich kg ofbody weight/month). Thelimits thority (EFSA) (equivalent to 0.0108 mg/ advisory body European Food SafetyAu body weight permonth),and itsscience tion (0.025 mg ofCdperkilogram (kg) of mulgated bytheWorld Health Organiza- the focusoftolerable intake limitspro function. Thistoxicological endpointis is sufficient toinduce a change inkidney point where the burden of Cd in kidneys effect ofCdaccumulation inthebody isthe distributed among theothertissues. ing 50percent becomes more orlessevenly the lungs andpancreas, andthe remain- threea further percent isshared between al-binding protein called metallothionein; and kidneys due to thepresence ofamet this accumulated Cdisretained intheliver history.personal About half(47 percent) of milligrams (mg) byage 50, depending on to at birth lionth of agram perhaps 15 to 80 that Cdmay increase rates ofbreast and in thisway because someevidence exists is unclear whether Cdshouldbetreated quence andthenworking backwards. It the mostsensitive toxicological conse - tolerable intake determining limitsbyfirst ily actascarcinogens, regulatory bodiesset For contaminants thatdonotprimar Unsurprisingly, thefirst reliable toxic February/M arch 2015 (Continued onp.50) 49 - - - - SPECIAL REPORT

(Continued from p. 49) soil contaminants, particularly if there are testicular cancers. The kidney is currently industrial inflows into the sewage treat- regarded the primary target organ of Cd ment plant. toxicity with tolerable intake limits based Once added to soil, Cd binds strongly on changes to kidney function, but a fu- to soil particles, causing this toxic ele- ture change in approach may result in still ment to accumulate with each fertilizer lower recommended limits. application. Only small amounts of Cd are Another, much harder, problem exists lost from the soil via surface runoff (with that is likely to prevent tolerable intake fertilizer runoff) and leaching, which limits from being reduced any further is not significant until very high soil Cd © Ze rb o r - Fotolia.com than the EFSA-recommended current fig- concentrations are reached. The rate of ure. This is that at ordinary levels of Cd in There is Only One Problem Cd accumulation in soil depends on the foods, we are already hitting against the Most Cd in food comes from the soil where concentration of Cd in the fertilizer. Low- kidney-function threshold. The preferred crops are grown and animals are raised. cost fertilizers and effluents used by poor toxicological approach for residues and As a chemical element, Cd is present at countries often have higher Cd concentra- contaminants in the diet is to apply an low concentrations in all soils. However, tions, resulting in a more rapid buildup of uncertainty (“safety”) factor to the lowest human activities are causing soil Cd con- this toxic metal in soil. observed effects level to allow for inter-spe- centrations to increase, which results Plant roots can cause soil particles cies and individual human variability, of in increased Cd concentrations in food. to release bound Cd, resulting in Cd en- perhaps 100. For Cd there is no such safety While industrial activity, waste disposal, tering the root and then the shoots of the factor: The first onset of apparently toxic and mining can result in localized soil plant. Grazing animals may consume the effects does appear to occur at the upper contamination, fertilizers and soil condi- Cd-containing plant or, in some cases, in- end of the usual intake range. tioners are the most important source of gest small amounts of soil directly. As with Recently, EFSA has released a set of Cd in food-producing soils. humans, the highest Cd concentrations in “risk-based” food standards for Cd that, if Elevated Cd concentrations are often grazing animals are found in the kidneys adhered to and averaged across typical di- associated with sources of phosphorus and liver. Fortunately, there are no reports ets, would help achieve compliance with (P), an essential plant nutrient. Human- of muscle or milk products containing con- their recommended tolerable intake limit ity needs to add P to soil to maintain cerning Cd concentrations. for Cd. The shift to risk-based food stan- productivity and feed an ever-growing There is a large variation in the abil- dards in recent decades has been a wel- population. P is added to soil via fertiliz- ity of plants to take up Cd from soil. Leafy come development because many of older ers, effluents, and sludge. These materials greens such as lettuce and spinach have food standards were not overtly linked to can contain Cd as an unwanted passen- the highest Cd concentrations, while tolerable intakes (toxicity is defined by the ger that cannot easily be removed. The grains tend to have the lowest. That said, dose), or if they had been derived on this ultimate source of P is phosphate rock, a Cd concentrations in grains are of concern basis, the process was obscure. For food non-renewable resource that is mined and because they can represent a large propor- producers, these and other pre-existing processed to give fertilizers (for example, tion of the diet. food standards for Cd primarily represent superphosphate fertilizer). Geologically, a product compliance and trade risk. With Cd is co-deposited with P and phosphate Managing Cd Concentrations a new set of food standards, it is likely that rock can have over 500 mg of Cd for ev- in Food European regulators and markets will be ery kg of P. While the Cd concentration of Reducing or reversing the accumulation of placing a heavier emphasis on food com- phosphate rock varies, low-Cd sources of Cd in soil requires the reduction of Cd ap- pliance monitoring for Cd in the future. this mineral are mined preferentially, com- plied with phosphate fertilizers. Removing Most dietary Cd comes from foods mand a premium price, and will eventually Cd from phosphate fertilizers would halt with elevated Cd concentrations that are be exhausted. In many countries like New further increases in the Cd concentrations consumed in significant amounts. These Zealand, current P and Cd levels in many of most agricultural soils. Unfortunately, include cereals, vegetables, nuts, starchy agricultural soils are now four to six times there is no cheap way of removing Cd roots or potatoes, and some meat products. higher than their natural concentrations. during fertilizer production. Vegetarians have higher dietary expo- Just as the majority of P in our diets could In most cases, reducing the amount of sures, as do regular consumers of bivalve now be traced back to agricultural use of phosphate fertilizer applied would result mollusks and wild mushrooms. Smokers phosphate fertilizers, it is likely that most in an unacceptable drop in productivity. A double their overall exposure, because dietary Cd now also originates from this characteristic of phosphate in soil is that it tobacco contains significant Cd and the same source. becomes immobilized and unavailable for lungs are efficient at absorbing it. Together, Municipal effluents and biosolids plants, thus requiring additional fertilizer ensuring compliance with tolerable intake (sewage sludge) can be used effectively as applications and further Cd accumulation. limits and food standards will ensure the P-containing soil conditioners. However, One line of research to reduce the reliance risk from Cd exposure from food is toler- these materials also contain elevated Cd on phosphate fertilizers is investigating ably low. concentrations, along with other potential methods of liberating immobilized phos-

50 FOOD QUALITY & SAFETY www.foodqualityandsafety.com phate by using selected crop varieties or Cd uptake by moving the Cd to a zone of inated soils. This gives additional time for other soil amendments. lower root density. This dilution effect in- the development of low Cd fertilizers, or Sourcing phosphate rock with a lower creases at greater plough depths. However, new soil cleansing techniques. Cd concentration reduces the amount of continued application of Cd-laden fertiliz- Cd added to soil. For example, most Cd in ers will eventually increase the Cd concen- The Conundrum New Zealand’s pastoral soils come from tration in the entire soil profile. While Cd concentrations in agricultural the application of superphosphate made Cd-contaminated soil cannot easily soils are increasing and Cd concentra- from Nauru phosphate rock, which con- be cleansed. There are no commercially tions in some foods are nearing food tained ca. 550 mg of Cd for each kg of P. available techniques to remove Cd from standards, there are no reports of wide- Subsequently, the fertilizer industry has contaminated soil at a cost that is less than spread Cd intoxication in the general pop- reduced the Cd concentration in fertilizers the value of the agricultural land. Extract- ulation. In many agricultural lands, food to less than 280 mg Cd/kg P by using phos- ing the Cd using fast-growing plants such production can probably continue apace phate rock from other locations. To avoid as willow may work in principle, but it is without a widespread health calamity. the accumulation of Cd in soil, phosphate unclear whether this will ever be a com- However, over the medium term, contin- fertilizers would need to contain less than mercially viable technology for farmers. ued accumulation Cd of agricultural soils 50 mg Cd/kg P. Further exploration and The amount of Cd that is taken up by is unsustainable because the upper end innovation in mining may yield fertiliz- plants and subsequently enter food prod- of current dietary Cd intakes are already ers with even lower Cd concentrations. ucts is dependent not only on the total Cd commensurate with tolerable intake An example is the potential source of in the soil, but also on a plethora of other limits, and regulators will be moving to low-Cd phosphate in the Chatham Rise, off soil factors and plant factors. Some of ensure that Cd in foods stay as low as rea- the cost of New Zealand. Accessing this these factors can be managed to reduce Cd sonably achievable. Modifications to soil resource has the technical and environ- concentrations in food. There is consid- and plant factors can soften the impact of mental challenges associated with under- erable variation in the Cd uptake among Cd accumulation in soils, and potentially sea mining. plant varieties. Selective breeding or ge- work to reduce Cd in both individual foods Most Cd in agricultural soil is bound netic manipulation can be used to obtain and the whole diets, but the benefits of this within the top 10 centimeters. Therefore, plant varieties that take up low concentra- work will ultimately be lost if Cd continues plowing the soil will dilute the Cd within tions of Cd. to strongly accumulate in growing soils. the soil profile. Plowing can reduce plant Plants in acid soils, soils with low Therefore, a primary goal for agricultur- organic matter, or soils that are high in alists should be to move to a steady-state chloride more readily take up Cd. Liming condition, where annual inputs of new Cd Itai-itai Disease to reduce soil acidity can effectively reduce to soils are no larger than losses. Cd uptake in some soils, but not others. The immediate issues for food pro- One serious case of environmental Cd poisoning first focused scientific and However, liming is a blunt instrument: ducing countries are that food exports regulatory attention on the possibility Over-liming can induce deficiencies of es- may be blocked if food standards are ex- that long-term accumulation of Cd could sential nutrients. ceeded and the image of the country as a cause serious harm. Between 1910 and Adding some types of organic matter safe food producer may be tarnished. For the late 1940s, several hundred people to soil can effectively reduce plant-Cd up- countries with protectionist governments, from villages on the banks of the Jinzu take. There is variation in the effectiveness Cd concentrations in foods may be a useful River, Toyama Prefecture, Japan suffered of various types of organic matter in reduc- means of circumventing the World Trade from chronic Cd poisoning. Among other ing plant-Cd uptake. Elucidating the crit- Organization and imposing non-tariff sources, Cd fumes and particulate mat- ical factors for such Cd immobilization is trade barriers to protect local producers, ter emitted from a nearby mining com- an ongoing area of research. Plants take up even if the local produce also contains high pany caused an excessive accumulation of Cd in soils of a farming community. more Cd from soils that are deficient in the Cd concentrations. Rice and soybeans grown in these soils essential micronutrient zinc (Zn). Alleviat- Any management decisions or regula- contained high concentrations of Cd (1 to ing Zn deficiency in soil may reduce plant tions that are designed to reduce Cd con- 3 mg/kg). Cd was not recognized as the Cd uptake and increase the Zn concentra- centrations in food need to be balanced cause until the mid-1950s. It was typi- tion in foods. This has the double bene- against the cost of food production and cally 30 to 40 years before the onset of fit of alleviating Zn deficiency in people the need to feed a growing population. symptoms, the most prominent of which (which affects some two billion worldwide) In the meantime, the clandestine threat was that the victim’s bones fractured un- and reducing the toxicity of Cd in Zn-defi- that Cd poses to food safety will inexora- der slight pressure due to their decalci- cient people. bly increase. ■ fication and subsequent softening. The Managing such plant and soil factors disease was extremely painful, and the can reduce the Cd concentrations in food Dr. Kim is an analytical environmental chemist who works sickness became known as Itai-itai dis- at Massey University in Wellington, New Zealand. Reach him ease, variously translated “it hurts-it over the short term. While these measures at [email protected]. Dr. Robinson is a professor of soil do not stop the accumulation of Cd in the and physical sciences at Lincoln University in New Zealand. hurts” or “ouch-ouch.” By the end of Reach him at [email protected]. 1965, some 100 deaths had resulted from soil, they can extend the time that food disease.—N.K. & B.R. production can safely occur on Cd-contam- References Furnished Upon Request

February/March 2015 51

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February/March 2015 53

Scientific Findings

For access to complete articles mentioned below, go to the “Scientific Findings” section of the February/March issue at www.foodqualityandsafety.com.

ARTICLE: Quality and Safety Attributes of Afghan Raisins Before and After Processing Raisins are an important export commodity for Afghanistan; however, Afghan packers are unable to export to markets seeking high-quality products due to limited knowledge regarding their quality and safety. The minimal analysis and availability of data for Afghan raisin safety and quality levels hinder the ability of Afghan raisin packers to choose which factors they should focus their efforts to improve raisin quality. In this study, the quality and safety aspects of pre-, semi-, and post-processed Afghan raisins were evaluated from multiple production lots in order to partially fill this data gap.Food Science & Nutrition, Volume 3, Issue 1, pages

ARTICLE: Exploring Natural Selection ARTICLE: Functional Beverages— to Guide Breeding for Agriculture The Emerging Side of Functional Agriculture faces increasing global demand Foods for food from population growth and strong There’s been growing recognition of the key growth in per capita consumption due to role of foods and beverages in disease pre- economic development. It is widely accepted vention and treatment. Thus, the production that this food needs to be produced from a and consumption of functional foods has similar area of land to that currently under gained much importance as they provide a cultivation, establishing the need to satisfy health benefit beyond

demands for more food by increasing agri- the basic nutritional © rdnzl - Fotolia.com cultural productivity by crop breeding and functions. Currently, improved crop management. Analysis of beverages are the current growth in productivity for major crop most active functional species suggests that productivity growth food category because ARTICLE: Predictive Microbiology

will not be sufficient to satisfy the predicted of convenience and pos- Coupled with Gas (O2/CO2) Transfer in growth. More aggressive innovation in plant sibility to meet con- Food/Packaging System breeding is a major option that may help sumer demands for Coupling gas transfer with predictive micro- to close the gap between the growth rates container contents, biology is essential to rationally design of production and demand. Plant Biotech- size, shape, and modified atmosphere packaging, or MAP, © seralex - Fotolia.com nology Journal, Volume 12, Issue 6, pages appearance, as well strategies to ensure and guarantee food 655–662, August 2014. as ease of distribution and storage for refrig- safety. Nowadays, these strategies are generated and shelf-stable products. Moreover, erally empirically built and over-sized since they are ideal at delivering means for nutri- packaging material with high barrier proper- ents and bioactive compounds including an- ties is often chosen by default even if such tioxidants, plant extracts, and fiber, prebiot- a high level of protection is not systemat- ics, and probiotics. However, in most cases, ically required. Protection strategies could specific concerns have been raised over their be improved using rational sizing based safety. This review reports on the scientific on quantitative analysis and mathematical advances in the emerging area of functional modeling of mass transfer. This paper aims beverages with a focus on commercially at reviewing the current knowledge available available products, as well as on the poten- for developing such a tool and the further tial health benefits.Comprehensive Reviews research needed. Comprehensive Reviews in Food Science and Food Safety, Volume 13, in Food Science and Food Safety, Volume

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