The National Provisioner June 2011

2011 PROCESSOR OF THE YEAR

TYSON FOODS The Tyson team has focused sharply on eliminating inefficiencies and re-dedicating itself to its customers.

Also Inside FOOD SAFETY: Putting metal detection/ X-ray technology to the test. SAUSAGE PROCESSING: Processors weigh in on a variety of topics.

Vol. 225 • Issue 6 • June 2011

PICTURED: Tyson Foods team members (seated, left to right) Nancy Trujillo, Kristal Delph, (standing, left to right) Mario Valdovinos, Mark Milbrodt and Jim Bob Spencer

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BY THE NUMBERS

Sausage Processing Survey

34

58| The National Provisioner surveys sausage processors on a variety of topics linked to sausage R&D and operations.

COVER STORY

2011 Processor of the Year: Tyson Foods Tyson Foods has kept its team focused sharply on eliminating inefficiencies and re-dedicating itself to its customers..

SPECIAL REPORT

Spare Parts 12 | Fight for Food Safety: Build sanity into sanitation 10 | Regulations & Legislation: What you may not know about frozen non-RTE products

Visit the new ProvisionerOnline.com

4

Consumer trends Podcast!

Read Us Online

Hear about the latest research on consumer buying habits and its correlation with meat and poultry sales in our newest podcast.

The National Provisioner is online in an easy-to-navigate, easy-to-read digital format at www.ProvisionerOnline.com.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

108 | Six tips to improve spare parts management

Departments NCBA Column ............. 14 Food Safety Perspective ...18 New Products ................ 26 Business Strategies ..........32 Immigration Update ........64 Farm to Plate ...................66 Guest Column ..................70 RFF Plants of the Year .....84 AMI Expo Wrapup...........98 Protein Problem Solvers 114 Tech Showcase...............115 Classifieds ......................123 Ad Index.........................130

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June 2011

Tech

Volume 225 Issue 6

Editorial Board

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The National Provisioner’s Editorial Board comprises highly respected experts associated with the meat and poultry industries who assist the editorial staff in bringing you insightful, relevant information. When you see this logo, you are reading content contributed by an Editorial Board member. Tim Biela AFA Foods

H. Russell Cross Texas A&M University

CONTRIBUTING THIS MONTH Dan Emery

FOOD SAFETY |76

Meaningful Solutions

Metal detection / X-ray Systems

John E. Johnson

Putting detection to the test.

JBS

Huston Keith Keymark Associates

INGREDIENTS & FORMULATION

PROCESSING TECH

PROCESSING TECH

94 | Meat and poul-

104 | Experts offer

28 | Donna Berry

try processors are employing precision cutting equipment for improved worker safety and ergonomics.

protein processors a list of indicators of sustainable operations on farms.

discusses the incorporation of health-conscious ingredients.

Lynn Knipe Ohio State University

Gary McMurray Georgia Tech Research Institute

CONTRIBUTING THIS MONTH Mark Reed Border Management Strategies

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Butterball LLC

“When it came to our new high-speed hot dog packaging line, no one could keep pace with Reiser and Repak.” “At Berks Packing Company, we are a thirdgeneration, family-owned and operated meat processor. We supply the food service industry and retailers with a wide variety of high-quality hot dogs. We were looking for a flexible, high-speed, automatic loading and packaging system that would allow us to easily produce upwards of twenty different package sizes. After talking with all of the potential suppliers, we chose the Repak RE25 form/fill/seal packaging machine from Reiser. “Reiser came to us with more options and better ideas. They took us to see a similar high-speed installation in Canada. The more we talked with Reiser, the more confident we became that the Repak would be the race car we needed. And they delivered! “The Repak works perfectly with our high-speed automatic loader to produce attractive, wrinkle-free, perfectly sealed packages. Depending on the package size, we can now package up to 1,400 hot dogs/minute. From sales, to support, to delivery, to installation, to their guarantee, our family couldn’t be happier with the Reiser team. In fact, we’re so pleased with the performance of our new RE25 that we just placed an order for an additional machine!” Pete Boylan, Product Development Manager, Berks Packing Company, Inc.

Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

Pete Boylan Berks Packing

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Regulations&Legislation

What you may not know about your frozen non-RTE products By Dennis Johnson

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veryone has heard the saying, “What you don’t know can hurt you.” If you make frozen, not ready-to-eat products, especially for household consumers, my question for you is, “How well does your product achieve lethality temperatures in the consumer’s home?” If you don’t know for sure now, you may find yourself in a bad situation later. Looking through the outbreak recalls of the past several years, the product implicated in the large majority of the cases was frozen, non-RTE products. Although frozen ground beef was the most common, the risk extends to all other non-RTE products that are sold frozen or could be frozen by consumers, whether beef, pork, chicken, turkey or veal.

One would expect that a prudent establishment would apply this lesson learned to assess the safety of its own products. The first and most basic question is whether preparation according to the cooking instructions on the label will ensure the lethality temperature was reached. In assessing the instructions, do not forget cooking on a grill; summertime is here and with it comes outdoor cooking. The second question is whether the product is designed to reduce risk of undercooking. Physical factors, such as size, weight and shape of the product can significantly impact cooking time. For example, in one study performed by an industry leader, frozen ground beef patties that were 1/2-inch thick cooked to 160ºF in just over 10 minutes; patties that were 3/4-inch thick needed more than 18 minutes to achieve the same temperature.1 One individual 3/4-inch thick hamburger took approximately 25 minutes on a flat top grill to reach 160ºF when cooked directly from the frozen state. One should not rely on a consumer to cook a hamburger for 25 minutes, even if instructed to do so by the label. If such a burger contained E. coli O157:H7, Salmonella, or a non-O157 STEC, an illness could have occurred. Beyond design, there are also production variables which may make the patty harder to cook. Common issues are: (1) formation of air pockets in the patty caused by separation and (2) abnormally dense patties caused by excess mixing during blending. Finally, FSIS has also taken an interest in frozen, nonRTE products and has been working on a regulatory response. The likelihood of issuance increases with each outbreak linked to frozen products. So, what do you truly know about your frozen, non-RTE products: Do the cooking instructions get the job done? Is the product designed to facilitate cooking?

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Are there production issues making the product “harder to cook?” In the case of frozen, non-RTE products, ignorance is not bliss. 1 Siemens, Dr. Angie, Designing a Risk Reduced Ground Beef Patty, Cargill, Inc., 2009 Beef Industry Safety Summit.

Dennis R. Johnson is a principal with Olsson Frank Weeda Terman Bode Matz PC in Washington, D.C. Johnson has 30 years experience in food-safety law and regulation, representing large and small meat and poultry companies.

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Build sanity into sanitation By Shawn K. Stevens

W

hat, one might ask, do sanity and sanitation have in common? Well, the etymology of the two words confirms they are each derived from the Latin word sanitas, meaning “health.” Effective sanitation is the cornerstone of any robust food-safety program. Companies faced with the daunting task of ensuring that unwanted pathogens never reach their food products, however, may on occasion become frustrated with the complexity of the task. After all, complete elimination of microscopic organisms — which exist naturally throughout our diverse environment — can sometimes seem a nearly impossible goal. Thus, before any effective sanitation program can be implemented (or enhanced), a company should identify and assess all potential sanitation hazards, then develop robust measures to combat each. Perhaps counterintuitively, the effective implementation of a standard sanitation operating program should start with a panoptic evaluation of the entire operation. Each step in the production process, including facility design, employee hygiene and dress, pre-operational sanitation, receiving, production, shipping, and maintenance must be carefully evaluated. Carefully assessing and then compartmentalizing each of the numerous potential hazards, once identified, will make the process of integrating them into a single sanitation program much easier. In addition, facilities and work areas should be engineered to mitigate cross-contamination, while also promoting the smooth, practical flow of product from receiving through shipping. Here too, careful assessment of hazards, followed by necessary enhancements to facility design, will allow unimpeded flow of traffic, effective use of space for critical interventions, and ample work area for employees, supervisors and inspectors. Controlled access to segregated break areas and restrooms, coupled with easy access to hand-washing stations located at each entry to the production floor, also will facilitate food safety by directing and keeping idle employees away from production areas. Pre-operational sanitation is also critically important

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

to prevent contamination of products and — if pathogens are introduced — persistence. Thus, each facility should be divided into zones for cleaning, ensuring that no areas are overlooked. Each zone should also have detailed procedures for cleaning and sanitation, including the complete breakdown and sanitization of all equipment. Critical task checklists should be published, reviewed and signed off on, each day. Finally, the weakest point of your HACCP plan also will play an integral role in maintaining proper sanitation. In this regard, the failure of a single critical control point can allow unwanted pathogens to contaminate product or the processing environment. Thus, remember that your sanitation and HACCP plans are each, ultimately, dependent upon the effectiveness of the other. In the end, whether maintaining your individual sanity, enhancing your sanitation procedures or ensuring food safety generally, the true best practices are always about safeguarding health. Shawn K. Stevens defends and counsels meat companies in foodborne illness matters throughout the United States. Mr. Stevens also assists industry clients with regulatory compliance, recall planning, crisis management and other issues in advance of and following major foodproduct recalls. Additional information about his practice can be found at www. defendingfoodsafety.com.

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GuestColumn

New guidelines issued for sampling, lotting and testing beef By James O. “Bo” Reagan, National Cattlemen’s Beef Association

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ackers and processors are often targeted when beef safety issues surface. But we all know safety is not the responsibility of just one link in the beef production chain. That’s why representatives of many U.S. packers and processors joined beef producers, retailers, foodservice operators and government officials to establish “best practices” to meet new guidelines for sampling, lotting and testing beef products — the “Guidance Document for Sampling and Lotting of Beef Products and Sample Analysis for Pathogens.” The new guidance document is a resource for packers and processors looking for step-by-step procedures for sampling, lotting and analyzing beef and beef products for the presence of pathogens. The best practices will assist beef processing companies in implementing proven pathogentesting programs as part of a multiple-hurdle foodsafety system aimed at advancing beef safety. The No. 1 goal of the new guidance document is to eliminate pathogens from the beef supply by placing multiple hurdles along the beef production chain. With product testing, we can validate that the multiple hurdles are working to reduce the incidence of potential pathogens in the food supply. Developed through the Beef Industry Food Safety Council (BIFSCo), the guidelines bring together the industry’s best knowledge coupled with years of experience in developing efficient and accurate sampling, lotting and pathogen analysis systems, essential to establishing sound food-safety programs for the beef industry. The new guidelines plainly explain the proper procedures and methods that should be used to sample, lot and analyze different types of beef products, such as whole-muscle cuts, trimmings destined for ground-beef production, as well as frozen ground beef. While the guidelines are voluntary, they simplify the process for companies that are revising their current sampling programs or creating new ones. They serve as a roadmap for implementing the

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

most current safety knowledge to optimize safety programs while also identifying the expectations and issues that should be considered when developing a program for pathogen testing.

Engaging the industry in united efforts These new guidance practices for sampling, lotting and testing beef products were released at the ninth annual Beef Industry Food Safety Summit, hosted by BIFSCo. The event brings together more than 240 top industry leaders who share a commitment to the highest principles and most effective practices with a common goal: offer the safest possible beef supply. The summit is becoming one of the most recognized and respected food-safety organizations in both industry and government. Both the summit and BIFSCo are funded in part by the Beef Checkoff Program. BIFSCo unites the industry around the common

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GuestColumn Our commitment to providing the safest goal of improving beef safety, and nowhere is this unity more evident than at the summit. It gives company food-safety officials a chance to work with their colleagues in similar companies, as well as with their suppliers and customers. The face-to-face relationship-building is a big reason the event receives a large turnout every year. Because the summit isn’t open to the public or the media, participants can be comfortable in speaking freely. Company officials are honest as they share safety issues in their operations and ways to learn from them. Informative programs on emerging pathogens and important new sampling and testing techniques give attendees new knowledge. Research is presented and companies with beef safety products are on hand to describe their ideas. Now, more than 70 diverse organizations are members of BIFSCo, represent-

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beef products possible to our domestic and global beef consumers is unwavering... ing equipment manufacturers, packers, testing laboratories, grinders, restaurant operators and processors. All members unite through BIFSCo to identify foodsafety solutions through research and best-practices documents. Our commitment to providing the safest beef products possible to our domestic and global beef consumers is unwavering, and this new document is an example of that commitment. The Guidance Document for Sampling and Lotting of Beef Products and Sample Analysis for Pathogens and additional best-practices documents are available, free of charge, in the technical resource section of www.bifsco.org. These documents were developed by

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

groups of industry representatives who have applied their collective knowledge and summarized the current science and technology information that can be applied to beef safety systems. The documents are dynamic and are updated as the science evolves and new data is collected. I encourage you to also visit www. bifsco.org for details about the 2012 Beef Industry Safety Summit in Tampa, Fla. and how to become a member of BIFSCo. James O.“Bo” Reagan is senior vice president of Research, Education and Innovation for the National Cattlemen’s Beef Association.

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FoodSafetyPerspective

Control the process, control food safety By Lee Johnson, West Liberty Foods

W

hen we use the term “process control” in food manufacturing, we evoke the idea of sophisticated manufacturing control systems and elaborate statistical graphs of microbiological or other analytical data. This is certainly the mainstream method of operations when detail is critical to the food-safety systems, such as temperature or pH control. Nevertheless, there is a much more simplistic use for the principals of process control in the management of food safety not related to detailed data capture. When we discuss process control, we are attempting to control the outcome of a system or process to a pre-determined level. This approach can and is used in simple manufacturing systems, such as basic good manufacturing practices (GMPs), as well as plant cleaning systems. West Liberty Foods is an advocate for developing manufacturing facilities and systems to make GMP and food-safety compliance easier. We believe that this approach to food-safety systems delivers far better results; and the management of these systems is easier with employee compliance being much more consistent. What do we mean by setting up plants and manufacturing systems with food-safety process control in mind? During initial planning of facility design or manufacturing systems, separation is key in making procedure compliance simple. This includes limiting access points into ready-to-eat (RTE) product areas, controlling the movement of people through physical separation, and having

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

GuestColumn

physical barriers to limit the exposure of product to unnecessary risk. One example is physical separation between raw and RTE areas — areas that many manufacturing facilities today still do not separate. West Liberty Foods included additional physical separation in our facility designs between the RTE area, where product is exposed and sliced, to where cooked logs are moved and stored. Hand-washing is required 20

prior to entry in the RTE area and again before you enter the slicing rooms. Each individual will wash their hands two times before introducing themselves to any exposed product. Furthermore, the rooms physically limit who is allowed inside, and as a result there is far less movement of nonessential personnel around exposed product. Secondly, eliminating corrugated packaging, palletizing and boxing

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

from RTE slicing areas reduces the risk of cross-contamination, as well as decreases forklift or tugger traffic around exposed product. This can be accomplished by having a boxing hallway separate from the slicing rooms. Another area of food-safety process control is cleaning of equipment. Microbiological data will certainly aid in identifying trends; however, the physical process of cleaning the equipment

GuestColumn

is very important. Having systems set up to make the teardown and disassembly of equipment during sanitation makes the process easier, and will enhance the compliance and execution much more consistent and thorough. Racks holding loose parts aid in reassembly as well as identification and location of cleaned parts. Make sure to provide a mechanism to disassemble the parts and use a COP tank to aid in the cleaning process. This will ensure the sanitarian does a thorough job and reduces errors. Establishing a belt-washing system on a timer will ensure belts are washed thoroughly for the required length of time, avoiding potential human error or oversight. Simple organization of how work is done systematically will ensure consistency. Over the last 10 years, cleanability of RTE equipment has improved substantially and has made our job much easier and food much safer. To deliver consistent performance in manufacturing, process control is essential, and it is no different when applying similar principals across the food-safety systems. Keeping procedures simple, easy to follow and clear are key to making sure many food-safety systems stay under control. To get a better idea for the difficulty level of the procedure to be applied to the process, ask these questions: What do I want the employees associated with this area to do? How easy is it for them to do this?

Balance food safety and shelf life with clean labels

Meat manufacturers are under increasing pressure to deliver safe products while satisfying consumers’ desires for foods that taste great, have improved shelf life and label-friendly ingredients. The PuraQ® Verdad family of ingredients fights pathogenic and spoilage organisms in a wide variety of meat and poultry products ensuring shelf life and safety while maintaining the clean label sought by consumers. Purac is your proven partner, developing innovative products and providing technical support for almost 80 years. For more information, please visit www.purac.com/meatandpoultry. Purac, 111 Barclay Boulevard, Ste. 100 • Lincolnshire, IL 60069 • 888 899 8014

GuestColumn What don’t I want them to do if they had to move, walk, disassemble or work around this procedure, and how can we make it more difficult for them to do this? Process control is key in the manufacturing environment and crucial to food safety. Dr.Lee Johnson has nearly 15 years experience in the food industry,including technical roles in research and development as well as food safety and processing.Johnson is a graduate of Virginia Polytechnic University (B.S.) and Texas A&M (M.S.and Ph.D.).Most recently, he was appointed to USDA’s National Advisory Committee on Microbiological Criteria for Foods by Agricultural Secretary TomVilsack.Johnson joinedWest Liberty Foods LLC in 2009.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

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NewProducts

Harris Ranch unveils Angus ground beef products

Day-Lee Foods launches Purely Asian Brand entrée line

Harris Ranch introduces new Angus ground beef options — frozen ground beef patties and refrigerated chubs — produced to the highest standards by Harris Ranch and available in multiple lean points. Harris Ranch’s new Natural Angus Ground Beef Patties are available in both 81/19 and 85/15 lean points. The threepound resealable packages contain nine, one-third pound patties that feature a natural, hand-made shape. The new one-pound refrigerated Natural Angus Ground Beef Chubs are available in 81/19, 85/15 and 90/10 lean points.

Day-Lee Foods Inc. introduces a new line of restaurantquality entrees that combine fresh vegetables with the company’s premium-quality beef and all-natural, sliced white meat chicken. Purely Asian Brand entrees are high in protein, easy to prepare and free of preservatives, transfat and MSG. Varieties include: Mandarin Orange Chicken, Broccoli Beef, Teriyaki Chicken, Teriyaki Beef, Sweet & Sour Chicken, and Lemon Pepper Chicken. Purely Asian Brand products are made with U.S. sourced ingredients at the company’s state-of-the-art, award-winning plant in Southern California. The new line is currently available regionally in Southern California, Arizona and Texas.

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Bar-S introduces Deli Shaved Oven Roasted Chicken Breast lunchmeat

J&J Snack Foods adds soft pretzel-wrapped mini-dog to its product line

Bar-S Foods introduces Deli Shaved Oven Roasted Chicken Breast Lunchmeat to its already popular Deli Shaved lunchmeat line. The new Bar-S Deli Shaved Oven Roasted Chicken Breast is offered in a 9 oz. and 1 lb. sized package that offers convenience to both single households and families. The lunchmeat packaging is pillow-packed for long shelf life and freshness.

J&J Snack Foods is excited to announce the latest addition to the SUPERPRETZEL Soft Pretzel product line: SUPERPRETZEL Soft Pretzel Mini Hot Dogs. SUPERPRETZEL Soft Pretzel Mini Hot Dogs are mini 100% all-beef hot dogs wrapped in gourmet pretzel dough. Perfect for snacking, appetizers or kid’s meals, SUPERPRETZEL Soft Pretzel Mini Hot Dogs are packed six 10-count bags per case, saving operators time and money by only having to open what they need at one time. Additionally, SUPERPRETZEL Soft Pretzel Mini Hot Dogs are preformed and frozen — simply heat and serve.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

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Ingredients&Formulations

Shopping for health-conscious ingredients By Donna Berry

he perceived healthfulness of foods and beverages continues to be a major factor influencing purchase decision, according to the hot-off-the-presses “2011 Food & Health Survey: Consumer Attitudes Toward Food Safety, Nutrition & Health.” Commissioned by the International Food Information Council (IFIC) Foundation, Washington, D.C., this annual national quantitative study took place this year during a two-and-a-half-week period in March and April. Of the 1,000 American adults surveyed, 66% identified healthfulness as a leading factor impacting purchase. This is a significant increase from the 2010 survey, when 58% of respondents said healthfulness impacted their purchase decisions.

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The survey data also indicate that 68% of Americans are actively using the Nutrition Facts panel for product information and almost half (49%) use the ingredient statement. Further, the majority of Americans believe that fortified foods and foods with added benefits have at least some impact on overall health.Yet, very few center-ofplate proteins are actively marketed for their healthfulness, other than the handful of lean meats that flag fat content, and now some products are highlighting reductions in sodium. There are many opportunities to improve formulations to better appeal to the consumer seeking healthful products. For example, Maxi Canada Inc., Quebec, markets a variety of frozen, fully cooked breaded chicken products, including nuggets, patties and dinosaur shapes. The company touts the omega-3 fatty acid content

28

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Photos courtesy of Mintel GNPD

of its products on package labels, and explains that the omega-3s come from heart-healthy canola oil and flaxmeal in the breading. These ingredients contain the omega-3 alphalinolenic acid (ALA), which is converted by the body to docosahexaenoic acid (DHA) and eicosapentaenoic acid (EPA). Both DHA and EPA are well recognized as contributing to many health benefits during all stages of life, in particular in children up to age three, where DHA is essential for the development of the brain and eyes. After the age of three, both DHA and EPA are important for cognitive function, and research suggests that these fatty acids may improve behavior and learning disorders. Additionally, research indicates that EPA and DHA may reduce inflammatory conditions such as asthma, childhood depression and reduce the risk of type 1 diabetes. Most kids like hot dogs as much as they like chicken nuggets, so in efforts to appeal to the gatekeeper seeking out preservative-free wieners, a number of manufacturers are now offering uncured

Photos courtesy of Mintel GNPD

varieties.What they are really offering are hot dogs (and sometimes ham and other sausages) free of chemical curing agents such as sodium nitrate and sodium nitrite. Instead, they are often curing the comminuted and encased meat with the nitrates found in celery or spinach, two of the richest all-natural sources of nitrates. Celery juice, as a liquid or dried into a

powder, has been shown to be effective in controlling bacterial growth, one of the primary purposes of curing sausages and other meats. The USDA defines an uncured product as one that has been preserved without the use of chemical agents, such as sodium nitrite or sodium nitrate, which is why such products can be labeled “uncured,”“no

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

29

Ingredients&Formulations Natural vinegar, lactic acid and even lemon powder have also been shown to function as natural preservatives in processed meats. nitrites added” or “no nitrates added.” Natural vinegar, lactic acid and even lemon powder have also been shown to function as natural preservatives in

processed meats. For example, at the American Meat Institute (AMI) Expo in Chicago in April, one ingredient supplier introduced a concentrated dry vinegar

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product that can be added to seasoning blends for application in fresh and cured meat products. It is declared on ingredient legends as “dried vinegar,” and at levels as low as 0.8% has been shown to inhibit the growth of Listeria. Also at AMI, a number of fiber ingredient suppliers showed how fiber can be used to improve ingredient declarations on brined and marinated proteins, as well as burger-style products based on beef, poultry or vegetables. Certain fiber food ingredients bind moisture, which will increase yield and subsequently reduce fat and calorie content, as fiber-bound water is virtually fat- and calorie-free.This natural system can also replace chemical-sounding ingredients, and depending upon the application, contribute to the fiber content of the center-of-plate protein. For the healthconscious label reader, the addition of fiber is typically welcomed. And as mentioned, most protein manufacturers are trying to reduce sodium contents. One common approach is to substitute potassium phosphates for sodium phosphates in brines and marinades, as they work synergistically with added salt. Because there is a slight bitterness associated with potassium, flavorings and seasonings are often added to mask such off flavors. Another option is to introduce the mineral magnesium along with potassium. Magnesium has been shown to decrease bitterness and at the same time enhance flavor and provide similar functionalities as sodium. With more consumers reading labels, choosing better-for-you ingredients is becoming increasingly important for all formulators. Donna Berry has a bachelor’s degree in food science from the University of Illinois at Urbana-Champaign and has been writing on food formulating for more than 15 years.

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BusinessStrategies

Price pressure — putting the squeeze on all

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he current commodity markets are bad for everyone. Our economic climate is tenuous. Consumers are struggling to make ends meet and current fuel prices are forcing them to manage what they spend on food. American consumers play an integral part in any recovery because their spending accounts for about 70% of the nation’s economic activity. After ratcheting back spending during the recession, households have started shopping again. But with unemployment still high and wages barely budging, Americans remain sensitive to shocks, such as higher food and energy prices. Privatelabel products are growing at double-digit rates and key national brands are losing market share. In April 2011, gas stations reported the biggest jump, with sales rising 2.7%. Grocery stores saw Dan Emery, sales rise 1.5%. Spending at auto Meaningful Solutions Editorial Board dealers, clothing stores and nonMember store retailers, which are mainly online stores, also increased. Sales ticked down 0.1% at restaurants and bars, which are often cited as a barometer of the willingness of households to splurge. Consumers are not being frivolous with their money. With ethanol, exports and corn byproducts usage consuming an ever-increasing portion of the supply, corn prices are again hovering around the record levels of 2008. With feed representing over 33% to 50% of the cost of raising an animal, this has put serious cost pressure on food producers in the animal protein sector to raise prices. In April 2011, the cost of food rose 0.3% and energy prices increased 2.5% last month. The flooding and weather forecasts have produced a big topic of discussion. Unrelenting rains have meant unprecedented delays in planting corn. Concerns include whether the total acreage-pie is shrinking and how much of which crop is being reduced. Planting progress will be essential as the calendar approaches several crucial planting dates. Concerns also center along the Mississippi River (corn, cotton and rice planting), as well as several states in the eastern and southern corn belt where progress lags

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

(Indiana, Ohio, Kentucky). There are northern states (North Dakota, South Dakota, Minnesota) where rain, flooding and cool temperatures have combined to raise concerns about spring wheat, corn and soybean planting. This is a moving target, but one that bears watching, as some commodities, especially corn, cannot stand to have acreage reduced by much. Regarding soybeans, supplies remain critically short. The 2011-2012 soybean output is projected to decline 1.3% to its smallest level in three years. Use estimates are similar to 2010-2011, which is expected to cause soybean supplies to remain critically short next year. World soybean supplies are expected to modestly tighten yet still be historically adequate. The combination of high corn and soybean prices along with the rising cost of transporting food and food ingredients will likely continue to contribute to higher food prices for consumers long-term. Retailers and foodservice operators are doing their best to keep prices low to satisfy their consumers. However, with the forecasted commodity markets, their ability to maintain low prices will be challenging. With producers already pressed to stay above water, the next few months will be challenging to all. Dan Emery has 25 years experience in the food industry, including 15 as vice president of marketing at Pilgrim’s Pride. He is directing Meaningful Solutions, a company founded to assist clients in solving problems.

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CoverStory

2011 Processo

TEAM-D turnaround Tyson Foods successfully navigated the recession by following a tried-and-true strategy that kept its team focused sharply on eliminating inefficiencies and re-dedicating itself to its customers. By Andy Hanacek, editor-in-chief Photos by Jeff Peak, Tyson Foods

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

or of the Year Andy Hanacek (foreground), editor-in-chief of The National Provisioner, discusses Tyson Foods’ successful strategies with members of the company’s executive team (from left to right, Jim Lochner, Hal Carper, Donnie Smith and Donnie King).

DRIVEN A

s the national and global economy began to unravel in 2008 and 2009, many companies ran for the hills, begged for answers and reinvented or rebooted their entire strategic plan in order to compensate for the fear that littered the headlines. But Springdale, Ark.-based Tyson Foods doesn’t appear to have put much stock in the phrase,“Desperate times call for desperate measures.” Quite the opposite, actually, has been embraced throughout the hallways of the nation’s top protein processor, which adopted a straightforward stabilization plan just as the economy went south. The success of that plan has allowed Tyson to grow its busi-

A renewed emphasis on the corporate culture of teamwork and attention to detail has propelled Tyson Foods’ turnaround in recent years. Representing the Tyson Foods team, at the company’s Springdale, Ark., headquarters are (seated, left to right) Nancy Trujillo, orientation trainer, Berry Street plant; Kristal Delph, account manager corporate communications; (standing, left to right) Mario Valdovinos, director culinary services, research & development; Mark Milbrodt, manager international sales; and Jim Bob Spencer, manager customer marketing.

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

35

CoverStory ness in spite of the economic headwinds, and has given it a head start, of sorts, as the economy begins to bounce back. Total company, year-over-year revenue growth from 2010 Q2 to 2011 Q2 (the latest results available at presstime) was a whopping 15.7%, and that follows a 9.7% increase from 2009 Q2 to 2010 Q2. Compare that with flat revenue results for the two 12-month periods prior. Based on these results, The National Provisioner honors Tyson Foods with the 2011 Processor of the Year award.

Making the moves that matter Based on numbers alone, volatility had begun to take hold of the food industry — fluctuating (and often skyrocketing) prices for commodities such as oil/fuel and grains/ feed had become the norm in the run-up to the 2009 recession. Tyson felt the pain, particularly on a quarterto-quarter basis (see “Tyson’s Turnaround” on page 38). Facing this instability, Tyson took a new approach to its own production. In the chicken segment, Tyson opted to discontinue the practice of scaling back broiler production — as Donnie Smith, president and CEO, says it had done repetitively in the past — and address the underutilized capacity it had created in previous cuts. “In our business, you often don’t cut the [general and administrative] expense and a lot of the fixed expenses when you cut production back, so you end up with a pretty severe cost problem,” Smith explains.“That was our issue, and so [labor and line] efficiency issues were absolutely a result of having cut back production.” Smith believes this decision was a turning point for the chicken business. “So we just said, we’re going to take care of our customers and run this business as efficiently as it should be, and get these plants filled back up,” he says, adding that demand (including seasonal adjustments) will, of course, still dictate Tyson’s supply strategies at the end of the day. In Tyson’s prepared-foods segment, Smith says the company began a project to “right-size” the production footprint to what it forecast three to four years down the road. Today, with the project completed, Smith says,“we are reaping the benefits of having a more efficient footprint spread over fewer facilities.” The beef and pork segments had already gone through a beneficial adjustment of capacity and redistribution of assets in the 2006-2008 time period. And Smith says that over the last couple years, the group has taken the next step in giving the business a shot in the arm. “Noel [White, senior group vice president, Tyson Fresh Meats,] and his team have done a phenomenal job in the plants driving yield, labor and line efficiencies, and those have made a tremendous difference in our business,” Smith says.“Their teams have been able to accomplish all this while improving our food safety, our quality and our service to our customers.”

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Remembering Don Tyson “Don [Tyson] meant a lot to so many of us, and we’ve learned so much about what to do from him. Maybe in a lot of our hearts, out of respect for him, there is a desire to carry on the legacy of taking care of our customers. Don taught us that this business is a people business, and our job as a leadership team is to take care of our Smith team members and trust them with the awesome responsibility of taking care of our customers. And you know what, they do a great job at doing just that. I think [his passing] brought back pride and heritage in what Don built, and then a desire to really follow through his legacy and that heartfelt desire to keep up the good work, doing what we’re doing and really making a difference for folks. He taught us well, and we’re still getting it done.” DONNIE SMITH, Tyson Foods president and CEO, on the impact of the death of former chairman and CEO Don Tyson on the company and its team members. Don, son of John W. Tyson, who founded the company, passed away Jan. 6, 2011, at the age of 80. John H. Tyson, son of Don, is the company’s current chairman of the board.

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Congratulations TYSON Foods 2011 Processor of the Year!

CoverStory

0.78 0.65 0.33

0.42

0.42

Q1

Q2

0.57 0.44

0.42

0.43

Q2

Q3 (e) Q4(e)

0.13

Q3

Q4

2008

|

Q1

|

Q2

Q3

Q4

2009

| |

Q3

Q4

2010

| |

Q1

2011 (e) - estimated

-0.01 -0.29

-0.28

Tyson’s Turnaround Quarterly earnings per share.

Source: Tyson Foods press releases; Charles Schwab & Co. Web site.

-1.23

Developing the playbook Certainly, the modified approach to doing business has brought a bountiful harvest to Tyson, but Smith and his executive management understand the real engine behind Tyson’s turnaround, and that’s its own team members — the people who interact with the customers on a day-to-day basis. “Last year, all four of our major segments operated in or above their normalized operating ranges, which has been consistency that we’d not seen in a while,” Smith admits. “But it is a direct reflection of this team’s focus on our customers and this team’s focus on operational efficiency.” Because of that, Tyson has returned to some of what Smith calls the “grassroots” corporate culture that was espoused by former chairman and CEO Don Tyson (who passed away in January 2011; see “Remembering Don Tyson” on page 36). “The key to any successful business is focusing on adding value to your customer — that’s our No. 1 goal as we come to work every day,” Smith says.“We’re going to take care of our people, our people will take care of our customers and that will take care of our shareholders. That’s the simple underlying principle.” It all starts with communicating clearly down the organization chart, something Tyson Foods has mastered to this point, explains Hal Carper, group vice presi38

dent, Research & Development, Logistics and Technical Services. “With the leadership that Donnie [Smith] and Jim [Lochner, COO,] have brought to the business, there’s no doubt among the people walking the hallways what is important to the company, and it gets cascaded down through the organization,” he affirms.“Everybody is really pulling in the same direction on the same things consistently without worrying about,‘Well, what will [our leadership] be

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

interested in tomorrow?’” The clear corporate messaging motivates the workforce to stay the course, regardless of the situation. “We’ve been able to focus and concentrate our efforts on the things that mattered and [pursue them] with tenacity,” Carper continues.“At times in the past, we might have had an initiative or something we’d focus on, but then we’d get distracted from that in the heat of the moment.” Donnie King, senior group vice president, Poultry and Prepared Foods, says Tyson was dissatisfied with its performance, but never its workforce, which it viewed to be hard-working and solid. But he agrees that focus was often an issue that concerned the leadership. “One of the things Donnie [Smith] used during that period of time was a clip from the movie ‘Seabiscuit,’ and said we were fast in every direction essentially, and we were,” King explains.“We wanted to be everything to everybody, and so we lacked focus.” Tyson’s executive team believes bringing that focus back was nothing particularly innovative or magical — it was simply getting back to basics and empowering employees to do their jobs with those basics in mind. “We really looked for every opportunity to simplify what we were doing, the fundamentals of the business — labor management, yield, customer service,

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CoverStory quality, taking care of our people and customer,” King says.“But there was no magic wand, and I think that confuses a lot of people.” White adds that, no matter where a team member works in the organization, these fundamentals are front and center. “There is tremendous clarity in what each of our goals and responsibilities are — it’s very visible,” he says.“We all understand [them], and it’s a matter of the team working together to assist in accomplishing each of those goals and responsibilities.” One revelation that helped team members get aligned under the same goals, Carper says, was the idea that the company could not run away from the realities of the core business and expect to maintain stability. “A big part of what has led to our improvement is a recognition that there is not a new product or new thing that can outrun sub-optimized execution of your business model,” he explains.“We need to chase new products and do it strategically, but we’ve got to have the strong foundation for the business for the long term. There’s been a really solid reinforcement of that concept here.”

Setting the objectives Once Tyson believed it had its workforce pointed in the same direction, the time began to narrow the primary objectives of the entire company — four goals that dictate where Tyson wants to go and how it plans to get there. The first two stated objectives — being the customers’ go-to supplier and being the best-in-class protein supplier by optimizing commodity businesses and driving out inefficiencies — are highly intertwined, particularly during times of inflationary wholesale prices. As a go-to supplier, Lochner says, Tyson can communicate with its customers the effects of grain and feed prices and what that does for demand and costs. Tyson can then advise them to adapt their product lines to be more efficient, and as a result, more cost-effective. Finally, Tyson can work with them within the scope of its own ability to drive inefficiencies out of the process, bringing the cost-savings to the customer. 40

The third objective Tyson has is to continue to build out its multinational enterprise, with poultry operations in Mexico, Brazil, China and India. Each is at a different stage of development, but Lochner says the company has been pleased with the job the teams in those countries have done so far. Finally, Tyson continues to pursue the use of animal products as raw material for renewable fuels and other processed products. Lochner advises that the technology has been very promising but has also been full of learning curves, as it is very new. The company’s Geismar, La., joint-venture with Syntroleum remains in startup mode, but Lochner says some of the challenges have been resolved and the plant should soon be converting fats to diesel or jet fuel, or even carbon for some plastics production.

Keeping it simple Regardless of the objectives Tyson pursues, its ability to maintain its focus throughout the entire organization — and keep the culture of teamwork a priority — will dictate how well the company operates moving forward. Smith believes Tyson has emerged from the worst of the recession with good momentum, and it’s hard to argue with the results Tyson posted through the recession. Despite the success, Smith doesn’t

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

expect anyone at the company will be satisfied. “I don’t ever anticipate a customer walking up to me and saying,‘That’s good enough,’” Smith says.“So we’ll never be satisfied either. Our job is to add value to their business. That means as they go more places, they’re going to want a consistent supply of high-quality food that meets whatever the demand is in that new region, country, segment, etc., and we need to be there for them.” Furthermore, Tyson will not limit itself in terms of growth — any angle, any idea is on the table, as far as the company is concerned. “That may mean we need to retool some facilities and maybe change from one type of processing equipment to another type of equipment to meet a customer’s changing needs,” Smith adds.“I can’t ever see a day when we’re not focused on innovation, being our customer’s go-to supplier, keeping our plants running full by growing our business, by meeting our customers’ needs, by being more efficient — adding value to whatever we touch.” That type of clear overall objective and its trickle-down effect throughout Tyson Foods are what unites the company’s thousands of team members and has them pulling the company in the same direction — far from the volatility that plagued it years ago.

CoverStory

Tyson Foods’ team at its Sherman, Texas, case-ready plant has done its fair share of helping the company turn itself around over the years, through its focus on efÀciency and corporate culture. Representing the facility are (front row, left to right) Pete Baker, industrial engineer; Mike Gerleman, complex manager; Bill McKeeman, operations manager; (back, left to right) Dustin Kratochvil, plant engineer; Rita Huske, complex H.R. manager; Yvette Weaver, asst. operations manager; Wayne Grove, material handling superintendent; and Tom Sharp, plant quality assurance manager.

CHIP OFF THE OLD BLOCK Tyson Foods’ Sherman, Texas, case-ready facility feeds its own growth via its versatility, innovation and reÁection of the corporate strategies and culture. By Andy Hanacek, editor-in-chief | Photos by Jeff Peak, Tyson Foods

A

company’s success occurs not because of the strategies of the board room alone. Achievement of top-flight results requires proper buy-in, execution and innovation at the plant level. The executive leadership at Tyson Foods, The National Provisioner’s 2011 Processor of the Year, certainly understands that and has made it clear in receiving the honor that their team members deserve this award at the end of the day.

42

When looking for a microcosm of Tyson Foods’ overall efforts, turnaround and strategies, one needs look no further than its five-year-old Sherman, Texas, caseready plant. Sherman epitomizes Tyson’s ability to adapt and pounce quickly on trends driving the industry, and it also displays team members’ abilities to be innovative and take responsibility for driving out inefficiency.When asked specifically about the Sherman facility, Donnie King, senior group vice president, Poultry and

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Prepared Foods, calls it a great asset for the company. “We have great people there, a great management and leadership team there, and they’re producing great products for some outstanding customers,” he says. “We operate that facility and two more like it that perform at the very top of the industry in every measure you would want to put before them.” King adds that the case-ready team as a whole has done an excellent job of making quality and customer service the top

CoverStory

Team members at Tyson’s Sherman, Texas, case-ready plant sort through a variety of fresh pork cuts traveling by them on a conveyor, and pack them onto pre-padded and labeled trays, each employee guided by detailed customer speciÀcations.

priority, led by Gary Sheneman, senior vice president of Case Ready Beef & Pork. “It’s interesting to watch, because every quarter they come in and find new and creative ways to absolutely wring out any waste in their system,” King adds. “They do a great job anticipating customer needs, and it runs very smoothly; we’d like to have a lot more like it.” The facts speak for themselves, with Sherman surpassing the six-millionpound production level (per week; beef, pork and ground beef production) in five years of operation. The facility employs nearly 1,500 people, and has been at that level consistently, says Mike Gerleman, complex manager. “We’re more efficient,” he explains. “Our pounds-per-man hour is at a higher level, and we’re getting more poundage with fewer folks.” Furthermore, as the industry has evolved (particularly case-ready preferences and technology), so has the Sherman plant, adding equipment as overwrap packaging grew in popularity to handle customer demand. 44

Sherman background While the plant is five years old in its current state, the building actually opened in 1974 as an Oscar Mayer bacon, hot dog and sausage facility. It was shut down in 1998 and purchased by IBP inc. in 2000. Four years after gaining control of the plant in the 2001 IBP acquisition, Tyson Foods announced in January 2005 that it planned to convert the plant into its third case-ready meats facility, building on the success of similar plants in Council Bluffs, Iowa, and Goodlettsville, Tenn. (both of which were also acquired in the IBP deal). Dustin Kratochvil, plant engineer, explains that work ramped up quickly, with the facility being an empty shell, for all intents and purposes. “The demolition had been pretty much complete, and there wasn’t much equipment left, so it was a wide-open space with no utilities for the most part,” he says.“The shell was one of the reasons we came here rather than build from the ground up. To build a shell this size would cost a lot more money and take a lot more time.”

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

With a crew of more than 600 people working to get the plant going, and despite sometimes uncooperative weather conditions, Kratochvil says Tyson was able to go from its announcement to a total conversion of the facility quickly, at a cost of more than $100 million. Sherman is no miniscule facility, either, featuring 561,000 square feet of workspace, 10 production lines producing a wide variety of fresh beef and pork products, and six lines producing ground beef items. Because Tyson was able to design the facility within an empty shell, it was able to lay out production lines with efficiency in mind, and Gerleman believes the plant’s ground beef section is highly streamlined as a result.

Technology breeds efficiency During The National Provisioner’s visit, production versatility was on display, with items such as bone-in pork chops, boneless pork chops, cube steaks, petit

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CoverStory

Bill McKeeman (left), operations manager for the Sherman facility, and Andy Hanacek, editor-in-chief of The National Provisioner, discuss the different speciÀcations and technologies that the team uses to efÀciently minimize waste during production of boneless fresh pork items.

sirloins, and a variety of ground beef patties, among others, moving through the processing rooms in a steady stream. Gerleman says efficiency is affected positively by the fact that the facility has the room to run a variety of products at the same time. “Whenever you can run isolated products down an individual line, most of your efficiency is affected by changing from one product line to another,” he explains. “So the more we can do consistent runs of product, the more efficient the plant will be.” Once products are packed into modified-atmosphere mother bags and placed into boxes, they head to a combined sorting and palletizing room, where bar-coding and labeling technology has allowed the facility to streamline operations. Furthermore, the plant’s own engineering team and its ingenuity have given it an efficiency and cost-savings boost. The team was looking for a way to improve the process of applying the pad to the inside and nutrition label to the outside of the trays it was using for its products. 46

Palletized cases of fresh, case-ready beef products are about to be loaded and removed from the sorting room at the Sherman plant.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

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CoverStory Sherman’s team members devised what the company calls the “concept room,” in which specialized equipment, designed in-house, applies the soaker pad to the inside of the tray and the label to the bottom of the tray quickly and efficiently. Kratochvil says the company has taken the design and incorporated it into all three case-ready plants.

48

“That is a very specialized room that we have in the plant,” he says,“and it took a year of development in-house to get the speed and consistency to fit together.” In the end, Gerleman says, the room adds tremendous value in that it costs less than purchasing pre-padded trays, it takes only nine team members to operate (in comparison to the several dozen

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

team members who used to apply those items manually), and gives the plant approximately 2.5 days of tray inventory with which to work.

The bottom line Gerleman believes Sherman holds its own in terms of producing results and following the corporate strategies set forth by the corporate leadership in Springdale, Ark. “From an earnings standpoint, we’ve done very well,” he says.“From a community-relations standpoint, and fitting in to the Tyson model, we’ve done very well.” Yet, Gerleman makes it clear that Sherman has not peaked in its capability, citing the fact that there are several areas in the building that could be renovated to house additional production lines as needed. He says the Sherman team looks forward to future expansion and adds that Sherman proudly shares in the responsibility of improving the company from top to bottom — for much of that, he passes the credit to his team. “I’m very proud of the management staff we have here,” he says.“We’ve developed managers here who have also gone on to be successful in other plants, so we’re also feeding that pipeline.”

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CoverStory

Training Sherman’s ‘army’ Tyson Foods’ commitment to its team members shines through in the training, educational and philanthropic opportunities available at its Sherman, Texas, plant. By Andy Hanacek, editor-in-chief | Photos by Jeff Peak, Tyson Foods Companies bandy about the idea of “continuous improvement” quite a bit in today’s catchphrase-oriented world, and while many of those businesses may practice just that on the operations side, not all of them go the extra mile to encourage continuous improvement in their own employees. Tyson Foods is not one of those “pretenders” when it comes to their employees — visit any Tyson facility, as we have, and it becomes quickly apparent that the Springdale, Ark., processor truly invests in its team members and their abilities to advance and succeed. Tyson’s Sherman,Texas, facility — which won an HREVOLUTION Award from The National Provisioner in 2006 for its training efforts — supports its team members in their efforts to expand their education and skillsets, as well as its community through charitable initiatives.What follows is a discussion about these programs with the senior management team at Sherman, during The National Provisioner’s visit to the plant in the spring.

AUTOMATIC

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Jeff Bodovsky (right), maintenance training supervisor at Tyson’s Sherman, Texas, plant, discusses the variety of custom-engineered, hands-on training stations available in the facility’s maintenance training rooms, with Andy Hanacek (center), editor-in-chief of The National Provisioner, and Dustin Kratochvil, plant engineer at Sherman.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

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CoverStory Charlie Stone (right), general foreman at the Sherman plant, explains the facility’s labeling and packaging capabilities to Hanacek.

NP: From the maintenance training rooms with the hands-on training stations to the variety of educational programs here at Sherman, it’s obvious training is a big part of what you do for your team members. Talk about the plant’s culture and perspective of management as to how training fits into daily life here.

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Mike Gerleman, complex manager: Training is extremely important to us, because team members don’t come in with the skills needed in most cases. So we have to develop those skills within our facility. It doesn’t make a difference if they’re a person on a knife line, an MET, or a maintenance mechanic, we develop those skills in those people to make us better, make them better and reward them as well. NP: What about production floor workers? How involved is their training program? Rita Huske,complex H.R.manager: On the production lines, we use our Alchemy system, and we have line meetings that consist of 40-60 people at a time who go through the training.The system does test for understanding, and if there is, by chance, someone who doesn’t understand the material, we’ll come back and re-train them.The more they know, the better they can do their job.We also have hourly trainers on the floor and our orientation trainer who also helps with annual training. NP: Do you offer anything to team members in the realm of educational assistance, and if so, how much participation do you see? Huske: We’ve had six team members go through our tuition reimbursement program, and we have two going through it right now

52

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

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as we speak. If it pertains to something that would help our business grow, from business to quality control to safety to maintenance, it pretty much encompasses anything you can imagine.We will reimburse employees up to $3,000 per semester, and they do have to maintain a certain grade point average. NP: How do you promote and encourage ongoing training for team members in order to improve the capabilities of the overall workforce? Dustin Kratochvil, plant engineer: Each mechanic gets roughly three hours of training per week, paid. That’s on our time, but it makes them better and makes the plant better as well.

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Huske: We are one of the few plants that has its own computer lab, and we do offer free training to our team members — anyone who wants to learn how to use the computer a little better.We also offer English as a second language — we use Rosetta Stone for the second-language classes, and we have our training coordinator and a couple managers who are certified to train Microsoft. NP: How does Tyson expand its culture outward from the plant to the community? Do team members get involved in those initiatives?

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Huske: We do a lot in our community. Our major charities that we contribute to are United Way, the American Cancer Society via the Relay for Life, and Big Brothers Big Sisters.We help out with Earth Day, planting trees at schools, and Hunger Relief here. This year, to date, we have donated approximately $116,000 in our community alone. And that’s not just Tyson donations, but also Tyson team-member donations as well. Gerleman: There are roughly 60,000 people in the Sherman area, and the town was very happy to see this facility open. … They were starving for an industry like us to move in. And I’m not kidding you, when we went out to eat during construction, people would come up and say,‘Golly, we’re glad you guys are here.’ So, you know, they’ve been very good to us, and we believe we’ve been good for the town.We’re good community citizens, and we’ve been recognized as a good community leader.

© 2011 Thermo Fisher Scientific Inc. All rights reserved. Copyrights in and to the Piggy Bank photograph is owned by a third party and licensed for limited use only to Thermo Fisher Scientific by Punchstock.

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BytheNumbers A NATIONAL PROVISIONER STUDY

Sausage Processing The National Provisioner surveys sausage processors on a variety of topics linked to sausage R&D and operations.

I

n March 2011, The National Provisioner and BNP Market Research surveyed sausage processing employees to get a glimpse into the market trends driving operations and research & development in the segment. What follows are a sampling of the survey answers, presented visually through charts and tables. To receive a PDF of the full survey including all of the results tabulated, go to www.provisioneronline.com, register for the site and search for Sausage Processing Study to download the PDF.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Fastest-Growing Type of Sausage What is your fastest-growing type of sausage (not necessarily best-selling)? Total Respondents: 69

Breakfast (3) Beef (2) ■ Chicken (2) ■ Pork (2) ■ Poultry (2) ■ Smoked sausage (2) ■ Bangers ■ Beef hot ■ Cheese sausage ■ Gourmet cooked ■ Green chili breakfast ■ Jalapeno and cheese ■ Kosher ■ Natural ■ Picked sausage ■ Plain sausage patty ■ Polish ■ Red hots ■ Rope ■ Snack items - sticks, bites ■ Spanish ■ Specialty ■ Vienna ■

Italian 27%

■

Other 42%

Bratwurst 25%

Mexican (chorizo) 6%

Bythe

Numbers Healthier Sausage Demand/Formulation Alterations Have you seen a demand for “healthier” sausages (reduced salt, reduced nitrites/nitrates, etc.)?

Have you altered any of your formulations to meet the demand for “healthier” sausages?

Yes 70%

No 30%

Yes 64%

No 36%

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

59

BytheNumbers A NATIONAL PROVISIONER STUDY

Smokehouse Smokehouse

23% 23%

Sausage-Processing essing Equipment Purchase Plans ns What is the next piece of sausage-processing equipment you plan on purchasing? g?

Stuffer Stuffer

22% 22%

Linker Linker

17% 17%

Grinder Grinder

Other Mentions: s: Other Mentions: Q Chopper (2) ƒ Chopper (2) Q Packaging (2)) ƒ Packaging (2) Q Declipper ƒ Declipper Q HPP vessel ƒ HPP vessel Q Patty-maker ƒ Patty-maker Q Smoke drench h cabinet ƒ Smoke drench cabinet Q Townsend continuous systemsystem ƒ Townsend tinuous continuous Q Variable speed ed mixer ƒ Variable speed mixer

6% 6%

Other Other

17% 17%

None** None

14% 14%

0% 0%

20% 20%

40% 40%

60% 60%

80% 80%

* “None” responses were taken from the “Other Mentions”

100% 100%

Note: Total may not equal 100% due to rounding

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

‘‘We switched to Vemag and couldn’t be happier.’’ “Sure, we were hesitant to make a change with our stuffers. Our entire business is built around producing high quality German sausage products and we couldn’t afford to make a mistake that would change our product or compromise the quality. But after testing the Vemag, we made the switch and bought three machines. The Vemag gives us a better quality final product and produces our natural casing links to exact weight and exact lengths. Plus, it’s easier to service. Now we use the Vemag to produce everything from Braunschweiger and Peanut Franks to Bratwurst and Chorizo and couldn’t be happier with the results.” Ralph Schaller, President, Schaller & Weber

Harald Nagel Production Manager

George Nici Plant Engineer

Ralph Schaller President Dieter Rosenow Plant Manager

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BytheNumbers A NATIONAL PROVISIONER STUDY All-Natural or Organic Sausage Products What percentage of your sausage products is either all-natural or organic?

50% 40%

36%

32%

30% 17%

20% 10%

6%

0%

1-25%

26-50%

6%

3%

51-75%

76-99%

100%

None

Liquid smoke 32%

Smokehouse Products Which product(s) do you use in your smokehouses?

Both liquid smoke and wood chips 22%

Total Respondents: 69

Wood chips 46%

Priority Trends for R&D Teams Which, if any, trends have become a priority for your company’s sausage R&D teams? (Multiple response allowed)

Cook-in-package elimination of anti-microbials High pressure processing Q Lean chicken Q Natural pork Q New age Áavors - chipotle, turkey, sweet, etc. Q Reducing saturated fat Q Removing MSG

100%

Q Q

80% 60%

52% 30%

40%

28%

20% 0%

62

10%

Reducing salt

Reducing nitrites/nitrates

Other

THE NA NATIO NATIONAL TIO ONA NA PR NAL PROVI PROVISIONER O SIO OVI SI NER ER | PROVISIO PROVISIONERONLINE.COM SIONERONL SIO IO O ON NLIN NL INE N .COM | JUN JUNEE 2 2011 01 011

None of the above

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ImmigrationUpdate

Foreign investors at risk

F

oreign nationals who acquired conditional permanent resident status based upon a qualifying investment in a new commercial enterprise are now routinely being required by the U.S. Citizenship and Immigration Services (USCIS) to submit Forms I-9 for inspection to demonstrate that they employ(ed) authorized workers in order to remove the conditions of their residency in the United States. The USCIS has also recently refused to credit indirect employment in certain situations where a multiplier was based upon direct jobs creation if the direct employment involved unauthorized workers.

As a result, regulatory compliance and unauthorized workers have become a significant risk for foreign investors. Recently, numerous investors have had their I-829 petitions to Remove Conditions denied and now face removal proceedings despite the fact that their investments met all eligibility requirements for the capital Mark Reed, investment, and for job Border Management creation, except that USStrategies (BMS) CIS determined from I-9 Editorial Board Member reviews that some jobs were held by unauthorized workers. What is especially troubling about this situation is that new commercial enterprises were attempting to comply with the I-9 employment eligibility requirements. BMS recommends that investors establishing new commercial enterprises build an immigration compliance program that provides assurance and confidence that unexpected issues will not be encountered when they attempt to remove the conditions of residence. Waiting until the I-829 petitions are filed is too late to implement an effective employment eligibility verification program. The risks to investors and to future recruitment of investors to new investment plans are too high. The time to ensure that each business has an effective program is before employees are hired. Although the success of investments may be

eb

64

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

impacted by a variety of economic influences outside of the control of investors and managing partners, this is not the case with compliance with the jobs for Americans requirements of Section 203 of the INA. Mark Reed, CEO of BMS, was the highest-ranking career government official within the Immigration and Naturalization Service (INS) during his career. At retirement, Mark directed border patrol, investigation, detention and removal, adjudication, and inspection operations from the northern to southern U.S. borders. Today as head of BMS, Mark is a knowledgeable and respected governmental insider. He advises many large companies in the areas of immigration compliance, policy and training. He also has a unique view into the world of key policy initiatives dealing with immigration issues and policy trends. For more information, please contact him at (520) 529-8750 or at [email protected].

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FarmtoPlate ANIMAL WELFARE

Animal welfare on the label? Consumers remain skeptical and uninformed regarding animal-welfare product claims, and processors need to respond with education and simplicity. IN EARLY MAY, I LED A SEMINAR ON CATTLE WELFARE for the California beef and dairy industries. On the morning of the seminar, a faculty member from Fresno State University took me on a tour of a large dairy operation in California’s Central Valley. I was greeted by a herdsman that was about the same age as my parents. He looked me in the eye and shook my hand in a manner that left me with a great first impression. When I asked if he would be attending the seminar later that day, his no-nonsense response — “Why should I take time out of my day to attend your seminar?” — didn’t surprise me, because I hear similar responses quite often. I didn’t mince words in my reply. “Because you need to understand what society expects from you and what will happen if you don’t deliver.” If you’ve been looking for an explanation for the value of animal welfare to the consumer that goes deeper than the impact on product quality and yield, here it is. The practices that we find acceptable 66

and unacceptable in the world around us are largely influenced by our personal ethics. Personal ethics are our individual Kurt Vogel, University of feelings of right Wisconsin - River Falls and wrong, good Editorial Board and bad. They Member clearly vary from person to person as the issue under consideration changes. Differences in personal ethic can fuel arguments or drive innovation, depending on the emotional reactions that accompany these differences. The choices that a business owner or manager make are always influenced in part by personal ethics. When the personal ethics of a majority of a group of people are the same for specific issues, these beliefs become part of the societal ethic. The provision of stunning for commercially slaughtered

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

livestock under the Humane Methods of Slaughter Act of 1978 made the use of pre-slaughter stunning in livestock slaughter facilities part of the societal ethic. The vast majority of society, which includes everyone from industry personnel to the consumer that has no more connection to meat processing than the meat case at the grocery store, accept it as a standard and necessary part of livestock slaughter. If we pay attention, it is not difficult to start to flesh out the basics of the societal ethic toward the care of livestock. In April, a gruesome undercover video of unacceptable calf euthanasia methods was recorded at E6 Cattle Company — a large calf ranch that grows dairy calves as replacement animals for dairy farms — by an activist group called Mercy for Animals. The employees in the video used hammers to euthanize calves that were very sick or had little economic value. This was not an acceptable method of euthanasia due to the high risk of not

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delivering a blow that caused immediate insensibility. The video is highly inflammatory to those who can bear to watch it. Not surprisingly, the reaction of the people in the livestock industries that I have observed watching the video is largely identical to the reaction of people that do not make their living in agriculture. This similarity uncovers a piece of the societal ethic toward livestock animals.We find it universally unacceptable to euthanize an animal with a method that has a high risk of inconsistency that can ultimately result in suffering on the part of the animal. This is exactly why society is supportive of adherence to humane slaughter techniques that have been proven effective. They understand that we raise and slaughter animals for food, but they do not tolerate negligence on the part of those who are responsible for the care, handling and slaughter of livestock. It is fair to say that society grants the members of livestock agriculture a certain level of trust that the animals under their care will be treated well, handled carefully and slaughtered humanely. Many call this trust a “social license.” If you do not keep up with the societal ethic, you can expect to lose your social license, which is the privilege to operate your business. In extreme cases, revocation of your social license entails complete closure of your business. More commonly, it results in decreased consumer demand for your products. It is difficult to put an exact monetary value on the impact of a breach of societal trust, but the reaction of consumers to such an event has been identified.

One study1 identified that when an animal-derived food product was offered to a consumer panel with a description of high-perceived standards of facility cleanliness and animal welfare, the consumers were more willing to pay for the product than other products that claimed different combinations of facility hygiene and animal welfare. The researchers also allowed the consumers to taste the products. They found that consumers relied more heavily on the taste and quality attributes of the product than perceived animal welfare after they tasted the product. This study clearly demonstrates the value of both animal welfare and product quality in consumer decision-making. A high level of perceived animal welfare is helpful in getting a product off the shelf, but the combination of animal welfare and eating quality brings impact whether consumers return to buy the product again or opt for another option. If a processor intends to add labeling that indicates the animal-welfare standards of their product, there are a few important factors to remember. A study in the U.K.2 revealed several common complaints indicated by adults that were surveyed on animal welfare-related food-purchasing decisions. The top complaint was that an excessive amount of label claims are unacceptable. It appears that too many label claims place the purchaser in a state of “information overload.” Consumers in the study also were confused about many label claims regarding animal welfare because they did not understand the production practices. Finally, and importantly, many consumers believed label information regarding animal welfare was biased, and they were unsure which companies were actually telling the truth! The importance of animal welfare to the marketing of meat, milk and eggs has been described in research and identified by many niche marketers in recent years. Information regarding good animal-welfare practices helps consumers to choose one product over another. However, before we flood the shelves with animal-welfare labeling, it is important to remember a few things. The consumer has to understand what the label claim means, you have to consistently source product or raise animals in facilities or using practices that adhere to your label claim, and most importantly, you have to make a great tasting product that the consumer will purchase again and again.

Kurt D.Vogel is an assistant professor of Animal Science with an emphasis in livestock behavior and welfare at the University of Wisconsin - River Falls. For more information, contact him at [email protected] or (715) 425-3704.

ENDNOTES 1) Carlucci, A., E. Monteleone, A. Braghieri, and F. Napolitano. 2009. Mapping the effect of information about animal welfare on consumer liking and willingness to pay for yogurt. J. Sensory Studies. 24:712-730. 2) Schroder, M. J. A. and M. G. McEachern. 2004. Consumer value conÁicts surrounding ethical food purchase decisions: a focus on animal welfare. Int. J. Consum. Stud. 28:168-177.


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GuestColumn

Commit to measure animal handling

Steve Sinn, owner of Lacuna Technologies, and his turkey farm’s automated turkey loader.

Photo courtesy of Steve Sinn

By Steve Sinn, Lacuna Technologies

I

’m lucky to be working in an extraordinary food system.Yet, as a second-generation turkey farmer, I am keenly aware of how our food system has evolved and that some of the biggest changes have occurred in animal agriculture. Most of us welcome modernization, but there are valid concerns. One area of scrutiny centers on animal welfare, or what I prefer to call animal state of being. I strongly believe there is a gap in our modern animal protein supply chain — an overlooked source of information that, if tapped, could help resolve the sometimes conflicting demands of stakeholders when it comes to animal care. The information I am referring to is individual live-animal measurements during pre-slaughter handling, which would provide the supply chain with powerful tools for creating quality and performance metrics.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

For the first time, a vaccine can help reduce the prevalence and shedding of Escherichia coli (E. coli) O157 much earlier in the chain — in the cattle — creating a way for cattle producers and veterinarians to team up with packers, retailers and consumers. Escherichia Coli Bacterial Extract vaccine* with SRP® technology, used at the feedlot, has been shown to reduce the number of cattle entering the plant with E. coli O157 by 85 percent.1 Less E. coli O157 entering the plant enhances your efforts to help eliminate foodborne pathogens. To learn more, visit www.SRPEcoli.com.

Together, we can reduce E.coli O157.

*This product license is conditional. Efficacy and potency test studies are in progress. Thomson DU, Loneragan GH, Thornton AB, Lechtenberg KF, Emery DA, Burkhardt DT, Nagaraja TG. Use of a siderophore receptor and porin proteins-based vaccine to control the burden of Escherichia coli O157:H7 in feedlot cattle. Foodborne Pathogens and Disease. 2009;6:871-877.

1

All brands are the property of their respective owners. ©2011 Pfizer Inc. All rights reserved. SRP11028

GuestColumn By adopting a system that yields objective evidence of ethical pre-slaughter care and handling, our good work can be demonstrated using clear descriptions of animal state of being. Lead the way We embrace “continuous improvement” in animal care, but we must also actively demonstrate our commitment to producers, processors, retailers and consumers. I have no doubt other individuals and groups will continue to tell us how to do it. Trouble is, initiatives that originate outside the industry focus exclusively on self-defined standards (“perception,” diet, confinement, slaughter method), rather than on outcomes (specific and measurable evidence of improved animal state of being). In short, the “feel-good” is too often designed for the media or an individual group’s fundraising goals and not necessarily for the animals (or the folks who husband the animals). The public would be surprised to learn there’s no objective evidence that the extra money paid does anything to enhance animal state of being.

“Data up” We need more data — specific, measurable and verifiable — informing discussions of animal state of being. While struggling with 30- to 40-pluspound male turkeys the past 20 years of my life, it had always occurred to me that we could make the arduous task of turkey loading easier on us and on the turkeys. About 10 years ago, I observed a custom grain-handling apparatus that removed corn stored in a silica sand mine using a unique telescoping conveyor belt. I realized a similar conveyor could load turkeys, hands-free. So we got to work, and after our second prototype, we had a viable automated turkey loader that our family farm continues to use today. We’re now working on constructing even more NP01104PDQ.indd 1

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12/15/09 2:15:45 PM

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An American-made design and build Non-proprietary components and controls Tool-less accessibility to sealing chamber Intelligent interface with training, manuals and bilingual options built-in • Faster Return on Investment (ROI) It’s time for a new level of performance. It’s time for Integrity.

Go to www.OssidIntegrity.com or call 1-800-334-8369 to find out how Integrity can raise your HFFS expectations.

GuestColumn We can and must balance the demands of consumers concerned m about animal care — some of a whom are increasingly raising w their voices and voting their consciences — with those of retailers, processors and producers. Let’s work together to tap the untold story of this productive meat supply system by measuring individual animal state of being prior to slaughter.

comprehensive technologies to assesss individual turkeys during both loading and unloading. These live-animal measurements will provide dispassionate data about our quality and performance — and a commonsense foundation for decisions about animal state of being by producers, processors, retailers and even consumers.

Reject false choices Some will argue you can’t be “big” and humane; others will contend we can’t worry so much about animal care and still maintain efficiencies. I don’t buy either argument. I’m confident we can work toward verifiable improvements in animal state of being and other performance outcomes that support our shared priority of maintaining an efficient and afford-

able protein supply chain. Economies of scale provide affordable, plentiful meat to millions of consumers. Our model should not be dismantled, but continuously examined for potential improvements. By adopting a system that yields objective evidence of ethical pre-slaughter care and handling, our good work can be demonstrated using clear descriptions of animal state of being.

Steve Sinn is the owner of Lacuna Technologies LLC. A turkey producer and entrepreneur, he is focused on developing synergistic solutions combining automated live-animal handling with individual live-animal measurements. His family’s grain and livestock farm has been producing turkeys for over 70 years.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

master grade ®

Top: Knife in sharpening wheel Top: Knife in sharpening wheel Right: Close-up of of wheel Right: Close-up wheel

Great for Butchers, Meat Processing plans, Slaughterhouses, Supermarkets and more Master Grade compared to the other sharpeners in its market Master Grade MG-5001

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F. Dick RS-150 Duo

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Safe to use

YES

YES

YES

NO 2

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Pre-sharpening

YES

NO

YES

NO

YES

Over heating

NO

YES

YES

YES

YES

Scratching knife blade

NO

Excessive

Excessive

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Burr

NO

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15° every pass

YES

NO

YES

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True Angle

True Angle

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15 mm

1 mm

2 mm

1 mm

1 mm

Debris storage

YES

NO

YES

NO

NO

Motor efficiency1

Top

Very Low

Very Low

Medium

Medium

Torque

High

Low

Low

High

High

Wheel type

Soft

Disk 3

Stone

Stone

Stone

NSF Certified

YES

NO

YES

NO

NO

$359.95

$599.00

$399.00

$968.00

$950.00

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Retail price (USD)

1. Our Efficient motors use the same electricity and output maximum power -- the best in the world. 2. F. Dick and Tru Hone both have a sharpening wheel without cover, which may cause serious injuries. 3. Diamond hone is steel plate coating with diamond dust always scratches the blade due to uneven disk surface. 4. The retail prices based on the year of 2010 survey.

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FoodSafety METAL DETECTION

Putting detection to the test By Elizabeth Fuhrman

METAL DETECTORS HAVE LONG BEEN FAMOUS at airport security checkpoints for their ability to keep unwanted objects off planes. Now X-ray scanners at airports have brought X-ray technology to the forefront of the public’s eye for their accurate ability to identify more materials that could be concealed. For meat and poultry processors, metal detectors and X-ray inspection systems are employed to identify foreign objects in their products in much the same way. These food-

Photo courtesy of OSI Group LLC

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

safety tools are helping meat and poultry processors reliably remove more foreign objects from their processing materials. Metal detection and X-ray technology are being used more than ever, says Donna Schaffner, associate director of food safety, quality assurance and training at Rutgers Food Innovation Center, Bridgeton, N.J. These detection technologies have become critical to processors’ food-safety initiatives. “A large number of companies have X-ray and metaldetection equipment as a critical control point,” she explains.

Many meat and poultry processors use metal-detection and X-ray technology to check their final product before it is ready to ship. Some companies also use detection technology for checking raw materials. “The way they have written their HACCP plans — their food-safety plans — they have to do that. They cannot release their product without putting it through the metal detection or through the X-ray machine, so it’s absolutely essential.” Many meat and poultry processors use metal-detection and X-ray technology to check their final product before it is ready to ship, Schaffner says. Some companies also use detection technology for checking raw materials. “If a processor brings in a chopped meat that they are going to use in something else, sometimes they will metal-

detect just the meat as it comes in as a raw material before they put it into their process,” Schaffner explains. “That way, if they find any metal, that protects their equipment. They are typically metaldetecting their final product also, but at that point, they’ve already put the meat together with the other ingredients, cooked it and packaged it. So if you only checked it at the end of the line, you’d lose everything and not just the meat.”

Advancing food safety with X-ray OSI Group LLC, Aurora, Ill., has worked closely with X-ray suppliers to

improve the application of X-ray technology and integrate it into its processing systems globally. In a short amount of time, the company has been able to improve product quality significantly, leading to a marked increase in customer satisfaction, the company says. Justin Ransom, OSI Group’s assistant vice president of food protection and government affairs, says several factors contributed to the success of X-ray implementation. The company first worked with technology providers to present the product to them in a manner providers could X-ray and then remove the affected product out of the stream.

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

77

FoodSafety “The best place to put an inspection system, in our opinion, as we continue to be committed to quality in food safety in all of our processes, is at the beginning of the process so that we’re not inspecting quality into it, but that we’re detecting foreign objects before they ever enter our process.” Justin Ransom, OSI Group’s assistant vice president of food protection and government affairs

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“So in taking a more holistic approach, we’ve tested X-ray application in different food matrices from raw material to preformed to finished product,” Ransom explains.“Understanding the challenges of each of those different matrices and how we reject foreign objects in our process has been critical to being able to get this technology going for us at the line speeds at which we operate.” OSI Group began putting X-ray technology into its processing systems about five years ago. “Basically once we began to understand where the best places to use X-ray were, we began putting it in processes all over the world, whether it be for some sort of patty, or a liquid product, or like beans and salsas,” Ransom says. “Each one of these different food matrices has a different algorithm that is used to detect foreign bodies. We just had to get into the process where we understand the risks, and work with the technology providers in making sure that we have the settings appropriate for the product that we are X-raying.” The ease of implementing X-ray technology depended on the product being processed. For example, for finished product patties, incorporation of X-ray technology has been fast, Ransom says. “It’s been relatively easy because the product is all the same size, the same shape and the same height, and that was relatively easy to implement there,” he explains. “The challenge has now become, how do we reject less product? “We only reject the product that has a problem rather than rejecting multiple patties at one time or multiple products at one time,” he continues. “That’s how we’re taking it to the next level.” Another challenge OSI Group cur-

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FoodSafety rently is undertaking is how to X-ray its raw materials. “The best place to put an inspection system, in our opinion, as we continue to be committed to quality in food safety in all of our processes, is at the beginning of the process so that we’re not inspecting quality into it, but that we’re detecting foreign objects before they ever enter our process,” Ransom says. “That’s what we really have spent the last 18 months on, working with different technology companies trying to help us identify a solution for raw-material inspection before it goes through our grinding process.” “It’s more of a whole systems approach that we are taking to identify and remove foreign objects from our process,” Ransom says. “That’s why working on the raw material is so critical and important to us.” While OSI Group continues to make progress in using X-ray technology in its food-safety strategies, the success of its currently executed X-ray detection systems has paid off already. “We’ve seen a significant improvement in reduction in total complaints, specifically bone complaints. In the U.S., we’ve also continued to improve, and with less sensitive customers, we have seen the same improvement in both our domestic and export markets,” Ransom says.

Moving detection forward X-ray has become a much more effective tool for processors since the technology has advanced to meet production demands. Ransom says that computers can run algorithms, identify a foreign object and remove it from the process to match today’s faster operating speeds. In addition to removing foreign objects from the processing system, X-ray has become an interesting tool for OSI Group because computers can analyze the data that’s generated by the X-ray system. “As data processing becomes faster and faster, I think we’re going to see increased ability from these detection systems to identify foreign objects throughout the process,” Ransom says. “Currently, they can do it. They just have to keep up with our line speeds [to allow us] to operate our systems efficiently.” While X-ray and metal-detection systems offer many viable detection solutions for processors, the detection field continues to grow. Plastics and materials that float continue to be a detectable challenge for processors. Non-metallic objects, especially brittle plastics, ceramic glass, wood splinters, also are a detection challenge for most processors, Schaffner says. “There are lots of other foreign materials that might get into a product — especially non-metal equipment parts — that could end up in a product that a metal detector cannot find,” she says. “X-ray is betNP03092JVH.indd 1

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2/17/09 3:45:25 PM

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

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Photo courtesy of Steven Thomas, Georgia Tech Research Institute

ter at finding them, but even X-ray is not good with small splinters of glass, and some of the plastics just don’t show up well unless a company buys the metal detectable products.” More companies now are using barium-impregnated plastics for

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

tools and small parts that were not detectable before as straight plastics, Schaffner says. The impregnated plastics can be found if lost in a product with the use of metal detectors or X-ray technology, she explains. “These materials are effective,” Schaffner says. “They are just expensive. Companies have to weigh the risk versus the cost, because it’s much more expensive to buy these products than the traditional ones.” False positives, particularly if a company works with frozen products with ice buildup, are another detection challenge many companies face. Location of the detection equipment in relation to other pieces of equipment also could cause electrical surges, which sometimes generate false positives, Schaffner says. “A big problem I see occurs when employees get used to false positives and [don’t pay] attention when there might be an actual problem,” she says, adding that accuracy is improving, however, as detection technology advances. Schaffner, who works with many small to medium-sized processors across the food industry, says that putting in X-ray equipment also is quite a large expenditure. “To go from just the simple metal detection to an X-ray machine is a big step for a lot of companies,” she says. Making the use of metal-detection and X-ray technology a priority also can be a challenge for some processors, Schaffner adds. “In the past, some companies have considered it non-essential, and now the way that food-safety concerns are growing, with much more emphasis on HACCP, I think that a lot more companies are being forced to metal-detect the finished product where in the past they didn’t,” she says. “I just see a much more wide use of it than it has been in the past.”

The little things that keep you Little things from contaminants to underfilled packages to inadequate control of food constituents can add up to big problems... or lost revenue! Finding ways to prevent little problems can enhance your brand quality and make a big difference to your bottom line. We help to do just that by controlling underfill and overfill, detecting contaminants in packaged, bulk and piped food, and by measuring moisture, protein, salt or fat that passes through a pipe.

One piece of bone = millions of dollars in lost sales and years of brand damage.

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One tiny, 2-mm metal piece = average of $8 million in recall and rework expenses. Imagine what a misplaced screw could do.

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SpecialReport

AND THE AWARD GOES TO… “Food Plants of the Year” is an annual honor published in The National Provisioner’s sister publication, Refrigerated & Frozen Foods. Nominations were solicited from industry experts and observers, industry suppliers and the editors of sister publications such as The National Provisioner, Food Engineering, Snack Food & Wholesale Bakery, Dairy Foods and Dairy Field Reports. Plant performance was evaluated against one or more of the following criteria: ; Worker Safety ; Community Involvement ; Food Safety ; Environmental Initiatives ; Process / Packaging Innovation ; Productivity R&FF then selected one plant from each of six refrigerated and frozen food processing sectors (regardless of sales channel). Want to be featured in 2012? Industry suppliers and food processors may submit nominations to Editor Bob Garrison at (574) 935-3724 or by e-mail at [email protected].

84

CUTTING-EDGE PERFORMANCE These food plants demonstrate industry-leading best practices in environmental achievement, worker safety and process technology. By Bob Garrison , editor, Refrigerated & Frozen Foods

H

ere’s a metaphorical look at springtime in the food industry. Three of Refrigerated & Frozen Foods’ “Food Plant of the Year” honorees are entirely new facilities that came online during the past three years. Meanwhile, R&FF is just as pleased to showcase three existing operations’ efforts to improve environmental performance, worker safety and productivity. The National Provisioner is showcasing the two plants honored by R&FF, that are part of the proteinprocessing industry. In the following pages, you’ll read about Sara Lee Corp. and Cargill Inc.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

of the MEAT CATEGORY AND THE HONOREES ARE: ENTREES: Sara Lee Corp.’s Zeeland, Mich., plant makes its name for worker safety; supports a growing Jimmy Dean breakfast business. (PAGE 87) MEAT & POULTRY: Cargill Inc. plants in Beardstown, Ill., and London, Ont., make noteworthy improvements to benefit the environment and workers alike. (PAGE 90) FRUIT & VEGETABLE: ConAgra Foods Lamb Weston builds the world’s first LEED Platinum certified frozen food plant in Delhi, La. DAIRY: General Mills picks its Methuen, Mass., Yoplait yogurt plant for the company’s first solar energy project. BAKERY: Chicago’s Gonnella Baking Co. invests in the latest technologies for its frozen dough plant in Hazle Township, Pa. SNACK, APPETIZER & SIDE DISH: Kettle Creations uses its new Lima, Ohio, plant and skilled employees to meet refrigerated side dish demand.

To read the proÀles of all honorees, go to

www.refrigeratedfrozenfood.com JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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TREIF offers value-packed options. TWISTER mat Michigan site spans 500,000 square feet with about 900 employees.

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Sara Lee’s Zeeland, Mich., makes its name for worker safety; makes its mark in the freezer case. JUST THE

FACTS Company: Sara Lee North American Retail Food plant(s) honored: Zeeland, Mich. Selection criteria: Worker safety, environmental initiatives Employees: Approximately 900 Facility size: N.A. Products: Processed refrigerated meats, frozen breakfast entrees

ake no mistake. Everything about Sara Lee Corp.’s processed meat plant in Zeeland, Mich. – is BIG. A flagship in Sara Lee’s North American Retail business, Zeeland is a 500,000-square-foot operation on a 123-acre site. It employs as many as 900 people and produces more than 200 million pounds of processed meats for nearly every Sara Lee’s retail and foodservice brand. Perhaps not surprisingly, Zeeland also has been a big contributor to Sara Lee’s Jimmy Dean breakfast business. When company officials wanted to push brand growth in frozen-bowl breakfast entrees, they selected Zeeland (in southwest Michigan) and renovated a portion of plant for frozen-food processing. Zeeland has helped fuel a growing business. Sara Lee has expanded the Jimmy Dean Breakfast Bowls line to seven items since the product’s 2006 debut. Officials say the latest offering, a new Jimmy Dean D-Lights Ham Bowl, offers 21 grams of protein per serving, contains just 220 calories and is ready in less than three minutes. Sara Lee says those popular new items – coupled with creative promotion – have propelled the brand to a 55.7 percent market share in the frozen protein breakfast category, according to Information Resources Inc. data (12 weeks ending Jan. 9, 2011). Plant Manager Ross Myers says no one could be more proud of Jimmy Dean’s success than Sara Lee’s Zeeland employees. “For Sara Lee to put its breakfast bowl line here

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Pride inside: Jimmy Dean Àrst- and second-shift team members.

was exciting for all us. It represented a big investment,” says Myers. “When it came to designing the new line, Sara Lee also sought input from those employees who would be running, maintaining and cleaning it. It was fun to take it from a concept and make it a reality.” Meanwhile, Zeeland employees also have much to be proud of. Sara Lee recognized the facility internally as its “Meat Plant of the Year” during fiscal 2009 (for achievement against internal key performance indicators). Sara Lee also honored Zeeland last year as the company’s top distribution center. Myers says the plant (certified at SQF Level 3) recorded “perfect scores” across a multitude of criteria including worker safety, on-time delivery and cost. Last but not least, the American Meat Institute also gave Zeeland a 2010 Worker Safety Recognition Award for employee safety and health performance. Myers notes that Zeeland’s recordable lost-time accident rate (as of February 2011) is less than 0.5 on a yearto-date basis. And again … remember Zeeland has nearly 900 employees. Myers says Zeeland embraced lean manufacturing in 2003 and says 88

– eight years later – its workers now adhere to a behavior-based safety program. Zeeland’s goal, he says, is to train every employee and involve them cross-functional, self-directed safety teams. In this context, he says co-workers help their peers identify and correct any potential issues. “It’s all about employee buy-in,” says Myers. “To be leaders in safety, employees have to be the ones who make things happen. It’s clear that they take pride in what they do.” For that matter, Zeeland employees likewise can point to several environmental achievements involving … … packaging and transportation. Myers said Zeeland employees helped corporate engineers design the Jimmy Dean breakfast bowl entrée line and even the bowl itself. Together, they eliminated handles that were fixed into the original bowl. Not only did this make line filling operations more efficient but the change also slimmed down the package – resulting in more cartons per case and more cases per truck. Officials say the slimmer package represents a paperboard savings of 74 metric tons per year and a reduced shipping case for corrugate savings of

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

34 metric tons per year. Plus, because Zeeland could add one more case to each pallet load, it saved an estimated 236 truckloads, 161,834 liters of diesel fuel and 431 metric tons of CO2 emissions annually, they say. … energy. Zeeland converted two older product mixers from hydraulic power to electric power. Myers estimates the shift “saves us the equivalent energy used to power as many as 150 homes.” … wastewater. Zeeland converted from a traditional brine chill system to a cold water chilling alternative. By eliminating salt in its chiller systems, Zeeland reduced overall chloride levels in its discharged water by as much as 50 percent, says Myers. While Zeeland does its part, corporate officials in Downers Grove, Ill., continue to do more to build Jimmy Dean and other brands. “We’re all proud when Jimmy Dean does anything – from a line extension to a new product,” says Myers notes. “And that goes for everyone here. We regard everything we do as a crossfunctional team effort, and it involves everyone from management to our hourly employees.”

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SpecialReport

Photos courtesy of Cargill Incorporated

Cargill reclaims methane from the wastewater lagoons and converts that methane into biogas to fuel plant boilers. Biogas now replaces up to 30 percent of natural gas demand at 11 meat plants.

JUST THE FACTS

Company: Cargill Incorporated Food plant(s) honored: Beardstown, Ill.; London, Ont. Selection criteria: Environmental initiatives Employees: N.A. Facility size: N.A. Products: Fresh and processed beef, pork and poultry

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THINKING OUTSIDE (AND INSIDE) THE BOX New technologies, creativity and partnerships help Cargill push environmental, energy achievements. aste not, want not” is the time-tested admonition. Yet what are meat and poultry processors supposed to do when so many daily production activities create waste? The answer: Don’t waste that by product … particularly if you can reduce, re-use or recycle it. And chances are your good deeds won’t go unnoticed. When quick-service restaurant giant McDonald’s Corp. published its 2010

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Global Best of Green sustainable supply chain report, it recognized Cargill Incorporated’s North American meats business for its waste recovery and reduction achievements. McDonald’s credited Cargill Pork’s Beardstown, Ill., plant, which eliminated 95 percent of waste that previously went to a landfill or land application. McDonald’s also commended a Cargill Meats Canada poultry facility in London, Ontario, which reduced daily freshwater use (by 28 percent) and started recycling all other chilled

water – not once but twice. Environmental improvements are a big deal for Cargill, a $108 billion global giant with 32 North American beef, pork and poultry operations. Recognizing its corporate responsibility, this private company talks quite openly about activities in five “cornerstone” areas including environmental and energy practices. “McDonald’s is one our largest customers, and we partner with them in every area from menu development, to restaurant operations and risk-management solutions,” notes Scott Hartter, vice president of Environment, Health and Safety for Cargill’s Animal Protein group. “Understandably, McDonald’s is very passionate about sustainability,” he continues. “It’s one of their cornerstones and – at their first U.S. sustainability conference – they challenged suppliers about best practices in this area. We sit on their sustainability leadership committee and believe that this is a non-competitive issue where it’s important to be transparent and share our ideas.” Hartter says he leads a global team that just set aggressive five-year improvement metrics across every environmental and energy area. He notes Cargill’s commitment to the Chicago Climate Exchange (a 2007 pledge to cut greenhouse gas emissions 6 percent by 2010) as well as ISO 14001 Certification (whereby all Cargill processing locations, feedlots and farms adhere to a strict environmental management system governing efficient water use and reuse). Cargill likewise has detailed goals and programs for responsible energy use, greenhouse gas reduction, water reduction and waste reduction. Many of those efforts caught McDonald’s eye and the foodservice operator chose to honor … … Beardstown, Ill. Cargill Pork Beardstown constructed a site to compost all agricultural waste from its plant – combining it with other cellulose material – to create a valuable compost material. This helped

Environmental improvements are a big deal for Cargill, a $108 billion global giant with 32 North American beef, pork and poultry operations.

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SpecialReport

Beardstown eliminate 95 percent of its land-applied and landfill waste materials. Other Cargill Meat plants have adopted this practice and reduced Cargill animal protein’s direct land application and landfill volumes by more than 75 percent during the past five years. …London, Ont. In its primary, slaughter area, this Cargill Meats Canada poultry-processing plant uses fresh water to prepare birds for further 92

processing. The system to chill these birds to their proper temperature uses approximately 71,000 gallons of water per day. The facility also evaluated using recycled water a second time from the HVAC system to pre-rinse empty chicken crates. Cargill London installed a rotary screen process to filters out solids from the chillers’ overflow water system. This reduced the amount of solids going to the wastewater treatment plant. London

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now pumps that chilled water to a makeup air unit in the primary area (cooling the room for employees). Then, it pumps the same water to a booster pump at the crate washing area. This helps create high pressure water, which employees use to remove large pieces of material before crates go through a fresh water and sanitizer spray. Cargill says this improvement reduced London’s freshwater consumption by 28 percent during the past 24

months. Moreover, 100 percent of all the chilled overflow water is being recycled twice. Employees now work in a cooler environment during summer months and London has eliminated fresh water use at the crate washer entrance. For his part, Hartter is just as excited about even more environmental achievements involving … … the Global Conference on Sustainable Beef. Cargill co-sponsored the fall 2010 conference with McDonald’s, the World Wildlife Fund and a handful of other companies. Cargill described the event as a forum to review current sustainability practices and build alignment around key impacts (both positive and negative) within the beef system. The conference featured tracks dedicated to science and research, better management practices and dialogue among all supply-chain members. … methane recovery at all large facilities. Cargill invested millions to install anaerobic reactors at all of its largest beef- and pork-processing plants. Here, Cargill reclaims methane from the wastewater lagoons and converts that methane into biogas that fuels plant boilers. That biogas now replaces up to 30 percent of natural gas demand at 11 meat plants. Cargill estimates that this already has reduced greenhouse gas emissions by more than 1.3 million metric tons in the last four years. “I call this a ‘triple bottom line,’ win-win-win proposition,” says Hartter. “It reduces pollution, increases our renewable energy and cuts cost. We are very proud that one out of every five cattle processed is done so with 100-percent renewable energy.”

Cargill Pork Beardstown constructed a site to compost all agricultural waste from its plant – combining it with other cellulose material – to create a valuable compost material. This helped Beardstown eliminate 95 percent of its landapplied and landfill waste materials.

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TechProcessing

Staying sharp During the Àrst-processing stage, meat and poultry processors are employing precision cutting equipment for improved worker safety and ergonomics. By Megan Pellegrini THE MEAT AND POULTRY INDUSTRY is constantly challenged by the balance of fostering a safe yet productive work atmosphere during production. In particular, during the first-processing stage, cutting equipment such as pneumatic cutters and automatic slicers can be a key focus of worker-safety and ergonomic programs, as well as efficiency improvements, cost reductions, proper manning and increased chain speeds. “Regular upright band saws are being phased out in larger processing facilities,” notes Paul McCauley, director of operations, Mountain States Rosen, Bronx, N.Y.“Hand knife cutting and trimming has been dramatically reduced in daily operations as well.” Instead, pneumatic trimmers and automatic slicers offer increased efficiencies while minimizing risk today, he says. More manufacturers are certainly offering precision cutting equipment then were years ago. And they can offer a wide variety of units with capabilities rang94

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ing from cutting specific thickness to portion control, says McCauley. However, with high-speed cutting equipment, certain flexibilities can be lost during the first-processing stage, explains Dennis Stiffler, Ph.D., CEO, Mountain States Rosen. “Animal to animal variation — or size variability — can create issues; certain equipment may tear product more than conventional methods, such as clean-andjerk systems; possibly foreign object material issues could arise, and there may be increased inherent personnel safety concerns,” he says. The lamb industry, for one, is handling safety issues by utilizing cutting equipment that provides improved precision capabilities and accurate data capture and reporting, as well as easier maintenance and sanitation, says Stiffler. McCauley adds that any time an employee is involved with any type of fabrication equipment, there are risks.

“We try and minimize the risk level through a lock-out, tag-out program and constant training,” says McCauley.“Concentration and fatigue are two of the largest factors when manning any cutting equipment.” In addition, proper hand protection for employees, such as safety cut gloves, is necessary to minimize accidents. Many equipment companies realize that proper training is necessary to ensure a successful program, so they include training sessions with the equipment, says McCauley. “Operator safety has always been a priority, but there is an elevated level of thought process being built into machines today,” he says.“The addition of more safety cut-off points in the operation of unit has increased.” In today’s climate, all equipment manufacturers are aware and making concentrated efforts to ensure equipment contributes and complies with good food-safety requirements, instead of primarily focusing on increasing unit capabilities and throughput. “Today with so much more emphasis being put on food safety, they have no choice but to offer additional precautions built into the unit,” says McCauley.“Adding input and output conveyors minimizes actual food contact, which reduces the possibility of contamination. Many of the newer models are also being built with full wash-down capabilities.” However, self-sanitizing knives and better bone-dust control are two features McCauley would like to see improved.

After the live hang method is first used on the birds, and up until the bird comes out of the processing line, the bird is not touched by a person.

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Running the gamut: From band saws to lasers To create its custom orders,Wasatch Meats, Salt Lake City, mainly uses band saws and knives. According to Roger Rausch, operations manager,Wasatch Meats, the inherent risk associated with band saws involves operator error. “With any piece of equipment, training plays a key role,” he says.“We provide a lot of training to our meat cutters. Their operation of the equipment is vital and key.” Larger beef operations are using laser-guided and computer-driven cutting equipment, says Dale Woerner, Ph.D., assistant professor, Department of Animal Sciences, Colorado State University, based in Fort Collins, Colo. “Foodservice has driven portion-control cuts to a high rate of speed,” he says, noting that food safety could be improved

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TechProcessing if equipment was continually sanitized during and after operations. The poultry industry’s cutting equipment is also highly automated due to the sheer volume of birds that are processed every day — up to 200,000 to one million per plant. “Most innovations relate to speeding up the processing lines,” says Gary McMurray, chief, Georgia Tech Research Institute’s Food Processing Technology Division, in Atlanta.“Companies are also pushing software solutions that will collect more data from the machines on key performance indicators.” After the live hang method is first used on the birds,and up until the bird comes out of the processing line,the bird is not touched by a person,he notes.Then,the bird is re-loaded by employees into production lines where the claws are cut off,and the bird is eviscerated and sent to the chiller. “There is a little bit of error introduced into the system because of bird weight

“Most innovations relate to speeding up the processing lines.” Gary McMurray, Georgia Tech Research Institute

differences and when operators set the blades,” he says. Tyson Foods works with suppliers to develop site-specific equipment that builds upon previous innovations, says Worth Sparkman, manager public relations, Tyson Foods Inc., in Springdale, Ark. “One opportunity we are beginning to make headway in is applying technologies that quantify sharpness in knives and scissors,” he says.“This helps us stabilize performance in the sharpening room, as

well as identify team members on the line who need assistance in mastering online maintenance skills.” Tyson Foods has active ergonomics committees in all of its plants that systematically review jobs and develop corrective solutions to make work easier for its people. Another helpful tactic employed by Tyson is continual education and training of its team members. “Also, our industrial engineering team analyzes the work content of our jobs using standard motion time libraries, which are ultimately used to establish staffing levels,” says Sparkman.“This data has fatigue allowances built in to ensure we provide our people with adequate rest and recovery time.” At the end of the day, a good working environment leads to even greater food safety. “Safe equipment used properly can reduce fatigue and strain, and therefore team members are better able to focus on the immediate task at hand,” he says.

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LOOKING BACK AT

EXPO

MEAT, POULTRY & SEAFOO MEAT M SEAFOOD CONVENTION AND EXPOSITION

Hayden kicks off AMI Expo 2011 Former director of the Central Intelligence Agency discusses the five key threats that the United States should fret about today in the Day One keynote session. By Andy Hanacek, editor-in-chief The kickoff keynote presentation at the AMI’s Meat, Poultry & Seafood Industry Convention & Exposition 2011 gave attendees an excellent perspective on our nation and the world through the eyes of a former top government intelligence official. General Michael Hayden, former director of the Central Intelligence Agency (CIA) and former director of the National Security Agency, spoke frankly about his time as an intelligence officer and as part of the presidential administration under George W. Bush. Hayden then steered his talk into the five major threats he believes should be of most concern to the U.S. government today.

AMI 2011 Expo wrapup The AMI Expo attracted 360 exhibitors and 6,000 industry leaders to Chicago. By Anne K. Halal, CEM, American Meat Institute

EDITOR’S NOTE: What follows is coverage of the AMI 2011 Expo as written by the editors of The National Provisioner for the show’s daily publication, distributed to attendees electronically each day of the show. he AMI 2011 Expo attracted more than 360 exhibitors and 6,000 industry leaders to Chicago in April. Recently separated from the Dairy Expo, the show’s overall attendance numbers disappointed some, but most exhibitors were satisfied with the true quality of the audience. A final audited list of more than 1,600 decision-makers and influencers on the show floor was shared with all exhibitors. There was a positive buzz amongst AMI members — all are thrilled at the prospect of being with FMI, United Fresh and the NASDA shows in 2012. AMI has taken the first steps to develop an international food processing show in North America — one that brings equipment, processors and retailers into one place at one time. And we know this is just the beginning. Early sales numbers, as well as exhibitor and attendee surveys, confirm that the new approach AMI is taking with the annual spring show is just what our industry needs. Reduced rates, inclusive drayage programs, a new city and new colocation partners are moving the show in a new and re-energized direction that will ensure AMI continues to host the industry’s premier convention and expo. Anne K. Halal, CEM, is vice president, Convention and Exposition Services, for the American Meat Institute. For more information, contact her at [email protected] or (202) 587-4230.

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Bethune gives attendees his business flight plan Former head of Continental Airlines gives his four-point plan that helped turn the company around, during Friday’s keynote session. By Andy Hanacek, editor-in-chief

Mintel talks food friends for meat & poultry industry As consumers are walking down the grocery aisle, they’re looking for value, convenience and delicious taste, Mintel reports. In Wednesday morning’s education session, Lynn Dornblaser, director, CPG Trend Insight for Mintel International, discussed some of the leading consumer trends to help processors better target their new products to meet the needs of the public. Dornblaser detailed the five key trends in the CPG (consumer packaged goods) market: quiet reduction; professionalization of the amateur; “less is more” redux; economy chic; and blurring categories. She pointed to products in and outside of the meat and poultry market that have successfully targeted these trends.

Gordon Bethune, former CEO and chairman of Continental Airlines, offered attendees at the keynote session Friday at the AMI Meat, Poultry & Seafood Convention and Exhibition insight into how he turned around the airline, which he called “the most dysfunctional company I’d ever seen” when he first arrived at the company. When Bethune was asked by Continental’s board of directors to form a plan to revitalize the company, he developed a “Go Forward” plan — a four-point strategy that would turn Continental’s fortunes around rapidly. Go Forward, he says, included the typical market strategy and financial plans, but added product and people plans to provide backbone AND muscle to the first two strategies.

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LOOKING BACK AT

EXPO

MEAT, POULTRY & SEAFOO MEAT M SEAFOOD CONVENTION AND EXPOSITION

The 2011 AMI Meat, Poultry & Seafood Convention and Exposition welcomed many returning exhibitors and attendees, as well as plenty of first-time visitors were more than 40 international exhibitors from 14 different countries also were in attendance. A variety of new machinery, ingredients, and services were on display at the show floor. Many of the industry’s latest products are designed to help processors meet their current needs, including improving food safety, improving the nutritional aspects of meat products without taking away from taste or shelf life, and reducing costs.

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Sights from the Show Floor Thank you for attending the 2011 AMI Meat, Poultry & Seafood Convention. The 2012 AMI Expo will be co-located with the Food Marketing Institute, the United Fresh Produce Association and the National Association of State Departments of Agriculture, and will be held April 30 - May 3, 2012, in Dallas, Texas. Preliminary information for next year’s show is now available at www.amiexpo2012.com.

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TechProcessing SUSTAINABLE OPERATIONS

Green flags and red flags Agriculture experts offer protein processors a list of indicators of sustainable operations on farms. By Lisa Duchene At most of the 550 U.S. hog farms growing for Niman Ranch, hogs are likely foraging outdoors on about 20 percent of the farm. Fields making up another fifth of the farm are likely growing corn, nourished by the manure left behind from the hogs that lived there last year, while another fifth is growing soybeans. Each of the last two-fifths is probably growing any number of produce crops — or simply left uncultivated. Next year, everything will shift. The hogs will forage on a different field, the corn will grow on another and so on. And that corn and soybean harvest will go to fatten the same farm’s pigs, helping to marble the pork that will be sold at specialty restaurants and grocery chains such as Whole Foods. This setup is one of the most critical hallmarks of sustainable agriculture. The diversity of land use, rotation of crops and cycling of nutrients — using manure to nourish the soil and crops, then the harvest to nourish the animals — are all important indicators of an environmentally responsible livestock farm, say sustainable agriculture experts. “A sustainable farmer always starts with the question, ‘How would nature do this?” says Brian Snyder, executive director of the Pennsylvania Association for Sustainable Agriculture in Millheim, Pa. “And when you look at nature, you find nature loves diversity. Nature loves to move things around.” In the system typically found among Niman Ranch farmers, says Nick McCann, agriculture specialist at the National Center for Appropriate Technology, a non-profit organization in Butte, Mont., promoting sustainable agriculture, “You’re keeping a lot of nutrients on the farm, and that’s very important from a closed-loop perspective. You want to bring in as little from off the farm and export as little as you can.” As a graduate student, McCann worked at the Leopold Center for Sustainable Agriculture at Iowa State University.

Doing it right Environmental responsibility is not just a niche market, issue or conversation. The Cattlemen’s Beef Board and National Cattlemen’s Beef Association last year issued its first formal review of the beef industry’s influence on communities, the economy, public health 104

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and the environment in “The Cattlemen’s Stewardship Review: Connecting our Vision and Values.” The review cited a Washington State University study that found each pound of beef raised in 2007 used 20 percent less feed, 30 percent less land, 14 percent less water and 9 percent less fossil fuel energy compared to 20 years ago. In all, the carbon footprint of a pound of beef is 18 percent lower than in 1977, according to the NCBA. On livestock farms, other “green flags” are healthy pastures of various heights with different kinds of plants — opposite of bare ground or a uniform, “golf course” look — and vegetation along the boundaries of the farm and any waterways to absorb excess nutrients from entering streams. Generally, the more the animals are outside, the better, and the more cows are fed grass over grain, the better. Animals should look healthy, alert and content, with shiny hair and coats, according to Ann Wells, program direc-

tor and veterinarian, and Mary Penick, livestock manager, at the Kerr Center, a non-profit in Poteau, Okla., affiliated with several southern universities. Those are signs of low-stress animals, and research is mounting

that gentle handling of animals from field to slaughter directly affects meat quality. Penick recommends processors check to see whether farms are following any of Dr. Temple Grandin’s livestock-handling protocols.

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TechProcessing Work still to do On the flip side, “red flags” — or indicators of an unsustainable operation — include gaunt, limping and sickly animals. Farrowing crates for pigs — indoor crates that do not allow a pig enough space to turn around — or battery cages for chickens — that don’t allow laying hens natural behaviors like walking, spreading their wings or laying eggs in nests, are definitely red flags, says Scott Exo, executive director of the Food Alliance in Portland, Ore., a third-party certifier of sustainable farms. The Food Alliance certifies to its standards 150 livestock farms, including many western rangeland beef producers. Its certified livestock farms represent about 5 million acres in the United States and Canada, and the value of alliance-certified meat is

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about $60 million. Other red flags would be manure concentrated in one place — versus dispersed on fields — or animals standing in a creek. Both are indicators that excess nitrogen is running off the farm into fresh waterways. Excess nutrient runoff from farm fields is a high-profile problem for the Mississippi River and Chesapeake Bay watersheds, where decomposing algal blooms rob the bay and Gulf of Mexico of oxygen, creating “dead zones.” If one type of animal is raised across all parts of the farm, uniformly and in high-densities, it’s a sign of unsustainable, environmentally irresponsible operations, says PASA’s Snyder. “You don’t ever want to see a lot of bare ground on a farm,” says Snyder. “That’s a sign of overgrazing, or in the case of crops, it means they may not be

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

using cover crops sufficiently.” According to sustainable agriculture experts, the highest-priority areas also include antibiotics use. The U.S. Centers for Disease Control has linked use of antibiotics in livestock production as a factor in the public health problem of antibioticresistant bacteria. The World Health Organization determined antibiotics used to promote growth in livestock is unsafe for public health. To achieve Food Alliance certification, a farm may use antibiotics only to treat a sick animal. While there are visual cues, so much about sustainable agriculture has to do with what can’t be seen, such as the quality of the soil on the farm and water leaving the farm, says Snyder. So he encourages processors to ask a lot of questions, visit farms and

— perhaps most importantly — understand their own power and influence in the food system. “[Concentrated animal feeding operations] and feedlots don’t appear because a farmer gets up some day and thinks, ‘Gee, this is how I want to farm,’” says Snyder. “They feel like what they’re doing is meeting the demands of the marketplace.” Beware of encouraging too much uniformity for the sake of ultra-efficiency at the farm level, such that the farms damage soil and water quality and engage in inhumane animal practices, he says. Consumers appreciate variety, he says. Definitions of sustainability encompass not just environmental practices, but the quality of life and profitability

of farmers, health of farm workers and animal-handling practices. The Kerr Center defines a sustainable farm as one that is making money, environmentally sound and provides a good quality of life for the farming family. Family ownership is a key part of Niman Ranch’s definition of a sustainable farm. Niman Ranch buys exclusively from family farms because it believes family ownership means a farmer is invested and has an incentive in the long-term health of the land versus a corporate owner that is likely to prioritize efficiency and squeeze maximum short-term profits out of the land, says Jeff Tripician, Niman’s chief marketing and sales officer. But other voices promoting sustainable agriculture do not draw such

stark lines. Not all feedlots are bad, explains Penick at the Kerr Center, and PASA’s Snyder says there are some appropriate uses for chemicals on farms. Exo, at the Food Alliance, emphasizes traceability and transparency. The more a processing buyer knows about where an animal came from, how it has lived, and how it has been treated, fed and handled, the better, he says. A great litmus test on farming practices is to consider whether consumers would want to see a video of it, says Exo. Perhaps the most critical thing protein processors can do around sustainability is understand their influence, ask questions and listen to the farmer’s philosophy — and story.

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SpecialReport

6

tips

to improve spare-parts management

By Phillip Slater, materials and spare-parts management specialist

S

pare parts are the lifeblood of operational reliability and plant capacity. No plant can operate at a high level of output without a reliable supply of functional spare parts. Spare parts form the bedrock on which operational reliability is built. Yet, spare parts are also the most overlooked contributor to reliability outcomes. Our research has shown that many companies routinely operate without properly implementing even the most fundamental aspects of spare parts management at their sites. Often these companies have storerooms with neat shelves and clear labels — but this is not enough for highly reliable spare parts management. To help make a difference in your operational reliability here are six tips to improve your spare parts management.

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Clear Spare No.1: Develop Parts Stocking Criteria

“To stock or not to stock,” that is the question. One of the major flaws in most spare parts management systems is the absence of clear criteria on when to stock an item and when not to stock an item. The absence of any guidelines forces your team into a process of ad hoc and inconsistent decision-making. The result is that you stock items that don’t require stocking and don’t stock items (sometimes critical items) that you should. To avoid this, you need to develop and implement specific guidelines to aid decision-making on when to stock an item and when to not stock an item.

Provide Clear No. 2: Guidelines on How Many Parts to Stock

Review the No. 4: Holdings of Critical Spare Parts

Once you have established clear spare parts stocking criteria, the next step is to establish clear guidelines on how many of an item to stock. By developing and implementing clear stocking guidelines, you provide the logic for decisionmaking on stock levels and calculating reorder quantities. The advantage of this is that it provides guidance to your team, continuity for decision-making, and provides the basis for future audits of inventory holdings.

Maintenance and reliability engineers will happily (well, not happily) undertake a review of spare parts that are not classified as critical, yet they will shy away from reviewing items that are classified as critical. The argument is: “The item is critical, and so we must stock it.” Thus the classification drives the review action rather than a cost benefit or stocking analysis. But what if the classification was wrong, or the item was significantly overstocked, or the supply arrangements had changed? Surely these are factors that can be reviewed and have nothing to do with the part’s criticality? It doesn’t make sense to limit your reviews based on the idea of criticality. This will drive you to review parts that are critical but not defined as such, and to not review parts that are defined as critical but which may no longer be critical. Critical parts may be just as overstocked as any other item, or there just might be a viable alternative to holding the item at all.

that Some No.3: Accept Stock Outs are OK

One of the main fears of most reliability and maintenance engineers is that, at the time of actual need, the required spare part will not be available. This is commonly referred to as a stock out. But how do you eliminate all stock outs? The short answer is, you can’t, not without tying up massive amounts of money that would be better used elsewhere. Even then, it’s not 100 percent guaranteed that you could eliminate all stock outs. This would possibly require holding multiple units of every part in your plant. That’s not viable. That’s the truth.What you can do is accept stock outs in areas where they have little or no impact or where a viable supply alternative exists. Then work to eliminate stock outs for the items that really matter.

Causes of No.5: Identify Excess Inventory

The impact of not holding a required spare part can be massive. Downtime costs often far outweigh the purchase and holding costs of spares and this can lead to hold-

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SpecialReport ing far more of some spares than is really required. As a result, accountants will often target this as an area of easy cost savings. If you want to keep the accountants off your back and maintain control of your spares holdings, it is important to regularly review your inventory and eliminate excess spare parts holdings. To do this most effectively, inventory reviews need to focus on much more than just data analytics. The real drivers of excess inventory lay in the processes and decision-making that influences your inventory levels, with the most common culprit being the returns process.

Your No.6: Review Storeroom Security

Many companies are fully aware of the importance of maintaining security around their spare parts inventories. They secure their spares in lock-up areas, ensure staff is on hand to manage the level of spares requests during periods of high maintenance activity, and provide a rocksolid approach for identifying storeroom entrants during the afternoon and night shifts. Then they leave the back door open! To “make life easier,” there is often a gate left open, through which anyone can enter. While the efficiency

in terms of supplying spares and minimizing downtime is obvious, this practice actually puts your reliability at risk. Removing items from the storeroom without proper record, no matter how honest the intent, will not trigger reordering when required, and next time you need that item, it will not be in stock. Spare parts management is like every other aspect of operations management: Success requires clear guidelines, differentiation of outcomes, critical evaluation and discipline in execution. Follow these six spares management tips, and you will go a long way to achieving the operational reliability that you need. Phillip Slater is an international materials and spare-parts management specialist. Following a career in manufacturing and operations management, he has spent the past 10 years as an independent consultant, during which time he has assisted 297 companies with more than 1,000 storerooms, holding $3.5 billion in inventory. He is also the author of four operations management books. For more information on spare parts management visit Phillip’s Web site www.PhillipSlater.com, or contact him at [email protected]..

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We have a seat at the eXchange

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productivity towards lasting partnerships to improve our bottom line, as well as the benefits that can be gained from networking opportunities.”

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ProteinLogisticsQ&A

Truckin’ TURKEY The National Provisioner’s sister publication Refrigerated & Frozen Foods talked with Dan DiGrazio, director of logistics for Butterball, LLC, headquartered in Garner, N.C. R&FF: Please tell us a little about Butterball. Dan DiGrazio: Butterball, LLC offers consumers a branded line of products to celebrate traditional holidays as well as everyday meal occasions. We distribute retail, deli and foodservice products throughout the United States and to more than 30 countries. Q: How is your logistics group structured? DiGrazio: Our chief operating officer heads Butterball’s operational group, which includes plant operations, logistics, demand/supply planning and purchasing. Our operational and supply chain structure facilitates communication and involvement for key associates and helps Butterball deliver superior products and services. Q: Any changes involving your group during 2010? DiGrazio: Each year, our logistics group defines its strategies and tactics for the coming year. Our “Strategic Initiative of Achieving Operational Excellence” had us studying our network during 2010. As a result, we shifted our Midwest distribution center closer to Chicago. After conducting request for proposals, Butterball awarded its Midwest consolidation business to United States Cold Storage. Q: How does Butterball approach warehousing and transportation? DiGrazio: Butterball’s current network includes six manufacturing plants, three distribution centers (managed by both the company and third-party partners) and 10 public warehouses. We run a small fleet but primarily use contract carriers and third parties to manage our transportation spend and service customers. Q: What were your biggest successes in calendar 2010? DiGrazio: 2010 was a year of change. We transitioned and shifted product to a state-of-the-art distribution center in Wilmington, Ill. Most importantly, the process worked seamlessly when it came to servicing customers. We also evaluated our transportation management system platform and decided to look for more robust solutions – offering real-time visibility – to manage cost and service. I consider it a success to reduce logistics costs in such an uncertain transportation marketplace. Moreover, we were able main-

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

MEET DAN DIGRAZIO Background: DiGrazio has more than 28 years of supply chain management experience. In addition to senior food company supply chain roles, he was president of Vector Transportation Services, a thirdparty logistics company. He also served for seven years as general manager for a Texas steel company. Education: B.S., Business Logistics, Penn State University; M.S., Commerce and Finance, Villanova University. FYI: DiGrazio belongs to the Council of Supply Chain Management Professionals and Food Shippers of America. He has served on the board of the Philadelphia TrafÀc Club and been a featured speaker at meetings sponsored by the International Association of Refrigerated Warehouses and public refrigerated warehouse suppliers.

tain high levels of customer service satisfaction. Q: What were your biggest challenges last year? DiGrazio: Transportation capacity was the challenge in 2010. During the second and third quarters, we saw a reduced number of trucks, shifting networks and pricing pressure. Our transportation procurement and operations group utilized TMS technology to solve the transportation issues to meet and exceed our operational goals. Q: What are a few warehousing goals for calendar 2011? DiGrazio: We will update our network model and study results to assure we service customers with product deployed at optimum locations. Meanwhile, we will emphasize cost containment in our managed third-party relationships. Q: How about a few 2011 transportation goals? DiGrazio: Butterball wants to better understand the costs associated with customer service. We want to ensure that we provide value and identify operational costs associated with business model rules. Our No. 1 goal is to implement a new, more robust TMS solution that will optimize modes of transportation. We expect this to further lower costs through efficient, effective optimization. Q: What will be the food industry’s critical logistics challenge in calendar 2011? DiGrazio: Carrier capacity. We’re watching various developments involving the Carrier Safety Administration, hours of service (pending legislation) and even electronic on-board recorders. Collectively, I believe we must find ways to be more time efficient, ensure quality service and capacity – all while offsetting costs.

A message for the North American food industry from the MEAT INDUSTRY HALL OF FAME

MEAT INDUSTRY HALL OF FAME announces Class of 2011 Plan now to join the industry’s leaders on November 1 at the Union League Club in Chicago for a special Induction Ceremony and Dinner honoring the outstanding careers and personal achievements of these distinguished gentlemen: r
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ProteinProblemSolvers

Kunzler bolsters food safety with new metal detectors FOR MORE THAN 100 YEARS, the one thing that has never changed at Kunzler & Co., a family owned processor of specialty meats, is its absolute dedication to producing the finest quality products. Kunzler produces more than 500 quality meat products, including hams, franks, bacon, luncheon meats and specialty items found across a multitude of retail, c-store and foodservice channels throughout the U.S. Because of the wide range of products of varying sizes, densities, moisture and salt content, metal detection can be a challenge for the company. “We considered metal detectors from two vendors and brought trial equipment from both into the plant for a side-by-side comparison,” said Rodney Shultz, facilities manager at Kunzler’s Tyrone, Pa., manufacturing plant. “Focused on food safety, we looked at detection sensitivity over our wide product range.” In the end, Kunzler installed three new PowerPhasePRO metal detectors from Mettler-Toledo Safeline. This installation was an extension of a relationship that began with Kunzler’s first detector purchased from the company in 2009. “Our sales rep … visited our plant and saw our production lines,” said Shultz. “He identified our challenges and anticipated our needs. He helped customize our first metal detector with a variable-speed drive that allows us to control the spacing and orientation of product running through the metal detector. The more consistently we feed the metal detector, the better the performance.” This custom detector, with an aperture 8 inches high and 17 inches wide, was installed on a line that packages 25 different products that range in size from 12 ounces to 11 pounds. The line speed varies from 20 to 70 feet per 114

minute, depending on the product being packaged. “It takes only 30 seconds [for detection changeovers],” explained Craig Dutrow, operations manager at the Tyrone facility. “We can either pull down a pre-programmed product recipe or we can auto-learn each product.” Detection sensitivity is increased (and false rejects are minimized) by an advanced coil and “Faraday Screen” design that filters out unwanted frequencies. Triple frequency operation allows Kunzler to achieve high sensitivity across its wide range of products, and the “product clustering” feature allows a family of products to be run with no operator intervention during

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

changeovers. Lastly, an IP36K-rated control panel allows the detector to exceed NEMA 4X specifications. In the Kunzler facility, the environment varies dramatically — from 36ºF to 38ºF during production shifts to soaring temperatures and high humidity during sanitation shifts — which the new equipment is designed to handle. “At Kunzler, our highest priority is assuring a wholesome, safe product for our customers,” added Dave Grazier, vice president and general manager. “The Safeline metal detectors have helped us achieve just that with perfectly reliable sensitivity and zero downtime. We’re very impressed.”

TechShowcase

Checkweigher Thermo Fisher offers its Thermo ScientiÀc Versa Rx checkweigher. Designed to replace the Thermo ScientiÀc AC9000plus Rx checkweigher, this system offers manufacturers higher accuracy at faster line speeds. With its new design, featuring upgraded electronics, the Versa Rx provides the highest level of accuracy and reliability in a checkweighing system. The Versa Rx’s accuracy and reliable reject performance is enabled by its effective slack belt knife edge conveyor design, which ensures maximum product stability. Thermo Fisher Scientific Inc.: (800) 227-8891 or visit www.thermoscientific.com/ checkweighers

Filler Handtmann’s new HVF Deli Series lower-volume conÀgurations have been developed especially for North American processors. The HVF 670-7 and HVF 670-11 versions join the HVF 670-16 to Get the free mobile app at http:/ / gettag.mobi deliver affordable, ultra-precise control of whole muscle stufÀng for local and regional processors seeking to effectively compete against national brands in today’s ultra-competitive environment. Precise weight accuracy for the lifecycle of the HVF equipment enables more efÀcient cooking and slicing and delivers a new level of production efÀciency. Handtmann Inc.: (847) 808-1100 or visit www.handtmann.com

Depositor NuTEC’s C-Frame Depositors have improved the way many processors deposit Àllings for stuffed sandwiches, multiple layered products, stuffed seafood, appetizers, and rolled or wrapped product. These portioning depositors provide excellent portion weight control and clean, accurate Àlling placement down the line. 45,000 deposits per hour are attainable on certain models. The C-Frame design of NuTEC’s Portioning Depositors enables the equipment to Àt right into existing production lines to deposit Àllings for numerous applications. NuTEC Mfg.: (815) 722-2800 or visit www.nutecmfg.com

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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TechShowcase

Pallet Lift Mepaco offers a solution to lost-time injuries with its ergonomically designed EZL2500 and EZ4000 Sanitary Lifts that offer relief to back strain and repetitive stress injuries. These Lifts are fabricated from T304 stainless steel and come with Mepaco’s unique pickle passivated sanitary Ànish. Both Lifts are designed to handle the harshest of washdown environments. The EZL2500 Sanitary Lift has a 2500-pound capacity, and the EZ4000 has a 4000-pound capacity. Mepaco: (920)356-9900 or visit www.mepaco.net

Vacuum Pump Busch has begun production of its new Dolphin LX B series liquid ring vacuum pumps. Offering improved pumping speeds at deeper vacuum levels, these high-efÀciency, single-stage pumps provide end vacuum levels comparable to most two-stage designs. All Dolphin LX series vacuum pumps are of a compact, motor-mounted design; ideal for a wide range of wet or corrosive applications. These rugged pumps are an economical alternative to traditional close-coupled, separate-drive or base-mounted liquid ring conÀgurations. Busch USA: (800) USA-PUMP or visit www.buschusa.com/ products/product-portfolio/ dolphin

Metal Detector The Phantom Pipeline Metal Detector is ideally suited for inline inspection of sausage meats that are transported through a pipe. Phantom Pipeline detectors are built rugged to withstand harsh production environments with Stainless Steel construction. Several material options are available for the non-metallic pipe including nylon, rubber, and TeÁon for the more demanding high temperature / pressure applications. Fortress Technology Inc.: (888) 220-8737 or visit www.fortresstechnology.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Foot Picker/Scalder Cantrell’s CSP-145 Foot Picker/Scalder completes any foot harvesting operation. The Cantrell Foot Picker/Scalder is available in 8-foot barrels with a capacity of 364 feet per minute and features an air operated top for easy access. New design in construction has improved water capturing capabilities to help reduce waste for a cleaner operation. The CSP-145 eight-foot barrel is powered by a 15 horse power electric motor. Cantrell: (800) 922-1232 or visit www.cantrell.com

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THE GLOBAL FOOD EQUIPMENT AND TECHNOLOGY SHOW™

NOVEMBER 1-4 2011 – CHICAGO Depackaging System The Dupps Co. has introduced the new Food Depackaging System, the Àrst product from its recently formed Green Technologies business group. The Food Depackaging System separates organic from non-organic materials, including packaging materials such as plastics and paper. The system has been speciÀcally engineered for turning food processing, supermarket and restaurant waste streams—and other food items suitable for recycling—into proÀtable, value-added product. The Dupps Co.: (937) 855-6555 or visit www.dupps.com

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©2011 FPSA

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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TechShowcase

Pallet Packaging Equipment The patented technology behind ITW Muller’s new Tail Tucker ensures that no loose Àlm tails occur on stretch wrapped pallets, meaning that pallets won’t come unraveled due to weather or handling. The Tail Tucker is available as an enhancement to the ITW Muller Octopus line of new stretch wrap equipment or as a retroÀt to most existing machines. It works by literally tucking the Àlm tail behind the last two full webs of Àlm. ITW Muller: (800) 628-6787 or visit www.itwmuller.com

Conveyor Belt Engineered with 70% open surface area, Wire Belt’s CompactGrid conveyor belt provides optimal performance in processes where product coating, drainage, and liquid or air circulation are factors. CompactGrid’s Áow through capabilities will reduce the time required to heat up or cool down a product, therefore reducing energy costs. Increased open area of the belt combined with its proven-to-be superior Áow-through characteristics enable easier and more thorough cleaning and sanitation of conveyor systems. Wire Belt Co.: (603) 644-2500 or visit www.wirebelt.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Ingredients Utilizing a proprietary process, Z Trim is created from either oat hull or corn bran to create powdered cellulose. Z Trim is unique among the category of cellulose ingredients due to its shortchain polymeric structure. This gives Z Trim a very smooth mouthfeel, easy dispersability and Áavor neutrality. The product can be used in the manufacture of sausage, frankfurters, patties, meatballs, whole muscle protein, marinade injections, coatings and more.

Online Training/ Testing

Z-Trim: (847) 549-6002 or visit www.ztrim.com

TPC Training Systems has released its eLearning test bank, TPC TestMaster Online. Free to all TPC Online clients, TPC TestMaster is a secure, online environment where tests can be created, assigned, and administered. Clients can tailor tests based to speciÀc job titles, training programs, and locations. These tests can contain questions from the TPC test bank or from those uploaded by the client. TPC Training Systems: (800) 837-8872 or visit www.tpctraining.com.

Lifter The pneumatically powered Famatec Friendly ergonomic manipulator from Haeco precisely counterbalances heavy loads to allow an operator to effortlessly suspend, rotate, tilt and transfer product with precision. Equipped with appropriate end-of-arm tooling, it is the ultimate “friend” for manipulating, transferring or installing product. Three different models offer load capacities of 330, 550 and 880 pounds, with a working radius of 20 feet. Haeco: (513) 722-1030 or visit www.haeco.us/materialhandling

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TechShowcase Supplier News 

Meyn-Ishida has just won its fourth major contract since its ofÀcial launch in January 2011. The project involves the delivery and installation of a complete wall-to-wall plant adjacent to the existing factory for Wipasz in Poland, and will be among the most valuable to be initiated in the European poultry processing industry this year. The Àrst task of Meyn-Ishida will be to replace the existing live bird arrival system and to upgrade the current bulk pack operation with advanced weighing and tray packing capabilities to enable it to produce a more sophisticated range of products. The next step will be to deliver and install Meyn-Ishida equipment for a completely new processing plant. Both steps will be accomplished during 2011-2013. “Our commitment to the poultry processing industry is demonstrated by our choice of state-of-the art technology that will put Wipasz on a level with Europe’s top producers” says Józef Wisniewski, CEO of Wipasz. Marel has announced several new hires. Will Sumner has joined the company as a product specialist – Meat and Poultry Harvesting. He will assist the sales teams in driving Marel’s meat and poultry harvesting equipment into the fresh meats, poultry and further processing plants in the United States and Canada. Additionally, he is responsible for recognizing opportunities for innovation in meat harvesting and is expected to communicate these innovation opportunities to the internal organization for possible development. David Hull has joined Marel Fresh Meats Division as Southwest territory sales manager. He will be responsible for developing new equipment and software sales and for serving Marel fresh meats customers in the Southwest region. Tom Rourke has joined Marel as the West Central Territory sales manager in the Fresh Meats Division. Rourke is responsible for developing new equipment and software sales and for serving Marel fresh meats customers in the West Central region (KS, NE, CO, SD, ND, MT & OR). 120

Unitherm Food Systems’ new, fully equipped kitchen is inviting European food processors to “kick the tires” on the latest cooking and freezing high-volume, high speed equipment options the company has to offer. Located just outside of London in Ashford, UK, the newly opened kitchen allows European food processors to test a variety of cooking and freezing options and to optimize the equipment and the process before they put down a penny. The facility houses a Micro Spiral Oven, the world’s smallest spiral oven measured by its 2m X 1.5 m footprint; equipment that can smoke a ham in a minute; infrared pasteurization equipment that in less than 60 seconds extends shelf-life by more than 30% compared to other methods; a Áame grill with the most ribbon burners in the industry that produce bar-marks for a Áame grilled appearance; and a newly released machine called the Tunnel of Fire that can Áame roast chicken in 30 seconds.

OCS Checkweighers conducted some major upgrades to its website, like the new online published training schedule and online registration form, making it easy to sign up for checkweigher training. In addition, the website goes international with Àve languages to choose from and an animated world map showing OCS’s ofÀces and distribution partners worldwide. Also available in several languages are the product brochures and success stories featuring well-known companies like Procter & Gamble. Additionally, users can take a virtual tour of major exhibitions, watch product videos and learn about OCS in general and the company’s latest news and events.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

Industry News

Food Safety Net Services has entered into a strategic partnership with AdvancePierre Foods to provide outsourced laboratory testing, consultation and general food safety programs. FSNS, a national network of laboratory, auditing and consulting services will provide AdvancePierre routine and non-routine testing. FSNS provides AdvancePierre with the technical expertise needed to ensure all products meet or exceed FDA, USDA and general food safety guidelines. Bill Toler, CEO of AdvancePierre Foods, stated, “Food safety has always been a top priority for AdvancePierre Foods, and we are proud of our excellent record. We are pleased to partner with FSNS to add an extra layer of support and testing above and beyond our current programs, providing even more conÀdence for our growing customer base.” Paratherm Corporation has recently announced that George Schreiber will Àll the role of General Manager, moving from his previous position as Food Industry Market Manager. Schreiber has more than 30 years of experience in the chemical and plastics industry with E.I. DuPont de Nemours. He has held roles in plant operations, market development and marketing.

The National Meat Association has scheduled a webinar, “Nutrition Labeling of Single-Ingredient Products,” for Wednesday, June 22. The objective of this 90-minute webinar is to provide participants guidance in complying with the Final Rule on “Nutrition Labeling of Single-Ingredient Products & Ground or Chopped Meat & Poultry,” which has an implementation date of January 1, 2012. The speaker will be Lamar Hendricks, a labeling expert and the former director of regulatory compliance for Sarah Lee Foods. The session is scheduled for 10:00am-11:30am PaciÀc on June 22. Registration for the webinar is $99 for NMA members and $149 for non-members. For more information, go to www.nmaonline.org.

SAFETY IF ONLY FOOD SY. WERE THIS EA

s concern. Hormel ination is a seriou ration. Deli meat contam ty in your ope ensure food safe

sandwiches

Vitiva has opened its new, key sales ofÀce in Southern Germany, in response to the growing regional market demand for Vitiva’s natural total food-protection and food-enhancement customized ingredient systems. Norbert Norbert Huber has taken the position Huber of Area Sales Manager and will lead Vitiva’s operation in Germany, Austria and part of Switzerland. “While Vitiva has enjoyed a strong presence in Germany, serving customers for a decade with its unique natural solutions, the new ofÀce will enable comprehensive and direct local service to the rapidly growing customer base,” says Ohad Cohen, CEO of Vitiva.

s solution. Foods has a seriou

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Hormel Foodservice has launched a comprehensive advertising campaign designed to inform and educate foodservice operators of the potential food safety risks associated with deli meats. In 2005, the company made a major investment in bringing High Pressure Pasteurization (HPP) equipment on site and named the proprietary technology TrueTaste Technology. Hormel Foods was the Àrst, and remains the only, company in the industry that oversees the HPP process directly on its own premises. Hormel Foodservice has set out to educate operators on deli meat contamination, and offer a solution – Hormel® Natural Choice® and Bread Ready® sliced deli meats, both of which undergo High Pressure Pastuerization. The food safety campaign includes impactful print and digital ads in industry publications. A food safety website, which includes a video demonstration of High Pressure Pasteurization, as well as links to additional resources, further emphasizes that Hormel Foodservice is committed to deli meat food safety. For more information, visit www. hormelfoodservice.com/foodsafety. JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

121

TechShowcase Kendall College announced the launch of a new bachelor’s degree program in foodservice management, focused on preparing graduates for careers in network-based, large scale institutional and corporate foodservice operations. The program, offered by Kendall’s School of Business, educates students in foodservice operations, logistics, procurement, nutrition, marketing, merchandising and retailing. The program prepares graduates for careers with food manufacturers, suppliers, nursing and residential care facilities, sports and entertainment service providers, educational services and schools, food marketing Àrms, and food retailers. “Today’s foodservice market is competitive, and an increasing number of employers prefer to hire graduates who have degrees in a related Àeld,” said Michelle Coussens, dean of the Kendall College School of Business. “At Kendall College, we have a long tradition of educating students in the Àelds of culinary arts, hospitality management and business. This innovative new business degree program leverages the strengths of our schools and provides students with a solid foundation to enter the growing and specialized areas of food production, retailing and distribution.”

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Read More TECH SHOWCASE 122

Meat Industry Hall of Fame Names Class of 2011 The Board of Trustees has announced that 12 new Members have been elected to the Meat Industry Hall of Fame. The Class of 2011 was chosen from a list of more than 60 nominees in voting last month by the Trustees and all the living Members of the Hall. The nominees included industry executives, scientists, innovators and association leaders from all sectors of the livestock, meatpacking and poultry processing industries. The members of the Class of 2011 include:

Alan Simon, Chairman and CEO, Omaha Steaks (retired)

Clarence Becker, President, Becker Food Co. (posthumous)

Dale Huffman, Ph.D. Professor and Researcher, Auburn University (retired)

Eldon Roth Founder, BPI Inc.

George Watts President, National Chicken Council (retired)

Jack Allen Professor Emeritus of Food Marketing, Michigan State University

John Bryan Former Board Chairman and CEO, Sara Lee Corp. (retired)

John Story Vice President of Meat Marketing, Fairway Foods (retired)

Manny Rosenthal Chairman Emeritus, Standard Meat Co. (posthumous)

Mel Salomon Chairman, Allen Brothers (retired)

Phil Clemens Chairman, Hatfield Quality Meats

Robert Madiera Executive Director, American Association of Meat Processors (posthumous) “This year’s class is representative of some of the industry’s true pioneers,” said Chuck Jolley, president and founder of the Hall of Fame. “Our Trustees and Members have chosen an elite group of leaders who have not only achieved remarkable business success but have spent their careers contributing to the progress of the entire industry. We are delighted to be able to honor this group, who truly represent the best of the best, both in business and in life.” “Over the years, I’ve had the privilege of interviewing virtually every one of our new Members,” said Dan Murphy, Hall of Fame Executive Director and a former industry trade magazine editor. “The Class of 2011 is a group of leaders who are outstanding examples of the innovation, integrity and service that characterize the values we cherish as Americans. They represent one of our nation’s fundamental industries and we’re proud to celebrate their accomplishments and their legacies.” The induction ceremony will take place on Nov. 1, 2011, at Chicago’s Union League Club. The dinner and presentation ceremony coincides with Process Expo, a Hall of Fame sponsor.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] CAREER OPPORTUNITY ®

“Specialists in Distinctive Deli Products” Charlie’s Pride Meats, a leader in Premium Deli Meats Since 1969, is looking for highly qualified direct Sales Representatives throughout the USA. The qualified candidates must have a minimum of ten years experience and are currently selling Roast Beef, Corned Beef and Pastrami Deli items. We offer a highly competitive salary and benefits package, and are recognized as providing exceptional Deli products at an excellent value from coast to coast. Contact us at: Toll Free (877-866-0992) | www.cpmhotline.com Or send your resume to [email protected]

TREIF USA, Inc. is a leader in manufacturing food cutting machines in meat, poultry and cheese. We are looking for a sales person(s) in capital investment goods for the USA. Qualifications: min. 5 years sales experience for processing equipment in the food industry. Highly motivated and professional sales drive. Excellent communication and customer service skills; who is willing to travel extensively. TREIF USA is a growing sales and service company offering an excellent benefit compensation package. For more information please go to: www.treif.com Interested candidates should forward their resume and compensation requirements to [email protected].

Regional Service Technician Amtrade Systems Inc., a Michigan based company, is looking for Service Technicians. We are a fast growing company serving the US food industry with Schroeter (German based manufacturer) smokehouses and equipment. We offer a position with an excellent opportunity for the right candidate possessing the following qualifications: · MS office (or similar) working knowledge · Experience in the food industry, smokehouse maintenance experience and / or smokehouse operation experience · Mechanical, pneumatic, electrical, and PLC hands-on experience · Willingness to travel extensively with short notice · Excellent communication skills within team environment and the ability to build customer relationships · Ability to understand and translate information from mechanical drawings and construct equipment to meet specifications

We are an equal opportunity employer

Kosher specialty shop in Hollywood, FL seeking

EUROPEAN TRAINED SAUSAGE MAKER with knowledge and training of Automated Linker. Must agree to formulate recipes for business. Salary & benefits. Steven Chase 561.632.7025/[email protected]

Robert Reiser & Co., Inc. stands out in the marketplace because we make it our goal to provide top-quality service by hiring top-quality employees who take pride in their own performance and enjoy working for an industry leader. If you have what it takes to be on the Reiser team, please review our open positions at www.reiser.com and www.provisioneronline.com

Please send resume to: ROBERT REISER & CO., INC Attn: HR Department 725 Dedham Street Canton, MA 02021 Fax (781) 821-1316 Email: [email protected]

WANTED Motivated Individuals or Agency to Sell our Equipment Line. If interested, please contact: Larry Wilson 662- 328-2750 [email protected]

RECRUITMENT

Interested? Please send your resume to: [email protected] www.amtrade-systems.com

RECRUITMENT

Night Mgr. (PC Steaks) .................................$70K Op.’s Mgr. (PC Steaks)..................................$75K Op.’s Mgr. (GB/Case Ready) ........................$65K Op.’s Mgr. (PC Steaks)..................................$75K QA Mgr. (Bf. Sl/Fab) ....................................$75K QA Mgr. (Sausage) .......................................$90K Asst. Mnt. Mgr (Bf Sl/Fab) ...........................$75K Safety Mgr. ....................................................$85K PM (Food Processing).................................$100K

Memphis 800-792-2474 Atlanta 800-562-1590 Atlanta 800-562-1590 California California866-909-6789 866-909-6789 Dallas 800-561-7568 Cincinnati 800-507-9423 Davenport 800-728-0363 Dallas 800-561-7568

Davenport 800-728-0363 Denver 800-354-8039 Denver 800-354-8039 Florida 941-412-8210 Kansas City941-412-8210 800-550-7980 Florida Memphis 800-792-2474 Kansas City 800-550-7980

Minneapolis 651-731-3211 Minneapolis 651-731-3211 Omaha 800-282-4975 Omaha 800-282-4975 Pittsburgh 866-318-0800 Pittsburgh 866-318-0800 Seattle 509-285-5657 Seattle 509-285-5657

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER NP0611BillBraggs.indd 1

5/19/11 1:40 PM 0610NP_AGRIAssociates.indd 1

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6/2/10 2:56:40 PM

To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] RECRUITMENT

FOR SALE

THE JUDGE GROUP Recruiting Excellence in the Beverage/Food manufacturing industry for over 35 years!! We can take your company and or your career where you want to go!!

*Handling both Contingency and Retained Searches* National Openings available including but not limited to: • Plant Management • Operations Supervisors and Managers • Maintenance and Engineering • Quality Control Supervisors and Managers • Sanitation Supervisor and Managers • Warehouse Supervisor and Managers • Engineering Project/Process/Management • Positions available at various levels!

Property and Warehouse For Sale USDA and HACCP Compliant Est #1439 -15,000 square foot cement block building on 7.5 acres. (Room for expansion) -Apprx 12,000 square feet of storage and 3,000 square feet of office space -The 12,000 square feet is cooler and freezer storage -Located in PA 4 miles from NYS border -Buffalo 2 hrs—Erie 2 hrs—Cleveland 4 hrs— Pittsburgh 3 hrs—Rochester 2 hrs -City sewage and all utilities available -Indoor truck parking for 4 vehicles -Low taxes—approx $2500 per year -Excellently Maintained Replacement Value $1,200,000 | Appraised $425,000 Selling $350,000 Whitehawk Beef Company (O’Jacks, Inc) 45 Railroad Ave | McKean County | Eldred, Pa 16731 1-814-225-4755 | fax: 1-814-225-4908 cell: 1-716-498-0065 (Steven Slavin)

To submit resumes or engage searches please contact: Kelly Meaney, Associate VP

Judge Inc. Tel: 904-435-1302 • Fax: 904-435-1303 [email protected] www.judgeinc.com

EQUIPMENT FOR SALE

BUSINESS FOR SALE

For Sale

Located in Central Indiana.

Retail butcher shop. Very profitable with sales exceeding $800,000. Owner retiring. Contact: Martin & Martin | 62 South 9th St. | Noblesville, IN 46060

EQUIPMENT FOR SALE

EQUIPMENT FOR SALE

Denman Equipment Partnership Equipment Liquidator & Locator

Meat Processing Equipment & Supplies Phone: 800-467-1201 • 402-597-5777 [email protected] www.mbasuppliers.com

Vemag LPG203 Link Processor

Slaughter Equipment Cutting & Boning Equipment Rendering Equipment Processing & Packing Equipment Packaging Materials / Containers Miscellaneous & Safety Supplies Consultation Repair Services Plant Design Mesh Aprons, Processing Gloves & Sleeves Equipment Equipment Appraisal Specializing in QUALITY NEW-USED-RECONDITIONED-REBUILT equipment for the food industry

124

60 gal tilt kettle (New)

VC999 Chamber Vacuum DP50E & DP100E • Toledo Exact 901-755-7135 Wrapping System Fax: 901-754-0105 • Grote Peppomatic www.denmanequipment.com • Weber CCS7000 Slicer e-mail: [email protected] • •

Place an ad in The National Provisioner Classified Network

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] EQUIPMENT FOR SALE

To advertise, call Diana Rotman at 847-405-4116

EPDM INFLATABLE DOOR SEALS,

JUNE 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

125

To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] EQUIPMENT FOR SALE

Wholesale Prices Used and Reconditioned Meat Dealers Welcome Processing Equipment from Europe

INJEKTOR 148 NEEDLES

KUTTER SEYDELMANN ALL SS 200 L loader unloader

011-52-722-213-6672 or 011-52-722-773-2337 | www.fleimatec.com | [email protected]

SLAUGHTER

Water Saving Washers SPECIAL SERVICES

Split Carcass Washers

Hide-on Carcass Washers

Head and Tongue Washers

Water Management Resources 800-552-5797 ~ www.watermr.com

126

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] EQUIPMENT FOR SALE

PARTIAL IN STOCK EQUIPMENT LIST * * * * * * * * * * * * * * * * * * * * * * * * * * * *

SEYDELMANN CS160 SELF FEEDING GRINDER ......................................... STOCK BUTCHER BOY 100 H.P. S.S. GRINDER ................................................... STOCK HOBART 4356 (500#) & 4266 (2000#) MIXER/GRINDERS ............................. STOCK KOCH ULTRAVAC 2100-A VAC. DOUBLE CHAMBER (12”).............................. STOCK GROTE 613VS MULTI SLICER ............................................................... STOCK 2- GLOBUS HSL 750 VAC. TUMBLER SYSTEMS ......................................... STOCK RMF POLAR 4000 VAC. COLD MASSAGER SYSTEM .................................... STOCK JACKETED KETTLES W/ADG, & SCRAPE 15O,250 &1000 GAL ........................ STOCK HANDTMANN VF20 W/ PORTION, LINK & LIFT .......................................... STOCK M-TEK GAS FLUSH VACUUM SEALER W/ 54” SEAL BARS ............................. STOCK HOLLYMATIC 865 MULTIFLOW PATTY MACHINE STOCK .............................. STOCK URSCHEL 5600 COMMUTROL,75 H.P. .................................................... STOCK MTC 5000# & METALCRAFT 2000 VAC. RIBBON BLENDERS ......................... STOCK REITZ 2000 # & 8000 # RIBBON BLENDERS.............................................. STOCK REITZ 2000# TWIN SCREW MIXER ........................................................ STOCK WOLFKING 1000# VACUUM PADDLE BLENDER W/CO2 ................................ STOCK APOLLO RANGER HOTDOG PEELER ....................................................... STOCK HANDTMANN FPVLH 242 PORTION / LINK / HANGING SYSTEM ...................... STOCK RYOWA RC 7800 SLICER W/BLADE SHARPENER ....................................... STOCK KILIA 175 LITRE S.S. BOWL CHOPPER W/ SWITCHGEAR ............................. STOCK KERRES 2 TRUCK ELECTRIC SMOKEHOUSE ............................................. STOCK ROSS 950-3 & THURN JR SLICING LINE .................................................. STOCK RISCO 5001 VAC. STUFFER W/ PORTION,LINK & LIFT ................................. STOCK VOTATER SS TWIN TUBE CONTHERM ON SS FRAME .................................. STOCK HINDS BOCK / UNIFILLER FILL SYSTEMS 1 TO 6 PISTON ............................. STOCK KASEL BH20-7 CONTINUOUS FEED SLICE-N-TACT,W/4 HARPSETS .................. STOCK ROBERTS 6000# VACUUM MASSAGER ................................................... STOCK DRAKE 2000 LINK LOADER W/ LOTS OF EXTRAS ....................................... STOCK

3262 Hwy. 76, Cottontown, TN 37048 (phone) 615.323.9127 (fax) 615.323.9128 (cell) 615-289-3029 Email: [email protected] Website: www.mrlindle.com $$ VERY INTERESTED IN YOUR SURPLUS EQUIPMENT $$ APPROX. 45 MINUTES FROM NASHVILLE, TN AIRPORT, INSPECTIONS WELCOME ...AND MUCH, MUCH MORE!!!

SPECIAL SERVICES

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To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] EQUIPMENT FOR SALE

BOILERS

FOOD SAFETY

Geor ge Lapsley Enterprises Food Safety Specialist www.getfoodhelp.net T: 267-221-2426

Repak Mdl. RE20/5 S.S. Rollstock Vacuum Packager

HACCP / SSOP / 3rd Party Audits E. coli, Lm, BSE Compliance Recall Technical Assistance USDA Assistance

SERVICES www.barliant.com email: [email protected] Ph (630) 553-6992 | Fax (630) 553-6908

PACKAGING

PLANT FOR SALE

PLANT FOR SALE Hog kill plant with processing facility for sale. The plant is located in the southeastern U.S. with several government incentives available to new owners. Call Scott 229-423-2093

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JUNE 2011

AdIndex Company

Page

Web site

AmTrade Systems, Inc.

3

www.amtrade-systems.com

Anritsu Industrial Solutions USA Inc

78

www.detectionperfection.com

AZZ/R-A-L/Rig-A-Lite

119

www.rigalite.com

Beacon, Inc.

100

www.beaconmetals.com

Bel-Ray Company Inc.

131

www.bel-ray.com

Bettcher Industries Inc.

97

www.bettcher.com

Biro Manufacturing Company

95

www.birosaw.com

Bridge Machine Company, Inc.

103

www.bridgeonline.com

Busch Vacuum Pumps and Systems

101

www.buschusa.com

Cog-Veyor Systems, Inc.

48

www.cog-veyor.com

CEM Corporation

21

www.cem.com

CSB-System International, Inc.

105

www.csb-system.com

Curwood Inc., A Bemis Company

67

www.curwood.com

DeWied International

63

www.deweid.com

Douglas Machines Corp.

110

www.dougmac.com

Eagle Product Inspection

37

www.eaglepi.com

Ecolab

47

www.ecolab.com

Eriez

109

www.eriez.com

EVAPCO, Inc.

49

www.evapco.com

Filtration Automation, Inc.

54

www.Àltrationautomation.com

Formax/Provisur Technologies

17

www.formaxinc.com

Fortress Technology Inc.

77

www.fortresstechnology.com

FOSS North America

106

www.foss.us/improve

FPEC, Food Processing Equipment Co.

41

www.fpec.com

Framarx / Waxstar

96

www.framarx.com

Fristam Pumps USA

5

www.fristam.com/fkl

Gleeson Constructors & Engineers LLC

82

www.gleesonllc.com

Grain Millers, Inc.

29

www.grainmillers.com

Grote Company

24

www.grotecompany.com

GPI USA

11

www.GPIglobal.com

Handtmann Inc.

2

www.handtmann.com

Hawkins Inc.

31

www.hawkinsinc.com

Henry & Sons Inc.

16

www.dhenryandsons.com

Ingredients Solutions, Inc.

74

www.IngredientsSolutions.com

James V. Hurson Associates Inc.

80

www.hurson.com

JBT FoodTech

45

www.jbtfoodtech.com

Kemin

27

www.kemin.com/foods

Marel

51, 81

www.marel.com

AdIndex Company

Page

Web site

Marlen International

22, 43

www.marlen.com

Master Grade

75

www.mastergradesharpener.com

Meat Industry Hall Of Fame

113

www.meatindustryhalloffame.com

Meat Processing Xchange

111

http://www.mp-xchange.com/

Mettler-Toledo Safeline

52

www.mt.com/pi

Multisorb Technologies

79

www.multisorb.com/maplox

NDC Infrared Engineering Inc.

91

www.ndcinfrared.com/meat

Niagara Tying Service, Inc.

60

www.niagaratyingservice.com

OSI

9, 69

www.OSIGroup.com

OSSID

73

www.OssidIntegrity.com

Packaging Progressions, Inc.

50, 93

www.pacproinc.com

Patty Paper Inc.

8

www.pattypaper.com

PDQ Plastics, Inc

72

www.pdqplastics.com

PÀzer Animal Health

71

www.SRPEcoli.com

Pack Expo

89

www.packexpo.com/food

PolyConversions, Inc.

19

www.PolyCoUSA.com

Process Expo

117

www.myprocessexpo.com

Purac

23

www.purac.com/meatandpoultry

Quickdraft

30

www.quickdraft.com

Reiser

7, 53, 61

www.reiser.com

Rochester Midland Corporation

25

www.rochestermidland.com

Select Technologies

39

www.select-technologies.com

Thermo Fisher ScientiÀc

55, 83

www.thermoscientiÀc.com

Treif USA, Inc.

86, 87

www.treif.com

Water Management Resources

15

www.watermr.com

Weber Inc.

33

www.weberslicer.com

West Liberty Foods

12, 13

www.wlfoods.com

Wire Belt Company

65

www.wirebelt.com

World Technology Ingredients

132

www.wtiinc.com

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PUBLISHER

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