The National Provisioner September 2011

Author: Andy Hanacek

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SPECIAL REPORT

Formulation Strategies 22 | Health and quality of key concern.

26

COVER STORY

A Smithfield education Smithﬁeld Foods takes a proactive approach to showing the public the truth about how it does business, from farm to plate and beyond.

14 | Fight for Food Safety: Don’t give regulators a bone to pick 12 | Regulations & Legislation: Third-party ground beef testing

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U.S. Meat Export Federation economist Erin Daley Borror discusses export data from the ﬁrst ﬁve months of 2011.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

SPECIAL REPORT

Injection and Marination 38 | Meat products enhanced through an injection process can have better taste and shelf life.

Departments Editor’s Journal ............ 8 New Products ................ 16 Process Expo Proﬁles.......87 Tech Showcase.................96 Classiﬁeds ......................106 Ad Index.........................114

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September 2011

Tech

Volume 225 Issue 9

Editorial Board

eb

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

Dan Emery Meaningful Solutions

WORKER SAFETY | 48

Safety is everyone’s responsibility

John E. Johnson

Superior Farms employees have a vested interest in a safe workplace.

JBS

CONTRIBUTING THIS MONTH Leigh Ann Johnston Tyson Foods Huston Keith

SUSTAINABILITY COLUMN

PROCESSING TECH

PACKAGING TECH

70 | Protein

84 | The expecta-

74 | Leigh Ann

processors are taking the “waste” out of wastewater more efﬁciently.

tions of sustainability in packaging have changed, says Chip Bolton, our newest expert columnist.

Johnston offers tips on the development of a sustainability program.

Keymark Associates

Lynn Knipe Ohio State University

Gary McMurray Georgia Tech Research Institute

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Kurt Vogel University of Wisconsin - River Falls

“Our new Vemag stuffer performs exactly as promised.” “At Maglio Sausage Company, we make a variety of sausage products – each with a very distinct look, bite and taste that our customers have enjoyed since 1947. When it was time to upgrade and automate our production line, we decided to look at Reiser and Vemag. We knew Reiser was well-respected throughout the industry and found them to be a company built on integrity. We were pleasantly surprised at the performance of the Vemag Stuffer during our tests. The Vemag was the only system that could consistently replicate the same look, bite and taste of our existing products. “With the Vemag stuffer, inline grinder, linker and link cutter, we now have the flexibility and reliability we need from our equipment. We’ve also discovered Reiser’s service and support to be second to none. For Maglio Sausage, partnering with Reiser has been a very pleasant experience.” Anthony L. Maglio Maglio Sausage Company, Philadelphia, PA

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Editor’sJournal

Engage the consumer

I

’m a big fan of two things. Well, I’m a fan of many others, but these two are pertinent to this month’s discussion, so I’ll limit myself. First, you listen to your customers. In any business, without them, there is no business. For the meat and poultry industry, it’s a little different in that there are customers and consumers, both of whose demands need to be heard. Second, as some of you know from my visits to your facilities and our off-the-cuff chats, I’m a big fan of Flat Iron steaks. We all should know the Flat Iron by now, so I don’t think I need to go into the history and attributes

of the cut. This leads me to my issue — as a consumer. My local supermarket’s meat department has disappointed me yet again. About a year ago, the meat department began selling Flat Iron steaks for a very reasonable price. I was thrilled, but concerned, as there was little information or reason for anyone NOT familiar with the cut to pick it up. So I stocked up whenever I shopped, and good thing, as over the last month or two, the Flat Irons have disappeared. This having happened before with other products, I decided to speak to the butcher. She said she would be happy to order some for me, but I was disappointed to hear her say she had not tried the Flat Iron. I advised her to try it, and then sample the product and show my fellow shoppers how to cook it. I was certain, I told her, that Flat Irons would sell if these working- and middle-class folks knew what it was and what to do with it. She promised she would try the cut next time, but I don’t have high hopes for the sampling and educational concept. I’ve never seen this supermarket do it, but any time I’ve seen it in other stores, customers are snapping up whatever samples are being offered (and often buying the product immediately afterward). My supermarket meat department has taken out other products that my family and I have come to love in the past, I can only guess because they didn’t meet sales expectations. A simple solution might be better engagement with the customers. Shoppers are “afraid” of approaching the butcher nowadays (if the butcher is even visible and not in the backroom) — they need to be “enticed” to try something and talk to someone about it. We all know how great these products taste, so why not enthusiastically sell that very thing? Coupled with a little bit of education in this “Food Channel” world we now live in, maybe products would stand a better chance of making it in different markets. If supermarkets won’t engage shoppers, meat and poultry processors should step up and take the reins. A little personal interaction with shoppers has to go a longer way than a simple coupon stack next to the product or in the Sunday paper. And I’d be first in line to stump for the Flat Iron.

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Regulations&Legislation

Prepare for more, not less, third-party ground beef testing By Dennis Johnson

T

he sampling of raw ground beef for E. coli O157:H7 at customer locations has become a fact of life. Beyond FSIS sampling of previously inspected ground beef being reground at inspected establishments, there are increasing “third-party testing” activities. These include state governmental samples of raw ground beef that has left the official establishment and customer sampling of incoming product as part of verification activities. Since even the very best establishment can have isolated contamination, the increased sampling may result in positive E. coli O157:H7 findings. If there is a positive finding, FSIS will consider whether a recall of all product implicated by the sample is appropriate, including product shipped to other locations.

In the case of third-party testing, FSIS will use the criteria in Directive 10,000.1 to determine whether the positive E. coli O157:H7 result is valid. If so, a recall could occur. This year there has already been one recall based on a customer’s downstream test and another based on a state’s test of product reground at retail. Accordingly, establishments selling raw ground beef should take action now to minimize the scope of product potentially implicated by such samples; in addition to all the steps they are currently taking to minimize the presence of the pathogen. In determining product implicated, FSIS looks to: common source (same lot of raw materials used in a positive batch that were also used in other batches) and cross-contamination (contamination of product contact surfaces). To limit product implicated, the establishment should control use of raw materials and develop support to subdivide a production day. On control of raw materials, the focus should be on minimizing the number of lots in each batch that are covered by different certificates of analysis. In addition to minimizing the numbers of batches a lot is used in, care should be taken to avoid carrying over combos from the lot of raw material (or rework) to the next day. One note, if the raw material has been treated with a validated antimicrobial, such as boneless lean beef from trimmings, use of these raw materials in multiple batches does not automatically link the batches. To subdivide the production day so that the time period is less than clean-up to clean-up, FSIS requires “microbiological independence between lots.” The best way to support independence is to conduct robust finished raw ground beef testing (samples drawn every 15-30 minutes, compositing

12

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

into 1-2 hour lots). If routine robust sampling is not viable, an establishment may still be able to generate data to permit the microbiological independence of batches. Since 2002, various scientific publications and journals, such as Microorganisms in Food 7, have discussed the “comet effect;” that E. coli O157:H7 contamination will clean itself out of a grinder. Newer studies awaiting publication further support the comet effect. Although FSIS has recognized the comet effect, FSIS will soon require in-plant data to support the application of the comet effect to an establishment’s particular grinding system; specifically, that the system will clean out contamination. This data gathering need not be excessively onerous. Together with a laboratory, the establishment can conduct a simple study. First, take raw materials and inoculate with a marker (askFSIS lists recognized surrogates). Run the inoculated raw materials through the system followed by normal raw materials. By robustly testing the finished product, an establishment would be able to determine, in terms of production, how long it took to totally clear the contamination from the system. This data would be used to demonstrate when the system would clean itself out, thereby establishing a buffer around any batch testing positive in a third-party test. We predict more, not less, third-party testing of raw ground beef. The prudent establishment would take action to minimize the product implicated. 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.

FightforFood Safety

Don’t give regulators a bone to pick By Shawn K. Stevens

G

enerally speaking, there are three types of hazards in a food-processing facility. They are physical, chemical and biological. A physical hazard is any extraneous object or foreign matter in a food item which may cause illness or injury to a person consuming the product. These foreign objects include, but are not limited to bones, metal fragments, plastics, stones, glass or personal items. Each year, companies across the nation are subjected to the stress and expense of recalls as a result of foreign materials finding their way into food products. The institution of effective interventions can greatly reduce the risk of the severe regulatory and civil pitfalls, which can result if foreign objects find their way into your products. Avoidance is not only important in terms of consumer safety, but can also do devastating damage to your brand through the publicity associated with recalls and injuries. Avoiding these incidents requires a frank, careful analysis of a company’s programs. Start by asking:What potential physical hazards exist within our products? Where might they come from? In the event that hazards are introduced, how can we ensure their removal? Each food product or processing facility faces its own set of unique risks and dangers. Once identified, these risks can be addressed through additional preventative measures, or by simply refining your existing Hazard Analysis Critical Control (HACCP) program. In many cases, the most effective measures are also the easiest. Metal-detection equipment, while costly, can ensure that your products are free of potentially dangerous metal shavings or other objects which can enter the food not only in your own establishment but in those of upstream suppliers as well.Working to keep contami-

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

nants off the processing floor is often as simple as ensuring that employees wear appropriate clothing and also keep personal items out of production areas. Physical hazards, unlike chemical or biological hazards, are unique in that their affects are unlikely to be widespread. Nonetheless, it is estimated that 8 in 10 injuries associated with foreign object contamination occur in children. Thus, even a single episode can have a lasting impact on the perceived safety and quality of a company’s products. Careful analysis, inspection and planning can help to ensure that, with respect to foreign contaminants or objects, no customer or regulator will ever have a bone to pick with the safety of your products. 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 food-product recalls. Additional information about his practice can be found at www.defendingfoodsafety.com.

Underneath it all—clean. When it comes to food safety, no detail is too small—and every surface matters. That’s why for over a century, dairies and food processors around the world have trusted Diversey to deliver the cleaning, sanitation, and hygiene solutions they need. We’re creating safer handling procedures and spotless facilities to help our customers focus on what they do best. We’re Diversey, and we’re leading the world toward a cleaner, healthier future. Learn more at www.diversey.com or call 1-800-233-1000.

NewProducts National Steak and Poultry launches new center-of-the-plate items

AFA Foods reformulates, reintroduces frozen patty line

National Steak and Poultry introduces a new line of cash-andcarry products under the brand name Steakhouse CertiÀed. The line consists of seven new items including beef, chicken and pork for the center of the plate. Each item is packaged with the consumer in mind; bright, colorful labels including product pictures; convenient dinner portions and seethrough packaging. The new cash & carry line is targeted for consumers and part of the more-than-adecade-old Steakhouse CertiÀed brand that is well-established in the foodservice marketplace. The seven new items are a 7-ounce NY Strip Loin Steak with Savory Flavor, Asian BBQ Áavor or Steakhouse Peppercorn Áavor; a 10-ounce Boneless Beef Ribeye Steak, a 5-ounce Bacon Wrapped Sirloin Filet, a 6-ounce Boneless Beef Sirloin Steak, and a 6-ounce Chipotle Adobo Flavored Pork Loin Chop. Each portion is individually vacuum sealed to maximize shelf life. These consistently sized portions are presented in bright and colorfully labeled boxes which include product pictures and nutritional information.

AFA Foods has heeded its consumers’ calls for affordable beef burgers with the launch of MILLER Frozen Beef Patties. MILLER Frozen Patties have been reformulated, and each quarter-pound patty features quality beef blended with soy and special seasonings, that has been individually quickfrozen and packed in gusseted bags MILLER Frozen Beef Patties are now available in select grocery retailers nationwide. They come in 48-oz. packages and are sold for a suggested retail price of $6.99.

www.nationalsteak.com

www.afafoods.com

Oscar Mayer Sandwich Combinations give consumers another lunch option

Jimmy Dean launches mini turkey sausage breakfast sandwiches

Oscar Mayer announces the launch of its new line, Sandwich Combinations. With a fresh tasting deli sandwich, crunchy side such as Wheat Thins Crackers and sweet dessert such as Jell-O Sugar Free Mousse Temptation, this new lunchtime option is geared toward the professional on the go. Sandwiches are made with Oscar Mayer Deli Fresh turkey, chicken, or ham, Kraft 2% Milk Reduced Fat Natural Cheese, and served on a multi-grain thin sandwich bun, which is made with 8g of whole grain per serving. Oscar Mayer Sandwich Combinations are available in three varieties: Oven Roasted Turkey & Sharp Cheddar, Southwestern Style Chicken & Sharp Cheddar, Honey Ham & Swiss Cheese.

In time for the busy back-to-school season, when mornings are more hurried and hectic, Jimmy Dean introduces a new addition to its lineup of Jimmy D’s breakfasts — Jimmy D’s Minis. Jimmy D’s Minis are an excellent source of protein, featuring hearty turkey sausage on a mini croissant, and they are microwaveable and ready to eat in less than two minutes. Two mini sandwiches make up one serving of Jimmy D’s Minis, which are packaged eight mini sandwiches per carton.

www.oscarmayer.com

www.jimmydean.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

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Ingredients&Formulations

Including nutrition By Donna Berry

s a parent of a picky eater, I have been secretly adding all types of veggies to my “famous” meatballs. When they are covered with red sauce and served with pasta, the spinach is barely detectable! But hiding nutrition is not the trend I am going to discuss; rather, it is the touting of the extras being added to prepared proteins that give the product an edge in the crowded marketplace. In adding everything from caramelized onions to smoked Gouda cheese to their products, gourmet burger, sausage and meatball formulators are getting creative through the inclusion of ingredients that add value in terms of eye appeal, flavor and often a touch of nutrition. I am not talking veggie burgers, rather the incorporation of fruits, vegetables and cheeses into red meat and poultry.This is not a new idea, but the ingredient selection and execution has definitely evolved from the pickle and pimento loaf that reached its peak in popularity during the first Great Depression.

A

One of the original players is Aidells Sausage Co., a 25-year-old gourmet sausage company that was recently acquired by Sara Lee Corp. The company is known for chicken sausage flavors such as Spinach & Feta, Artichoke & Garlic, and SunDried Tomato with Mozzarella Cheese, with all of them containing detectable bits and pieces of the characterizing flavors. Aidells also makes Teriyaki Pineapple Meatballs with real pineapple chunks. And Sabatino’s has a 180-calorie fully cooked Chicken, Spinach & White Cheddar Burger that is to die for. Kayem Foods Inc. created a chorizo sausage that puts the bodega butcher to shame. New al fresco Chipotle Chorizo with Mango is made from skinless chicken meat blended with chipotle peppers and 18

diced mango in a smoky adobo sauce. The chorizo joins other chicken sausage favorites such as Sweet Apple, Roasted Pepper & Asiago, and Sweet Italian. According to the company, the fully cooked sausages contain no artificial ingredients, have 70% less fat than traditional pork sausage and are gluten free. Not all such products are fully cooked. For example, Koch’s Turkey Farm LLC developed All-Natural Cranberry Turkey Burgers, which consist of turkey and diced dry cranberries. Sold frozen, these burgers require proper cooking. Because many of these products are based on poultry, this gives them a healthful edge to red meat products. The valueadded flavorful ingredients also often contribute to an improved nutrition profile

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Photos courtesy of Mintel

by reducing fat and calorie content. In particular, fruits and vegetables can displace fat, as well as reduce the need for added sugars and acidulants, which are often added to such comminuted foods for moistness and to round out the salt and protein flavors. The difference between these packaged products and the fresh items sold at the butcher counter, such as readyto-bake meatloaves stuffed with veggie and cheese combinations, or flattened steaks or chicken breasts rolled with a colorful garden of chopped produce, is that the fruits, vegetables and cheeses are selected specifically for this application. It’s not as easy as walking to the produce department and chopping up some fresh spinach leaves.

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Ingredients&Formulations Suppliers offer fruits and vegetables that have been blanched, to retain color and integrity, as well as products that are individually quick-frozen in a manner to control free moisture. The latter eliminates excess water, which improves integrity in fresh, frozen and refrigerated applications. Such products can also be treated to various culinary cooking techniques prior to freezing.This includes caramelizing, fireroasting and grilling. Such cooking steps add flavor as well as color, as the sugars in the fruit and vegetable pieces can participate in the Maillard reaction, with the end result being charring or browning, as well as authentic grill marks.These cooking techniques, coupled with the addition of flavorful herbs and spices, often contribute flavor profiles that allow formulators to reduce added salt, which can positively improve the information on the nutrition panel. Cheese also complements many of these gourmet meat products. And similar to how fresh produce is not the best choice for a prepared and packaged product, nor is cheese right from the case.

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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.

When functionality such as moisture content and melt needs to be controlled, as in the application of cheese to multi-component meat products, process cheese is often your best choice.The term “process cheese” represents a range of products with specific standards and allowable ingredients. Simply, process cheeses start out by blending a minimum amount of specified natural cheese with other ingredients including those with emulsifying properties, followed by a high-heat treatment. There are a variety of other ingredients and processes that can be included, depending on desired end product, which is usually a smooth cheese with varying levels of melt and firmness. Almost any natural cheese can be made into a comparable process version.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

There are, however, some lowermoisture natural cheeses that have been successfully added to meat products. For example, Gorgonzola, which is a type of blue cheese, has a sharp, salty flavor profile. Its smell is pungent, its texture crumbly and a little goes a long way. Most cheeses in the blue family take a longer time to melt than other natural cheeses, and the melt is slightly grainy, making them a natural complement to many value-added prepared proteins. The same is true for hard cheeses, such as Asiago, Parmesan and Romano, which are extremely low in moisture (less than 3%) and do not readily melt and run out of the protein when it is cooked. Feta and some Mozzarella cheeses also tend to be slower melt cheeses that do not run. Because an infinite number of ingredient combinations exist to add eye appeal, flavor and nutrition to your gourmet protein, this category of prepared meat products is likely to continue to boom in the next few years. Maybe I should get into the meatball business.

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New launch activity in ready-meals category addresses nutrition and quality trends. By Olivia Sant’ Angelo, Innova Market Insights The global market for ready meals is estimated to be worth between $50 billion and $75 billion a year, according to definition and the types of product included. The largest markets are, perhaps not surprisingly, in North America and Europe, which combine to account for three-quarters of sales value. However, the Asian market is also now quite substantial and showing generally much higher growth rates than the developed markets in the West. Although frozen foods make up the largest part of the market in countries such as the U.S. and Germany, chilled meals have emerged as a major force to be reckoned with over the past 25 years or so, as chill-chain distribution has developed internationally. There is also a significant market for canned and ambient lines in some countries. The U.S. has not only the largest readymeals market in the world in value terms, reflecting both population size and the 22

highly developed state of the processed and convenience-foods market, but also one of the highest per-capita consumption levels, at more than 22 pounds. The UK ranks just behind the U.S. in ready-meals per-capita consumption terms, at just under 22 pounds, but market value is obviously much lower, reflecting the smaller population size, and the market structure is considerably different. The UK ready-meals market is now dominated by chilled meals, where sales are more than three times those in the frozen market. Moving to continental Europe, the market for ready meals tends to be much less developed, with chilled meals generally much less significant and many countries still having large and well-developed canned and ambient meal markets, particularly France and Spain. Innova Market Insights recorded a 4% rise in global launch numbers in the ready-meals category in the 12 months

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

to the end of June 2011, although the total includes a wide range of prepared foods not necessarily regarded as ready meals in all cases. Pasta and noodle products accounted for the largest number of introductions, with prepared lines alone accounting for over one-fifth of total launches. Rice products were also popular, with 13% of the total, just ahead of main dishes with just over 10%. As might be expected, Europe had the largest number of ready-meals launches overall, reflecting the large number of countries and cuisines and the relatively highly developed convenience-foods market. Overall, Europe accounted for more than half of total ready-meals introductions recorded over the 12-month period, with Western Europe taking the vast majority of that. The diverse, dynamic and highly fashion-conscious Asian market accounted for

about 18%, just ahead of North America with 15%. A review of global launch activity recorded on Innova Market Insights over the 12 months to mid-2011 highlights key product trends, including ongoing interest in healthy options, more authentic-style ethnic recipes, more emphasis on natural, organic and locally sourced ingredients, and more interest in restaurant-quality products for in-home dining or home entertaining as an alternative to eating out. Convenience obviously continues to be the key platform, used by 80% of ready-meals launches recorded in the 12 months to the end of June 2011, yet nearly 38% of launches also used a health positioning of some kind. Particularly common were passive health claims (i.e.,“food minus”), such as low-calorie, natural, organic, etc., but also more active claims, such as vitamin- and mineral-fortified, added-calcium or with omega-3/DHA, or perhaps offering specific health benefits such as immune health, heart health, digestive health, etc. Rising interest in “naturalness” has been a feature of the food and drinks market as a whole in recent years, although it is much more challenging in some product sectors than others. Ready meals, with a highly processed image, might be seen to be a good example of this, although recent launch activity appears to indicate that it has taken on the challenge, with more than 17% of global launches marketed as being additive- and/or preservative-free and nearly 5% as natural, meaning more than one-fifth of total ready-meals launches were positioned as additive-/preservative-free, natural or both. This compares with more than 11% of launches positioned as vegetarian, 9% as ethical, nearly 8% as low-fat or low-calorie or both, and just under 7% as organic. The majority of launches on a vegetarian platform are in Europe, particularly Western Europe, with its share several percentage points ahead of its share of ready-meals launches as a whole. This was also the case for Asia, where more than one-fifth of launches recorded were positioned specifically on a vegetarian platform, while in the U.S. the converse was true, with just 10% of launches on a vegetarian platform, behind its share in ready-meals launches as a whole.

Poultry was generally the most popular meat-based ingredient in ready meals, ahead of beef, and there has been ongoing activity across a whole range of formats and types, with a strong focus on ethnic lines, hand-held products and bowl meals. Microwave options continue to dominate, with popular new options including frozen steamer meals, such as ConAgra’s Marie Callender Flavor Steamer range

SEPTEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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FormulationStrategies designed specifically for steam-cooking in the microwave in five minutes or less using ConAgra’s proprietary tray-intray packs. The range includes Sesame Chicken, Chicken Teriyaki and Chicken Stir Fry with Vegetables. Marie Callender’s Home Style Creations line also uses innovative technology, designed with a built-in-strainer for cooking pasta in the microwave before mixing with sauces. Heinz, meanwhile, has been developing its frozen microwave breakfast line under the WeightWatchers Smart Ones branding, featuring reduced-fat and reduced-calorie options of traditional breakfast favorites, such as Stuffed Breakfast Sandwich, Ham & Cheese Scramble and English Muffin Sandwich. Rising interest in premium, superpremium and restaurant-quality meals has also been evident in the market, particularly in the more developed processed food markets in North America, Europe and Austral-Asia. However, in terms of

Figure 1 Top Positioning Categories for Tracked New U.S. Ready Meal Launches (Jan-Jun 2011)

Positioning Category No Additives/Preservatives Natural Allergy Free Traditional

Count (%) 23.5 16.0 16.0 15.5

Source: Innova Market Insights

launch activity, this has been less clearly visible in terms of product positioning globally, with just 4% of total launches positioned on a premium or indulgence platform, rising to nearer 8% for markets such as the U.S. and Australia. This relatively low level may simply indicate a focus on offering higher quality and more authenticity in standard lines, however. Despite difficulties in some parts of the market, product activity in ready meals seems to be continuing unabated in the

face of continuing demand for convenient meal solutions among time-pressed consumers. The downturn in consumer spending in many countries and increasing concerns over the health aspects of convenience foods may have a negative effect on the market in some countries over the next few years. Nonetheless, overall the market is well placed to take advantage of consumers cutting back on eating out and take-out, moving rather to a range of in-home options, including individual portion meals, family packs and upmarket options for in-home special meals and even informal entertaining. The author,Olivia Sant’Angelo,is a market analyst at Innova Market Insights,(www.innovadatabase.com) a leading supplier of new product and trend information in the food and beverage space.Innova Market Insights is organized by food industry professionals to rapidly record new product activity and identify the trends driving the industry today and in the future.For more information,contact [email protected].

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CoverStory

A SMITHFIELD

education

26

Dennis Treacy, senior vice president, corporate affairs, and chief sustainability ofÀcer for SmithÀeld Foods, and Don Butler, director of government relations and public affairs for Murphy-Brown. THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Smithﬁeld Foods takes a proactive approach to showing the public the truth about how it does business, from farm to plate and beyond. Story and corporate photos by Andy Hanacek, editor-in-chief Farm and ﬁeld photos courtesy of Smithﬁeld Foods o describe the interactions between the meat and poultry industry, activist groups and consumer media over the last few decades as “apprehensive” and “antagonistic” would be a kind gesture. The public side of the relationship has featured suspicion, overemphasis on bad-apple examples and often biased, misleading claims made by activists against the industry. It has been a dysfunctional existence built around mistrust and the ability of the loudest voices to get the most publicity. On the industry’s side of the equation, its own response, for a very long time, had been to shutter itself behind closed doors and react only when attacked. “[Many people thought], ‘If our procedures are working and we believe we’re doing the right thing, then let’s defend that,’” explains Dennis Treacy, senior vice president, corporate affairs, and chief sustainability officer for Smithfield Foods. “Well, that doesn’t work anymore.” Indeed, some protein processors are coming out of their shells and exploring new ways to inform the masses about their business. Just as companies want to be nimble in their operations from farm to fork, these processors have a level of flexibility in dealing with new media, from video to social media such as Twitter, Facebook, etc. Smithfield Foods — which had been attacked repeatedly through a variety of books, stories, movies and videos — realized this nearly a decade ago, transitioning itself to become a more transparent, more informative member of the new media conversation.

T

SEPTEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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CoverStory “Ag for years has been of the opinion that we need to educate city folks, and I’ve slowly but surely determined over the last 10 years that that is almost tilting at windmills,” Treacy says. “We’re not going to be able to get children that live in New York City to come to the farm; we’re not going to get kids in Seattle to understand that it’s OK to raise animals to eat.” “But what we do have with social media, YouTube and the Web is the ability to show the world what we do, not with the intent that they need a lecture and need to be educated, but with the intent of opening the doors,” he adds. Instead of joining conversations, Smithfield now starts many of them, using these new media vehicles to offer information to those who want it. “It gives us the opportunity to have two-way, real-time communication, which is different,” explains Don Butler, director of government relations and public affairs for Murphy-Brown, Smithfield Foods’ independent hogproduction company. “That’s a gamechanger.” Smithfield answers questions, concerns and complaints about practices and products, quickly and with honesty. “The majority of the calls are that they had heard something, and they’re mad about it,” he says. “They call up to chew me out about it, but almost always, I’m able to engage them, ask if we can have a two-way conversation, and those calls almost always end well.” Seeing is believing An approach focusing on individual attention to emails and phone calls has always worked well, Treacy says, but to really make an impact, Smithfield needed something more. “There are more than 300 million people in the United States, so when we get a call from a person who is not happy and we call them back, … we know they’re going to feel better about it and maybe tell 10 people about something that they learned,” he 28

Requests from SmithÀeld Foods’ customers spurred the company to embark upon an initiative to convert its entire sow housing to a group format, and SmithÀeld is well on its way through that transition.

When the quality of waterways was under question in the communities where SmithÀeld operates, SmithÀeld decided to test the water on a regular basis and publish the results with an independent third party.

explains. “But we need a better way; we need a way to reach a lot more people. The people who make books, movies and videos are reaching for the masses, and they tell one side of a story.” The answer was to create a more dynamic, wider-ranging media offering that could be accessed by anyone, who could then formulate their own opinions based on information from both sides of the coin. “We could provide objective evidence to customers or shareholders [on our processes and results] — people who really wanted to see factual information. But we didn’t really have a way to communicate that to people who were merely curious,” Butler says. “When you’re one-on-one with someone on the phone, it’s really not hard to convince them [of how] it is. But you can’t take the whole world through a farm.” So, a couple years ago, Butler approached Treacy with the idea to

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM SEPTEMBER 2011

create a video series called, “Taking the Mystery out of Pork Production,” which would show the entire hogproduction process at Murphy-Brown and be posted online. The project was quickly approved and fully supported by Smithfield and Murphy-Brown executives. In just more than a year, the entire video series was scripted (though none of the answers were scripted, Butler points out), shot, edited and produced, and it made its debut on YouTube, SchoolTube and the MurphyBrown Web site in March 2011. Butler says he wanted the video to have a realistic feel to it, rather than have it look as though actors were delivering scripted answers to easy questions. “We interviewed and filmed real contract growers and people who make real feed and drive real trucks — people I work with every day,” Butler explains. “We found out Temple Grandin was going to be in North Carolina at another event, so I called her up and

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CoverStory asked if we could come and talk to her on video for this series — I didn’t write a script for her either.” At presstime, the seven-part series had racked up more than 2,800 views (totaling the views of all parts) on SchoolTube, and nearly 26,000 views on YouTube in just under six months. Change as a catalyst Smithfield has an open, meaningful dialog with its customers — retailers and foodservice operators — and that will continue down the road. “They’re interested in educated answers and knowing the facts [about Smithfield’s sustainability programs],” Treacy says. “They’re also interested in people’s impressions of the industry, protecting their brand and making sure they’re not supporting a company that does bad things.” One current initiative brought about by an open dialog with customers was Smithfield’s decision to convert its farms to facilitate group sow housing. “It wasn’t consumer pressure or activist pressure — there was no pressure at all,” Treacy adds. “It came from interaction with our customers, who said, ‘Can’t you do this in a different

way. It seems to us, all things being equal, if you could, it would benefit all of us,’ and we decided to move forward with it.” Butler reports that by the end of the calendar year, the company will have converted approximately 30 percent of its total sow herd to group sow housing of one kind or another. Treacy makes it clear that Smithfield is not using any open-door policy to invite outsiders to alter the company’s strategies, or to bow to pressure from outside forces — Smithfield recognizes that it must be flexible in order to keep up with technology, regardless of its ability to spread its message to the public. “We’re going to continually change, and the public now, in this WikiLeaks world without secrets, is going to watch us change,” he says. “Sometimes they’ll demand change, sometimes we’ll change and get a reaction from them.” “Either way, we need to continually get better, and to Smithfield, that means improving our efficiencies, improving our bottom line — and we’ll make no apologies for that because it’s what we do for a living — making animal health better, making environmental impacts much less,” he says.

All the while, Smithfield will use the new media tools to show people what it is doing and how it is trying to do those things better — for everyone that the process touches. In today’s cynical world, it will take small steps first — but Smithfield believes that once the factual information from the company spreads further out to the masses, momentum will keep it rolling along through new methods. “People don’t believe us, they don’t believe the government, they don’t believe corporations, they don’t believe the media — they believe each other,” Treacy says. “We need to become one of the ‘each other’ by talking directly to people who have a concern or compliment. We have to react to them personally, because that’s what the world has become.” As such, Treacy believes Smithfield — and the industry in general — would be remiss to draw the proverbial line in the sand and hunker down to play defense. “New media is not a threat to us, it’s an enormous opportunity for us to tell our story, and for people to criticize what we do and have us interact with them for the first time,” Treacy concludes.

Leading the discussion Andy Hanacek, editor-in-chief of The National Provisioner, sat down with Kathleen Kirkham, sustainability coordinator for Smithfield Foods, to discuss some of the trends she sees Smithfield following in terms of being proactive and informing people through a variety of media.What follows is a Q&A with Kirkham: Hanacek: How would you describe your daily work duties, in your own words? Kirkham: On a general basis, what I do is take all the wonderful things Smithfield Foods does, and find a way to communicate them to the public. For example, sometimes I will represent the company at our Learners to Leaders or Helping Hungry Homes events. But [it also] translates into

32

Kathleen Kirkham, sustainability coordinator for SmithÀeld Foods, spearheads the company’s efforts to inform the public about SmithÀeld’s processes, strategies and actions through a variety of media.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

communicating our messages to the public via social media. [The rest of my job is] different every day, but the one ongoing responsibility is social media. Hanacek: So, in a sense, you do a lot of public-relations type work, but with an extremely heavy slant toward social media? Kirkham: I hesitate to call it public relations though, because that has the connotation of spinning things to benefit the company, and that’s one of the things I’ve been impressed with about Smithfield is that we don’t spin things — we just tell it like it is. When I came on board, Dennis [Treacy, senior v.p., corporate affairs, and chief sustainability officer] told me, ‘If someone asks you a question, be honest and give them the truthful answer.’ That

public-relations connotation isn’t true here at Smithfield.

stuff, so we’re still in the beginning stages of it.

Hanacek: Discuss your approach to being proactive in getting the word out about Smithfield’s good news, as sustainability coordinator.

Hanacek: Which media tool do you believe has the most potential for Smithfield moving forward as a communicator?

Kirkham: In my experience, social media is about 90 percent listening, and only 10 percent talking. A lot of what I do is just watching what other companies are doing, what’s going on in the social scene. I do think we are pretty progressive. I haven’t seen too many other food companies utilizing this stuff in a very positive way. It’s free, you post things and people will listen to it. But, in saying that, we have a long way to go. We just started this program a year ago, and it takes a while to build a repertoire of all your

Kirkham: That’s easy — it’s video. I was researching the other day for a presentation I was giving, and I found out that YouTube is the world’s second-most popular search engine — Google’s No. 1 and YouTube is No. 2. I just found that to be shocking because it’s not Yahoo, a news site, or Wikipedia. It’s a site that’s all video and all user-generated. There’s no fact-checking or anything like that either — you’re finding things that some user just put up there. And that’s terrifying for a company like us, …

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CoverStory that that is where people are getting their information, because so much of it is inaccurate or outdated — so that’s where we need to go, to show folks how we really operate and the truth about modern food production.

after our reply is positive, thanking us for the information. So they’re really receptive to what we have to say, which was surprising to me, because I kind of expected them to just say, ‘Oh, go to Hell.” So that’s pretty cool.

Hanacek: How does Smithfield handle responding to complaints or incendiary comments? Maybe someone says they just watched an activist-produced movie and is angry at Smithfield for how it was depicted, for example — do you have a standard operating procedure or does your response vary?

Hanacek: Where do you see Smithfield needing to build to keep moving forward?

Kirkham: We definitely don’t have a standard procedure, because like I said before, we’re trying to just answer people’s questions, so it will depend on what the question is. … We always answer someone the first time — if it’s the first time we’ve heard from someone,

we’ll talk to them. And usually if someone were to refer to a particular movie, I’d ask them for their email address and tell them I’d love to send them more information about that. We try to take the conversation offline, especially on Twitter since it allows only 140 characters, and it’s hard for us to state our case in that limited space. Traditionally, I’ll take it offline. On Facebook, I might take it to a Facebook discussion, as opposed to talking about it on the Wall. The surprising thing about it is, I would guess 70 or 80 percent of the responses we get

Kirkham: I can tell you that we are moving our [Corporate Social Responsibility (CSR)] report online. We’re building this new Web site scheduled to launch in November, and it will house our CSR report and be an interactive site that will be updated all the time. … Realistically, I’d love to see even more frequent reporting. I think regularly updated information would be valuable, and we’re consistently moving in the direction of increased transparency.

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ĞǆƚƌĂĐƚƐͿ͕ŽŶƚŚĞƋƵĂůŝƚǇĂƩƌŝďƵƚĞƐŽĨƌĂǁĨƌŽǌĞŶŐƌŽƵŶĚ beef. Rosemary extract and other natural plant extracts have become a staple among the meat industry for increasing ƐŚĞůĨͲůŝĨĞďǇĚĞůĂǇŝŶŐŽǆŝĚĂƟǀĞƌĂŶĐŝĚŝƚǇ͘

The quality parameters of ground beef that most strongly inŇƵĞŶĐĞĐŽŶƐƵŵĞƌƐ͛ƉƵƌĐŚĂƐŝŶŐĚĞĐŝƐŝŽŶƐĂƌĞƚŚĞĂƉƉĞĂƌĂŶĐĞ ĂŶĚĐŽůŽƌŽĨƚŚĞƉƌŽĚƵĐƚ͘DŝĐƌŽďŝĂůƐƉŽŝůĂŐĞĂŶĚŽǆŝĚĂƟǀĞ rancidity throughout the shelf life of raw ground beef are the key factors that lead to appearance and color changes.

ZĂǁĨƌŽǌĞŶŐƌŽƵŶĚďĞĞĨƚƌĞĂƚĞĚǁŝƚŚ&KZd/hDΠbrand Natural Plant Extracts compared to untreated ground beef resulted in higher Hunter a* values (a measure of redness) throughout the study as shown in the chart below. Higher a* values ĐŽƌƌĞůĂƚĞƚŽĂŵŽƌĞĚĞƐŝƌĂďůĞƌĞĚĐŽůŽƌ͘ƚƚŚĞĮŶĂůĂŶĂůǇƐĞƐ on day 315, all FORTIUM treatments maintained more of the desirable red color as compared with the untreated ground ďĞĞĨ͕ŝŶĚŝĐĂƟŶŐĂĚĞůĂǇŝŶŽǆŝĚĂƟǀĞƌĂŶĐŝĚŝƚǇǁĂƐĚĞŵŽŶstrated.

Natural extracts derived from plant materials have been ƐŚŽǁŶƚŽĚĞůĂǇŽǆŝĚĂƟǀĞĐŚĂŶŐĞƐĂŶĚĐĂŶďĞůĂďĞůĞĚĂƐĂ ͞ŶĂƚƵƌĂůŇĂǀŽƌ͟ŝŶƚŚĞhŶŝƚĞĚ^ƚĂƚĞƐ͘^Ž͕ŚŽǁŵƵĐŚŽĨĂŶ impact can adding a natural plant extract have on the color of raw ground beef?

FORTIUM®brand Natural Plant Extracts are your solution! <ĞŵŝŶĐŽŶĚƵĐƚĞĚĂƐĐŝĞŶƟĮĐƐƚƵĚǇƚŚĂƚĐŽŵƉĂƌĞĚ FORTIUM®brand R30 Liquid (rosemary extract) and FORTIUM®brand RGT12 Plus Dry (rosemary and green tea

KEY CONCLUSION – Treating with FORTIUM®brand Natural Plant Extracts can delay oxidative rancidity, maintaining the desirable red color of raw frozen ground beef that consumers demand. They are versatile, natural flavors with antioxidant activity and are label-friendly. <ĞŵŝŶƐĐŝĞŶƟƐƚƐƐƉĞĐŝĂůŝǌĞŝŶŝĚĞŶƟĨǇŝŶŐĂŶĚĚĞǀĞůŽƉŝŶŐďŽƚŚ ŶĂƚƵƌĂůĂŶĚƐǇŶƚŚĞƟĐŵŽůĞĐƵůĞƐƚŚĂƚŚĞůƉĨŽŽĚůŽŽŬŐƌĞĂƚ͕ taste delicious, remain safe and stay fresh longer. We deliver ŝŶŶŽǀĂƟǀĞ͕ƐƵƉĞƌŝŽƌĨŽŽĚƚĞĐŚŶŽůŽŐŝĞƐ͕ŚĞůƉŝŶŐƚŽĞŶƐƵƌĞ that what your consumers put on their plate looks great and tastes delicious.

Kemin Industries’ natural plant extracts is your solution for delivering quality ground beef products! Time in Days

brand brand brand

For more information on this study e-mail – [email protected] Note: Certain statements may not be applicable in all geographical ƌĞŐŝŽŶƐ͘WƌŽĚƵĐƚůĂďĞůŝŶŐĂŶĚĂƐƐŽĐŝĂƚĞĚĐůĂŝŵƐŵĂǇĚŝīĞƌďĂƐĞĚƵƉŽŶ government requirements.

:(%5,1*025(727+(7$%/(

We promise to keep your meat and poultry products looking great, tasting delicious, safe & fresh longer. :::.(0,1&20)22'6 .)7#.(0,1&20 © Kemin Industries, Inc. and its group of companies 2011 All rights reserved. ® ™ Trademarks of Kemin Industries, Inc., U.S.A.”

SpecialReport

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

RTANCEof

JECTION By Sam Gazdziak, editor, Independent Processor

Meat products enhanced through an injection process can have better taste and shelf life.

I

n the fast-paced world of meat processing, every machine on the plant floor has to do its job quickly, efficiently and correctly. The injector is no exception, and it can add a great deal of value to a product in a very short time. For diffusion of curing substances, flavor marinades or tenderizing solutions, an injector can pump these different solutions directly into the protein. Unlike the traditional manual injection process, today’s multi-needle injectors are more likely to have an even distribution of the solution. “This process greatly decreases the time required to achieve even distribution of the ingredients in the solution, compared to earlier immersion or marination methods, particularly for larger cuts of meat,” says Lynn Knipe, extension processed meats specialist at The Ohio State University.

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Traditionally, injection has been used to make products like ham or bacon by infusing a brine or curing solution into the center of the cuts. More recently, brine solutions — primarily salt and water, but no nitrite — have been added to whole-muscle cuts at lower levels to improve the juiciness of the cuts that contain less marbling. These products are referred to as “enhanced.” “I first saw this process applied to pork loins, in response to chefs’ complaints of dry pork loins and chops from our leaner, less-marbled pork,” Knipe says, “but leaner, less tender

beef cuts are also being enhanced.” Knipe notes that the speed of injection equipment has increased in recent years to match the demands for increased throughput. However, as the speed of conveying the meat through an injector is increased, the injection pressure has to be increased as well in order to meet the same injection target. Increasing the pressure comes with its own set of challenges, he says. “Increasing the injection pressure can result in other quality and injection uniformity problems, particularly with smaller cuts of meat,” says Knipe. He added that injections that

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SpecialReport contain inorganic phosphates pose an environmental hazard when they are flushed through the wastewater system. Along with the injector itself, a full line of other equipment has been developed to complement the machine, says Glen Meskimen, president of GHM and Associates, a meat industry consulting firm. That list includes mixing stations or tanks that can mix large amounts of the solutions and pumping systems to move those solutions into holding vats prior to being pumped into the injection machines. “Technology has trained the meat processor that temperatures are of critical importance, so the mixing tanks, holding tanks and injection areas must be kept to a constant chilled temperature based upon the meat protein you are using, as well as the injection levels you are pumping at,” Meskimen says. The size of the needle is dependent on the size and type of needle that is being run through the injector. Meskimen points out that replacing worn or bent needles assures the highest injection efficiency.

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“The needles, along with the temperature of the solution, the filtering of the particulates from your solution being used, and the speed of the injection bed are important to allow the producer to manufacture the best product possible,” he adds. Knipe adds that along with the size, the number and spacing of needles, combined with pump pressure will determine the machine’s ability to reach the target injection level and maximize the uniformity of the brine distribution.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

“For example, a larger number of smaller, closely spaced needles will allow for better solution distribution in the meat and will allow for lower pump pressures to achieve the targeted injection level,” he says. Food safety focus As with other areas of the meatprocessing plant, meat injection has become a critical area for food safety. It became a particular focus in late 2009, when almost 250,000 pounds of non-intact beef products

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The self-cleaning FM80 Filter is always clean, eliminating brine ﬂow restrictions and pressure drops, as well as clogged needles and declining yields. At the end of the day, you’ll realize higher yields and a more consistent product.

Individual stripper feet conform to the shape of the product and hold it in position for accurate injection and improved product quality. Brine ﬂows only when the stripper feet are in contact with the product. This allows uniform injection, even with irregular product or partially loaded belts.

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A unique pump-to-pipe system ensures uniform brine ﬂow and distribution to each needle. Constant pressure is maintained as the brine ﬂows from the pump to the needles through pipes with continuously decreasing diameters. The system is rounded to eliminate particle traps. The design allows easy cleaning without elaborate, time-consuming disassembly found in manifold systems.

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were recalled due to an outbreak of E. coli-related illness. While those products were blade-tenderized prior to being further processed, it still raised the possibility of translocating pathogens — that a pathogen on the surface of the meat could be pushed into the center of the cut by a knife or a needle, making it harder to kill when it is cooked. “Since the needles are entering the meat muscle, it makes it of vital importance that the sanitation crew is informed on how to assemble and disassemble the machine for a thorough cleaning,” notes Meskimen. “They must ensure that the needles are blown free of any meat protein particulate and set the needles in 46

a sanitizing solution until they are to be used. It is also vital that the side holes of the needles are free and open to allow the spray action that distributes the solution you are pumping into the product to be pumped evenly.” Knipe says that many processors are applying organic acid rinses to the meat cuts prior to the injection process, to eliminate the surface contamination and the chance that a pathogen may be pushed deeper into the cut during the injection process. “Another partial solution to this challenge is to avoid recycling brine or curing solutions that run off meat cuts during the injection process,” he adds.

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Injection equipment will continue to walk the fine line between speed and quality — producing quality products at ever-increasing rates, but doing so in such a way to preserve food quality and food safety. Future developments in injection will likely help give processors the quality they need at the speed that they want. Knipe notes that there are other improvements that could yet be made, “to reduce the amount of brine that is wasted or not used, either because of the amount of brine that is needed to prime the injector pumps or the brine that is not recycled because of inadequate filtration systems.”

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It’s the shape that makes it great. Alberger® brand salt, exclusively from Cargill, is created from a process that starts with a hollow pyramid shape to form multi-faceted crystals. These unique crystals with a large surface area and low bulk density provide superior adherence, blendability and solubility compared to regular cube-shaped granulated salt. The rapid solubility also gives Alberger® salt its ﬂavor burst when used in topical applications. To ﬁnd out what else we can bring to the table, call 1-888-385-SALT or visit cargillsalt.com. collaborate

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SpecialReport

WORKER SAFETY

Safety is everyone’s responsibility

Photo courtesy of Peter Marcouillier

Employee ownership gives Superior Farms employees a vested interest in a safe workplace. By Angela Gentry, Superior Farms To the average visitor, some of the safety precautions taken at a meat-processing facility are obvious; such has hard hats or steel-toed boots. Look a little closer and you’ll find the mesh gloves and the arm guards, protecting against the slip of a sharp knife – important on a meat cutting room floor. But other systems aren’t so obvious. Worker attendance incentive programs, accident-free awards programs, and especially employee stock ownership options are the key reasons why lamb processor Superior Farms enjoys one of the lowest rates of illness or injury in the United States. “We take our safety very seriously here,” said Alfredo Saldivar, human resources manager for the company’s Dixon, Calif., harvesting facility. “We have programs and incentives in place to help ensure that our injuries are at a very low rate. And our workers compensation modification 48

rate is even lower.” The industry standard is 10.4 injuries out of 100 workers. Superior Farms is currently at 2% and has significantly reduced the number and severity of injuries in the past 11 years. According to the American Meat Institute’s Web site (www.meatami.com), “Dramatic reductions in the rate of illness and injury at U.S. meat packing plants speak to the value of voluntary, industry specific worker safety and ergonomics programs.” They cite four categories that employers implement: Work Site Analysis; Hazard Prevention and Control; Medical Management; and Training and Education. Even though its rate is low, Superior Farms isn’t free from accidents resulting in injuries. Each case is thoroughly investigated, and the human resources department puts on

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

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%$ SpecialReport their “safety hats.” The accident is re-created and analyzed to learn how to prevent it from happening again. Proposals are made to adjust the equipment, or even down to the ergonomic stance that our employees have. Since a big majority of the line work is repetitious, job rotation is important. Workers in problem areas are crosstrained so there is rotation throughout the day to cut down on potential injuries in those departments. “Luggers” are a good example, where employees may be lugging a 100-pound lamb carcass from one hook to another, sending it to different areas of the plant for further fabrication. The same is true for those moving boxes on and off pallets for orders going out. Strenuous jobs like this are rotated each day, usually within the same department, so they are not using the same muscles each day. New equipment has also been helpful in repetitive motion issues. Simple tools such as automatic label machines, design of conveyer belts or even positioning platforms for employees to stand on can curb the ergonomic issues for many positions. When one speaks with Superior Farms employees, the message is clear: employee ownership is the key to worker safety. “I think the difference is ... when any of us look at a task or a job or what needs to be done, as employee owners we look at it differently,” said CEO Ed Jenks. “Because you realize that if you don’t do it correctly or safely, the likelihood is that you could be out of work or worse — you could get one of the other owners injured. We tend to be more careful because we’re all owners.” Vice President of Human Resources Karen Ellis agreed. “It starts with company leadership and setting the tone from top down that safety is really important.” Superior Farms was founded in 1963 in Ellensburg, Wash. It later moved to Dixon, Calif. Since then it has purchased locations in Boston, Mass.; Denver; Vernon, Calif.; Blue Island, Ill.; 50

and Hawarden, Iowa. Managers in each of the company’s plants in California, Colorado, Illinois and Massachusetts meet once a week with all employees at the facilities to give training on topics. The managers and HR also meet once a month to review current injuries and to discuss safety. Employees themselves are rewarded with a luncheon and prizes every six months. “At the employee lunches we raffle off great prizes. Everybody who is injury-free is eligible. Plus we purchase lunches throughout the year, t-shirts, hats and other logo items for departments who keep a good safety record,” said Saldivar. “ We just started a program called Lamb Bucks – they are a voucher that employees get when they are doing something right on the job for safety or quality – like wearing their helmets and glasses, bending down properly, catching leakers and quality-control issues. We want to make sure the job is done right the first time.” Employees can use the Lamb Bucks to buy lunches or company apparel. The locations are stocked with safety items so they can be immedi-

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

ately replaced on site. These include arm guards, belly guards and chain gloves, and they are given replacements as needed. “It’s pretty unusual to have a meat plant that’s employee owned – it’s unique,” said quality control manager Matthew Livingston. “The departments work together – it’s not an ‘us against them.’ I don’t think anybody really realized it until about 10 years ago, when people started retiring and realizing that they were getting a real value from the company doing well. Longer-term people are telling the newer coworkers about it.” “Being an ESOP holds everyone accountable also,” continued Livingston. “Employees don’t have that much control of the hours, but they do have control over their shares and the share value based on how well they do their job.” Livingston has seen co-owners point out missing hairnets and safety goggles, and reminders to use care on forklifts to help each other be safer. Angela Gentry is the marketing director for Superior Farms. Superior Farms has been an employee-owned company since 1991 and currently holds the title of California Western States Chapter ESOP Company of the Year. More information is available at www.superiorfarms.com.

In 1907 Giuseppe Cozzini emigrated from Italy to the United States and founded a successful knife sharpening business in Chicago. Three generations and over a century later CozziniPrimedge has grown and evolved into a leading supplier of knife sharpening equipment, edge maintenance tools and replacement blades for the meat and food industries. CozzinPrimedge features innovative sharpening technologies, including hollow grinders, honer/edgers, rotary surface plate grinders and hand-held and bench mounted knife-edge maintenance tools. CozzinPrimedge has also developed an unsurpassed reputation for providing premium quality replacement parts for all major makes of grinders, emulsifiers, slicers and bowl choppers. Some of the products offered by CozziniPrimedge include high quality blades for skinners, band saws, dicers, tenderizers and numerous other specialty blades. Amongst the equipment available from CozziniPrimedge are sanitizing units for knives and gloves. Also available is expert sharpening for all types of blades. CozziniPrimedge is proud to be the original inventor and developer of such industry leading technologies as the Ergo Steel ergonomic edge maintenance tool. The easyto-use “ERGO STEEL” is designed to be integrated into the production line to insures razor sharp knife-edges in seconds without training and contributes towards worker safety by minimizing fatigue related to use of dull knives. Still maintaining its old world focus on excellent workmanship and customer satisfaction, COZZINIPRIMEdge is continually developing new technologies to meet the demands of an ever-changing global market. The next generation of edge maintenance tools has been introduced this year with two new PRIMEdge Ergo Steels in a fully stainless steel version, a design for improved hygiene and durability. PRIMEdge, Inc. headquartered in Chicago, Ill., and has European manufacturing and distribution facilities in Germany, France and Denmark and a network of global sales agents in most countries. 52

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

ADVERTORIAL

Comparative study: Hygienic properties of conveyor belt materials

Results

Soiled and dipped in water

Figure 2

Cleaned with foam and a low-pressure cleaner

Under a recent independent Figure 1 study, three different conveyor belt materials — stainless steel (AISI 301), solid plastic and modular plastic — were tested for their hygienic properties and cleanability after being soiled with microbes. Each material was tested using both undamaged and damaged surfaces. The material samples were soiled with a mixture of Pseudomonas fragi E98200T, Candida albicans C-85161 and Listeria innocua E-991340 in blood. These microbes can be found in meat-processing facilities when cleaning is not sufficiently thorough. The microbial mixture was applied at room temperature to the test surfaces for various periods — 4, 8, 16, 24, 72, 72/72 and 72/72/72 hours (for the latter two, the belt was cleaned between each 72 h period) — to simulate procedures in different meat factories.

The visual inspection of the material samples showed dirt accumulations in the areas that were damaged with a knife. The dirt was clearly visible on the damaged Stainless steel, Stainless steel, Solid plastic, Solid plastic, Plastic slats, Plastic slats, plastic surfaces. The amount of microbes present on soiled 16 h damaged, soiled 16 h damaged, soiled 16 h damaged, the surfaces was determined using swab samples taken soiled 16 h soiled 16 h soiled 16 h from the surfaces with cotton swab sticks and culturing microbe colonies on Agar plates. Figure 1 shows the resistant and easy to clean, a pre-welded endless stainless-steel results for the damaged belt surfaces after 4h, 8h, 16h and 24h, belt provides an immediate hygiene upgrade. No crevices, joints, both before and after cleaning. Cleaning was done using foam textures or fibers means no places for bacteria to hide. and a low-pressure cleaner. The amount of microbes is expressed as colony-forming units (CFU/cm²). The scale of the y-axis is logarithmic, as the differences in microbe results that are larger Wherever there’s a need for maximum hygiene than one logarithmic unit are usually considered relevant. The — from surgical tools to catering equipment — diagram shows that the microbial load on damaged stainlessthe material of choice is stainless steel, so why steel surfaces after cleaning is more than one log unit smaller should your conveyor belts be any different? For than that on the two damaged plastic surfaces.

Conclusions According to the cultivation results (Figure 2), stainless-steel belting can be significantly better cleaned than the two plastic surfaces studied. The difference in terms of cleanability is significantly higher on damaged surfaces. Inert, corrosion-

a free copy of the complete comparative study, or for more information about Sandvik steel belt conveyors and meat cutting tables, call (973) 720-7051, visit www.processsystems.sandvik.com on the Web, or e-mail [email protected].

New packaging, product positioning, brand promotions and a team of leaders help drive Ruiz Foods’ growth, success and sales, making it one of the top 500 Hispanic-owned companies in the United States. By Marina Mayer, executive editor, Snack Food & Wholesale Bakery, and Bob Garrison, editor, Refrigerated & Frozen Foods Photos by Ruiz Foods

hen it comes to introducing new products and staying on trend, food manufacturers must drive on the fast track. Even the slightest delay in a launch or the smallest of production interference can push a company behind the rest of the pack. But some companies come equipped with the right stamina, drive and persistence to keep up with the competition, regardless of the challenges on the road ahead. The folks at Ruiz Foods are the perfect example. From its first days producing bean and cheese enchiladas and chili rellenos, 46-year-old Ruiz Foods now employs approximately 2,500 people who process more than 200 retail and foodservice stock-keeping units (SKUs) at three facilities in its Dinuba, Calif.-based headquarters, as well as its Tulare, Calif., and Denison, Texas, plants.

W

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BonusFeature

At a Glance Company: Ruiz Foods Headquarters (and plant): Dinuba, Calif. Plant Locations: Tulare, Calif.; Denison, Texas Products: Frozen hand-held entrees and snacks Brands: El Monterey, Tornados Distribution: National No. of Employees (Company-wide): 2,500

Key Personnel: Co-Founder, Chrm. Emeritus: Fred Ruiz Chrm.: Kim Ruiz Beck Pres., CEO: Bryce Ruiz Sr. V-P., Supply Chain: Brian Miller V-P., Foodservice, Sales & Mktg.: Kimberli Carroll

Louis Ruiz, the company founder, and his son Fred Ruiz, co-founder and chairman emeritus, began producing and selling frozen Mexican foods to mom-andpop grocery stores in the San Joaquin Valley. Today, the third-generation company boasts an estimated $450 million in sales, and is ranked as the as the sixth largest Hispanic-owned company in the United States and the largest in California, according to Hispanic Business magazine. Just like any good race driver though, to stay ahead of the curve, leaders must instill a great team in the trenches. That’s why Fred, a 2006 inductee into the industry’s “Frozen Food Hall of Fame,” handed the responsibilities of president and chief executive officer over to his son, Bryce, and appointed his daughter, Kim Ruiz Beck, as chairman. “My dad always said, ‘If you’re not growing, you’re dying,’” says Fred. “As a result, we were very opportunistic and growth-oriented. Today, Bryce and Kim have embraced the Ruiz family legacy and are as driven as my dad and I ever were. “I don’t exactly know when we became a national company, but there is a different dimension now,” he adds. “Bryce is not limited by the past, and I think that it’s an advantage. Sometimes the past can be a burden and be limiting in terms of your outlook.” Ruiz Foods continues to stay on the fast track to success, even as other companies are riding a rollercoaster ride, and fending off economical woes. “Today’s consumer continues to look for quality, innovation, convenience and value,” Bryce says. The company’s outlook continues to remain bright, even as it hits the halfway point of 2011. According to data from Chicago-based SymphonyIRI Group, Ruiz Foods is the leader in the frozen Mexican foods category with a 24% dollar share for the latest 52 weeks, ending June 12. “We have consumer research that shows El Monterey is No. 11 among the top prepared-food brands,” he says. “Moreover, of the top 20 frozen prepared – foods brands, El Monterey is growing by 5.3%, which at the second fastest rate. That tells us there’s still a lot of opportunity, and that El Monterey is still a new idea in most households. We’ve been at this for so many

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BonusFeature years and just didn’t realize that our brand means as much as it does.” Behind the scenes, Ruiz Foods flourishes because of its advanced sales planning schedules (more than a year out). “Today, we’re looking out further,” says Bryce. “When you think more strategically, you can better utilize your funds. Although marketing and sales teams have not grown, we’re doing more and becoming more focused on our core. Our theme is, ‘Fewer. Bigger. Better.’ Let’s do fewer things, think bigger and then execute to a T.” To coincide with its bigger and better theme, in January 2010, Ruiz Foods launched Tornados, created to give it more elbow room to branch out from Hispanic flavor combinations and into broader varieties. The 3-oz., hand-held snack consists of freshly baked flour tortillas rolled in a crispy seasoned batter and stuffed with savory meats and melted cheese. They come in Ranchero Beef & Cheese, Grilled Chicken & Cheese, Chicken Club, Southwest Chicken, Cheesy Pepper Jack and Cheesy Pepperoni varieties. Then, Ruiz Foods introduced an even larger mainline packaging shift, further targeting the multi-serve, snacking occasions. In May 2010, Ruiz Foods repackaged 12 different El Monterey retail products — everything from six-count tamales and quesadillas to 14- and 16-count taquitos and mini chimichangas — by upgrading the packaging graphics and photography for the first time. “This takes all the complexity out for retailers,” says Bryce. “No longer will we have one-off items, such as tamales, in meat-style trays. Now we can bundle all of our El Monterey brand equity with a common look and common price points. This will give us greater presence across a full door, while it makes it easier for retailers to feature and display our products.” For instance, the El Monterey snack bag line features a resealable standup pouch, and includes flour and corn tortillas, Chicken and Shredded Beef 58

Party With a Purpose A company trying to exceed last year’s sales goals isn’t really news, especially since most companies make that a primary goal. But, a company trying to break its annual nonproÀt fundraising record? Now that’s newsworthy. Since 1990, Ruiz Foods, Dinuba, Calif., has raised more than $2 million to fund Ruiz 4 Kids, a non proÀt organization supporting area children’s programs. On Oct. 7, more than 600 people attended the event, which included dinner, a silent auction, dance and games at the Visalia Convention Center, Visalia, Calif., and helped Ruiz Foods raise $197,000, the largest annual Àgure in its nonproÀt’s history. The money portioned out to help fund the Boys and Girls Club of the Sequoias, CASA of Tulare County, Family Services of Tulare County and the Visalia Police Activities League. “We are proud to support each of these nonproÀt organizations,” says Kim Ruiz Beck, chairman of Ruiz Foods. “We couldn’t be more pleased with the results of our 2010 fall fundraiser when we recognize the funding cutbacks affecting organizations serving children. Although we see some ease in the economic crisis, it will take longer for nonproÀt organizations – particularly those depending on donors and grants – to recover.” taquitos, Southwest Chicken taquitos, two kinds of mini chimis, quesadillas (Chicken and Shredded Steak) and tamales (Chicken and Beef). The El Monterey 2-pack burritos and chimichangas are packaged for the one- to two-person household and consist of similar items as above. El Monterey Supreme burritos, butcher-wrapped burritos, XX large burritos, chimichangas and the Gigante burritos are manufactured specifically for the convenience store customer, as they look for products for their hot case, microwaves, freezer, etc. These lines entail the same recipes of freshly baked tortillas, real cheeses, authentic Mexican spices and chunks of white chicken meat or shredded steak.

Full speed ahead In addition to its lineup of new products and packaging initiatives, the past few years have been historic ones for Ruiz Foods and its El Monterey and Tornados brands. For starters, in 2009,

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Ruiz Foods teamed up with StewartHaas Racing (SHR), the NASCAR Sprint Cup Series team, to sponsor SHR driver Ryan Newman. Newman represents Ruiz Foods’ convenience store and retail snack brand, Tornados, in the NASCAR competitions. In October 2010, Ruiz Foods sponsored Newman in a Nationwide series car featuring the company’s El Monterey brand at Fontana’s Auto Club Speedway. This year, Tornados continued its Ryan Newman NASCAR sponsorship and El Monterey became an associate sponsor of Tony Stewart, another SHR driver. In the fall of 2010, the NASCAR also treated 300 of Ruiz Foods’ team members to hospitality events, garage tours and pace car lap activities. (A month later, approximately 250 team members at Ruiz Foods’ Denison, Texas, plant enjoyed the same NASCAR treatment in Dallas.) “Just think. More than 300 team members got on a bus at two in the morning to do this [NASCAR trip],”

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Bryce says. “For many, this was their first exposure to the NASCAR, and after visiting the hospitality tent, touring the track and more, they had a great time and the full experience. It really created a team-building atmosphere.” “Such an event would’ve surpassed anything my dad ever thought it would be,” Fred says. “The most important thing he talked about was that we build a brand. He also talked about investing in your business, automating and becoming a low-cost manufacturer. If we could build a brand and do that, we could compete against anybody.” Recently, Ruiz Foods showcased its Tornados Sampling Tour at the Kentucky Motor Speedway on July 9. Staff in a 27-ft. painted-out truck produced more than 1,000 Tornados an hour and distributed Tornados coupons redeemable only at Thornton’s convenience stores in Kentucky. A full-size NASCAR #39 Tornados Sprint Cup Series racecar accompanied the tour. “In most markets, we overlay the promotion with radio and geo-targeted social media to drive awareness to our customers’ locations,” says Kimberli Carroll, vice president of foodservice sales and marketing. “To date, our Tornados Sampling Tour promotions have been very successful, so much so that we are already committed to continue our NASCAR customer promotions in 2012.” Ruiz Foods also finalized developing promotional campaigns with six Six Flags locations (Six Flags Great Adventure in New Jersey is home to a Tornados Zone ride).

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Ruiz identifies NASCAR dads as its core c-store shopper. That’s why it developed the company’s first multi-media promotional campaign, complete with in-store merchandising materials, social and digital media and 30-second TV spots. Themed “Full Force Flavor. Full Force Fun,” the spot ran in metro markets on SPEED TV, which reaches the NASCAR family. “This was a case where, because you have family working this business, we allocated the extra funds,” says Bryce. “Although a national ad campaign was not in the plan, it reflects the family’s commitment to our brands.” A young dad himself, Bryce led Ruiz Foods into social media – first creating a Facebook page for Tornados fans, and then a second page just for El Monterey lovers. “I quickly understood the potential of social media for our brands,” he says. “And looking back, I believe I was right. In 2010, our two brands received more than 2 billion impressions and drove more than 3.5 million brand engagements on Facebook.”

As of press time, the Tornados page alone boasts nearly 354,000 fans , while the El Monterey page boasts more than 243,000. “[Social media] gives us a way to ‘activate’ our brands and engage our consumers. It gives us a platform where we can solicit flavor ideas, recipes and even have some fun with our fans. We also found that the average fan spends five to seven minutes interacting with the medium,” says Bryce. Ruiz Foods continues to demonstrate its willingness to take its message to just about any media channel by introducing a media mix of NASCAR, television, in-store promotions, YouTube channels, advertising, Facebook and other social media channels to boost brand awareness and increase exposure. For instance, in February, Ruiz Foods launched a three-month campaign for its El Monterey brand that included traditional 30-second commercials, which were themed after a comical telenovela (Spanish soap opera) and starred a fictional family (the El Montereys) bound by their love of El Monterey food. There were six total spots, each one featuring a comi-

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cal “episode” from the El Monterey soap opera. Three of the spots aired on network and cable TV, whereas three aired as YouTube videos, scoring millions of impressions within three months. At the store level, Ruiz Foods featured large floor graphics in the frozen aisle with an image of the telenovela family. On Facebook, the El Monterey Hacienda Challenge gave fans the opportunity to submit their own story line for the El Monterey telenovela. Fans received a chance to win prizes like digital cameras, t-shirts or a grand-prize trip to San Diego. The Hacienda Challenge generated more than 350,000 engagements and an additional 35% Facebook likes. In addition, Ruiz Foods continue to use free-standing inserts as part of its customer support and consumer trial initiative for events such as the Super Bowl, Cinco de Mayo, back to school, and more. “We’re not doing anything different from 10 years ago,” says Bryce. “There may be different [communication] media and different business cycles 62

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

but the rest is the same. My last name is on the building – just like it is for dad, Kim and our other family members. We believe in this business. Today, it’s just a matter of how we’re going to go about growing it. And then, let’s go.”

Meeting mom at the finish line In addition to the company’s noteworthy NASCAR consumers, Ruiz Foods also strives to meet mom (the other core grocery shopper) at the finish line. In doing so, in March, Ruiz Foods partnered with the National Sodium Reduction Initiative to help cut the salt by 20% over the next five years. To date, its entire line of El Monterey family-pack burritos and chimichan-

gas are already in line with the 2012 guidelines. Ruiz Foods also established sodiumreduction plans for the remaining SKUs to better partner with the NSRI goals. “The consumer typically grows with their ethnic food choices,” Bryce says. “For example, when they begin to enjoy Mexican, they will begin with the basic burrito. As they become familiar with Mexican flavors, spices, levels of heat, etc., that same consumer becomes both willing and interested in trying new and innovative flavor

profiles and textures.” Therefore, Ruiz Foods is driven to provide the bestof-the-best products with a healthier label. “Our greatest opportunity is two-fold,” Bryce says. “One, to maintain our high level of quality in the products we currently offer our consumer and two, to continue to listen to what our consumer is looking for. Convenience? Value? New textures? New flavors?” Whatever the consumer is in search of, Ruiz Foods has the drive, passion and ability to continue positioning itself in the fast lane. Editor’s Note: This article was originally published in Refrigerated & Frozen Foods and Snack Food & Wholesale Bakery, two sister publications of The National Provisioner. Facts and figures have been updated where possible.

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Operators hand roll freshly baked tortillas Àlled with chicken, cheese and Mexican spices for El Monterey Chicken and Cheese Taquitos.

Quick-change artists Quick changeovers and enhanced technologies help Ruiz Foods’ Dinuba, Calif., plant meet ever-changing consumer demands. Marina Mayer, Executive Editor Snack Food and Wholesale Bakery | Photos courtesy of Ruiz Foods hen it comes to consumers, no two are alike. While one wants quality, the other wants quantity. While one seeks out better-for-you ingredients, the other is in search for the most eco-friendly packaging. This may put some food manufacturers in a bind to please the every-consumer, but for companies like Ruiz Foods, there’s an art to staying ahead of the game. “Every day, the complexity increases in our business. You can’t just sell the same box of macaroni and cheese,” says Brian Miller, senior vice president of supply chain for Ruiz Foods. “Consumers are quite different today and it’s almost as though we’ve become a restaurant. We’re developing new products all the time. Whether it’s out of boredom or something else, consumers demand more flavor and flair.” That’s why Ruiz Foods, producer of frozen, handheld entrees and snacks, remains flexible in its 42-acre, 260,000-sq.-ft. plant, and continues churning out as many as 200 distinct stock-keeping units (SKUs) for retail, food-

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service and club store channels. For starters, this 20-year-old plant dramatically retooled and reconfigured several packaging lines, discontinued several bag-in-box packages and other formats and converted as many as 12 different food packages to stand-up recloseable, zippered pouches for tamales, mini chimichangas and taquitos, among others. “Many companies would have needed 6-8 months to change production and packaging, yet we did it within 90 days,” notes Miller. “We’re definitely a ‘brand-driven’ facility with the same type of mindset and environment as a copacker. We have to be flexible and oriented toward customer service. We’re going to deliver to our sales and marketing plans, no matter what.” The plant is also home to six production lines, 10 packaging lines, a raw materials warehouse, a tortilla bakery, production and a finished goods storage room. The plant runs 24 hours, six days a week, with 15-17 hours of production alternating with sanitation, preventative maintenance and food safety activities.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Making its mark To be successful, Ruiz Foods needs to employ good people who can bring passion, dedication and diligence to the front lines. That’s why it helps to have a veteran workforce. For example, of the 1,650 employees, 511 joined the company 10 years ago and another 144 have 20 years of tenure. Since the Dinuba facility opened in 1990, Ruiz Foods has attracted hundreds of workers within a 40-mile radius, and has even employed two generations of families. It’s these ongoing relationships that have helped Ruiz Foods reach some noteworthy achievements, Miller says. “Eight or nine years ago, repetitive motion activities put us in a high-risk category for workers compensation,” says Miller. “Then we developed a program involving job rotations, job qualification standards, preventative injury exercises and other disciplines,

Taquitos are packed in stand-up, reclosable pouches that travel along a conveyor to receive code date registration, and are then sent to the automatic casepacking lines.

so team members are doing various things throughout the week. Years ago, our injury index was seven or eight (injuries per business hour), which was comparable to the industry standard for a company our size. Today, we’re at an index rate of 1.5 and in our ship-

ping and receiving area alone, we’ve accumulated more than 3,650 days (or 10 years) with no loss-time accidents.” When it comes to food safety, Ruiz Foods takes extra measures to inspect raw materials coming and finished products going out. “We handle allergens and highrisk ingredients such as chicken, beef, pork, cheese, eggs and other items,” Miller says. “Because of the high risks associated with adulteration or bacteria, we inspect at least 98% of all raw materials entering the plant. In 2010, we even exceeded that standard, even though we handle as many as 200 different product SKUs.” Additionally, Ruiz Foods issues a quarterly bonus program with three parameters, says Miller. “Our goals are 98% first-time quality, schedule attainment of 95% or better and no equipment damage inflicted by team members. We’re giv-

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Ruiz Foods Celebrates 10 Years of No Loss-Time Accidents The Ruiz Foods shipping department reached a milestone through the collective efforts of its Dinuba, Calif.-based team members. Through direction, support and the necessary tools, the shipping department accumulated 3,650 days (or 10 years) with no losstime accidents. “From the Ruiz Foods perspective, safety is No. 1, whether it’s food or people,” says Brian Miller, senior vice president of supply chain. To reach this goal, Ruiz Foods installed state-of-the-art equipment, such as battery changing machinery, battery watering systems and impact records, in its 260,000-sq.-ft. plant. A digital counter was then placed in the warm-up room to count each day the department went without a loss-time accident. “At Àrst, there wasn’t much attention paid to the counter, but once the number reached 1,000 days, and then 2,000 days, team members really started to notice, ask questions and make commitments to do their best,” Miller says. In addition, Ruiz Foods offered coaching, scheduled safety meetings, incentives and visuals to create awareness and excitement among the three-shift shipping department. The safety team even scheduled regular meetings to remind team members of their responsibility to producing great results. “Over half of the team members in the shipping department have been with the company 10 or more years,” Miller says. “This exceptional milestone shows safety is not only the Ruiz way, it’s their way.”

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

ing more [equipment upkeep] ownership to team members and believe in a system where 1,600 peers help each other achieve success. Last year, our factory’s average hit 99.5% for product ‘right first time.’ We also review first-time quality against a consumer complaints measure. For a factory our size – per millions of items produced, – the industry average is five or six pieces per million (drawing complaints). Our goal was 1.3 eaches per million and we achieved just 0.91 million.”

“Fresh-frozen” process To produce the best-quality product, the folks at Ruiz Foods treat taquitos the same way a frozen vegetable plant handles beans – with one-on-one care. “We are 100% self sufficient,” Miller notes. “This includes our own flour delivery system and a complete fresh tortilla bakery to how we blend our own spices and prepare all of our fillings on the factory floor within just a few hours of freezing. Even though our products are frozen, we ensure that each is ‘fresh-frozen,’ so when a consumer prepares it, it tastes as though it’s been cooked for the first time.” At the time of the plant visit, Ruiz Foods was preparing chicken and cheese taquitos. The pre-batch kitchen team members arrive at midnight to remove cheese and chicken from shipping boxes. These ingredients arrive at the cold mix room and are held at 40°F to ensure food safety and proper mixing consistency. “Our products require lots of material handling

Shipping department members are responsible for the 3,650 days (or 10 years) of no loss-time accidents.

because we don’t believe in ‘pump-inplace’ fillings,” says Miller. “We emphasize [ingredient] piece integrity, which is one way we differentiate ourselves with high quality.” Following computerized formula print-outs, workers then add water, spices, green chilies and other vegetables. Once the mixture reaches proper consistency, it’s dumped into a mobile stainless-steel tote, which are staged in a chilled holding area (and sampled by quality assurance technicians) before entering the production room floor. Two external flour silos feed flour (using an air conveyance system) into the plant on a batch-volume basis. Pre-set amounts of flour and metered water are released into one of four large, upright mixers. After the blend is created, the dough is transferred into proprietary tortilla equipment where it’s formed and cut. The tortillas then

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BonusFeature travel onward through a continuous oven, where they bake for seconds before exiting at the other end. Wire conveyors then allow the tortillas to cool slightly before employees remove, stack and stage them for subsequent use on the line. Next, operators transfer filling mixtures into filling machines positioned beside each filling line. Once tortillas are placed on the production belt conveyor, they receive filling and are quickly folded and rolled via a proprietary process. Rolled and filled tortillas then head into a continuous fryer, which cooks for approximately 30 seconds. Operators then check the newly created (now golden brown) tortillas before they travel into a spiral freezer. Taquitos travel upward and exit the freezer in the second-story packaging room. Here, operators pack them in new stand-up, recloseable pouches,

Freshly made tortillas travel on a multi-level cooling rack before being transported to the taquito line.

apply code date registration and feed them to automating casepacking lines. Ruiz Foods’ successful transition to stand-up pouch has officials considering even more new product and package applications, without expanding the plant’s existing factory footprint, Miller says. Team members also add their own outer case labels to track product in the plant’s adjacent storage

freezer. Each Ruiz production line is flexible enough to process as many as six to eight different items, Miller says. And, even as pallet loads ship out to Ruiz Foods’ thirdparty distribution network, Miller says he and Dinuba team members remain focused on the next load to come. “We always challenge ourselves to come up with new ideas,” he says. “Our supply chain goal is to be the industry’s leader and ensure the best experience for any consumer buying frozen Mexican foods and flavorful frozen snacks.” Regardless of how often or how drastically consumers’ demands change, Ruiz Foods holds the skills and qualities to continue being quickchange artists. Editor’s Note: Parts of this article were written and published in the January 2011 issue of Refrigerated & Frozen Foods, a sister publication of Snack Food & Wholesale Bakery.

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By Elizabeth Fuhrman | Photos courtesy of GNP Co.

ach year, regulations for wastewater treatment have become more stringent, challenging processors to develop new environmental initiatives and facilitate new technologies. Additionally, protein processors are working harder than ever to save water. “Our goal related to wastewater management as a protein processor is, full compliance at all times while

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optimizing the efficiency of the operations,” says Thomas Raymond, director of environmental sustainability at Hormel Foods. “Accomplishing this goal can be challenging when we are faced with evolving regulatory requirements and changes in wastewater characteristics due to the implementation of water-saving projects at our production facilities.”

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Another challenge the industry faces is tighter permit limits placed on wastewater released to municipal treatment facilities or receiving streams, says John Askegaard, manager of new technology for Tyson Foods. Tyson constantly works to enhance its food safety initiatives, many of which involve water use. At the same time it looks into these areas within its processing plants, it studies areas that may present potential opportunities to save water, Askegaard says. “Tyson Foods is continuously reviewing ways to improve our wastewater treatment processes,” he says. “Embedded within that effort is reduction of water use. Plants are being very inventive at identifying areas where water use can be reduced and formulating alternatives without compromising quality or safety. We implement best-management practices, employee education and various water-conservation measures in support of water reclamation as part of our efforts to

conserve and reuse water.” The company believes technologies are emerging now that will benefit the entire industry as it relates to wastewater. “Tyson is evaluating and piloting several new technologies that have the potential to improve our specific wastewater processes,” Askegaard says. “These concepts are still under evaluation at this time.” Hormel Foods also is taking steps

to advance water conservation and wastewater treatment in its facilities. “We have a longstanding tradition of investigating, reviewing and applying technology to improve our operations and minimize our environmental footprint,” Raymond says. “At our manufacturing facilities, we focus on reducing wastewater volume and strength at the point of generation. We continue to look at applying technologies and practices that improve manufacturing efficiency and improve equipment reliability.” Hormel Foods’ recent advancements to manage water use and wastewater treatment have included installing closed water-cooling systems, investing in new wastewater treatment equipment, upgrading existing processes and working with municipal partners to identify long-term approaches that can meet a common goal of efficient and effective wastewater treatment. Although Hormel Foods regularly reviews new technologies for

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wastewater treatment to help achieve treatment goals, conservation continues to play a large role in its sustainability efforts. “The application of advanced technology is important, but we must also continue to focus on source reduction and process efficiency as well,” Raymond says. New technologies In order to meet increasing government regulations on wastewater, some processors are constructing new facilities to manage new requirements. At the end of July, GNP Co. — formerly known as Gold’n Plump Poultry — finished a major wastewater expansion at its Cold Spring, Minn., facility to maximize U.S. Environmental Protection Agency and Minnesota Pollution Control Agency rules and limitations. The company spent two years researching new technologies for the wastewater facility, and environmental manager Clay Watson believes parts of the facility’s system are among the first in the poultry industry. With a flow of about 1.4 million gallons a day, the chicken-processing facility already has experienced improved results in its wastewater treatment system’s turbidity, or the cloudiness of the wastewater, in comparison to its previous system. “Typically a wastewater treatment plant’s water will have 8 to 12 turbidity going through the system, and now we are seeing turbidity of 0.1 to 0.3,” Watson says. GNP’s improvement in 72

turbidity partially is achieved through membrane bioreactors. “The wastewater gets vacuumed through little hallow fiber filters that have a 4-millimeter size opening, and you basically come out with what looks like drinking water,” Watson says. The company’s new wastewater treatment plant operates 24 hours a day, seven days a week. With the facility upgrades, which include biological phosphorus and ammonia nitrogen removal, the company also has been able to achieve energy savings using new technologies. Another upgrade that has resulted in savings was the installation of an energy-efficient air blower system. “Air is pumped into the aeration system, or the activated sludge, and also into the membranes,” Watson explains. “These blowers are the highest efficiency blowers on the market today. If you look at them, they almost look like a jet engine. The blowers run about 30,000 to 35,000 RPM and produce up to 2,800 cubic feet per minute. Once they get up to that level, they actually glide in air. There are no bearings. The blowers have a five-year payback.” From a labor standpoint, the blowers also do not require any mechanical work, such as belt and oil changes, which can be hazardous, Watson says. In addition, the air blowers are set on variable frequency drives (VFDs) that are controlled by the amount of the oxygen reduction output, or dissolved oxygen, that the company logs in its aeration system. The only maintenance requirement is air filter changing.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

“Once they are in place and running, they’ll just ramp up and down according to what the plant’s needs are,” Watson explains. On all of the facility’s pumps, GNP installed VFDs as well. “They ramp up and down as needed by PLCs and by probes to maintain efficiency,” Watson explains. “So the VFDs are saving us a tremendous amount of energy costs.” The probes the company installed also use advanced technology to deliver dissolved oxygen, and automatically inform the company how fit the wastewater material is, Watson says. In the past, the testing was done manually. “We’re relying on automation,” Watson says. “By going with more automation, it’s allowed the operators to better maintain the rest of the plant and gained more overall efficiency in our operations, which will allow the plant to operate better in the future.” Already having measured the carbon footprint for GNP’s Just BAREbranded products, the company is committed to reducing its carbon footprint. With plans of improved energy efficiency in the future, GNP installed solar panels on one side of its wastewater treatment facility and is selling that electricity back to its electric utility. Although the solar panels do not result in immediate cost savings, they help support the company’s long-range goal of becoming a sustainability leader in the industry, says Paul Helgeson, GNP sustainability manager, and fourth-generation team member from the Helgeson family —

which founded GNP. “The panels were installed because they help generate awareness for our commitment to renewable energy generation — it’s something visual,” he says. “That’s because it’s not just about the big things, but it’s also about the small things that lead to a significant impact over time in reducing our carbon imprint.” The company also plans to add prairie grass and a stormwater pond. The challenge of any wastewater treatment plant is keeping the plant balanced. For any protein processor, the challenge is using the water and then putting it back into the environment better than it came in. Some of the data GNP has recorded so far has registered better than the data collected from water in the river, Watson says. With the new facility, GNP has been able to re-use about 300,000 gallons a day of treated water in its processing plant in non-contact areas. The company started working with the U.S. Department of Agriculture and other

government agencies about the potential of being able to use treated water in additional areas of the plant. In addition, since 2000, GNP has centrifuged its secondary sludge and supplies the resulting product to a business that produces organic composting from it. GNP built the new wastewater treatment plant with an eye on regulations and their potential effect on future production needs. Today, Minnesota’s regulations have applied a phosphorus limit to the company’s wastewater, which the new treatment facility meets.

“We were definitely limited on our flow prior to this construction,” Watson says. “Now the Cold Spring plant is able to process probably 15 to 20 percent more birds if they ever need to in the future. … The wastewater treatment plant will not be a stopgap.” GNP continues researching new technologies for its facility, such as reverse osmosis, which could possibly bring its wastewater to drinking water standards. “In terms of water and wastewater, I don’t think the technology will ever end,” Watson says.

SEPTEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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SustainabilityColumn

Economic growth

Social Progress Environmental stewardship

A sustainability checkup How to assess the pulse and vitality of a sustainability program, based on Tyson Foods’ own strategic analysis. sors, whether just beginning or several Food-processing companies are no years into their sustainability journey, longer viewed as sustainable solely may find themselves questioning the based on their “green” efforts. The direction, and potentially the relevance, industry serves a global commuof their sustainability program. nity faced with unequaled economic, As manager of Environmental, Health environmental and social challenges and Safety Training, and Sustainability including: Q high unemployment rates and for Tyson Foods Inc., I help design our sustainability program and am respondevastated financial markets, By Leigh Ann Johnston, Q endangered natural resources and Tyson Foods sible for producing our company’s Editorial Board biennial sustainability report. As I look destructive weather events, and Member Q a rising number of adults and for opportunities to strengthen key elements surrounding the pulse and vitality children suffering from health issues of our company’s sustainability program, I’ve found related to diet and nutrition. the following list of questions and insights helpful. These challenges bring increased pressure I believe they ensure our sustainability efforts are from stakeholders for companies to develop relevant to our business, and economic, environsustainability strategies incorporating economic, mental and social impacts receive consideration in environmental and social responsibility into evTyson Foods’ decision-making process. ery aspect of a business. Therefore, food proces-

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

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SustainabilityColumn Is your definition and vision for sustainability y relevant to your company?

Have you conducted a sustainability inventory? Companies often view sustainability as separate from their core business. The truth is, much of what a company does throughout the normal course of business is directed toward sustainable practices. A sustainability inventory is a crucial step for identifying gaps in how a company performs against its mission, strategy and, most importantly, its definition and vision for sustainability. When conducting a sustainability inventory, consider everything you do. For those in the meat and poultry industry, evaluate not only environmental efforts, but also practices related to, but not limited to, food safety, animal welfare, employee relations and safety, shareholder return, supply chain engagement and community support.

A “one size fits all” approach to sustainability doesn’t exist. This, however, allows companies to define and implement a sustainability program unique to their business. A review of internal documents and statements pertaining to a company’s culture, mission and strategic direction is a must. These items commonly serve as the foundation of a company, often articulating the fundamentals of a business approach. A company’s definition of and vision for sustainability should be aligned and integrated with these business elements. If a solid connection isn’t made, sustainability efforts are likely to be more of an afterthought rather than part of an overall business strategy.

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SOLUTIONS THAT WORK.

How do you choose sustainability goals? Sustainability goals are the building blocks for achieving a vision. At Tyson Foods, our goals must be integral to our business. I urge you to not set goals separate from your company’s core business. Instead, set sustainability goals that are: Q based on historical, quantifiable data; Q manageable and impactful (don’t try to set a sustainability goal for everything you do); Q achievable (but raise the bar to a level in which economic, environmental and social improvements can be recognized), and Q meaningful, understandable and quantifiable. Additionally, establish an internal system for managing and assessing your performance against your goals. The system should assist with goal prioritization, improved communication, regular performance updates, accountability and innovation.

Are your sustainability communication efforts on target? Sustainability communications share information on goals and activities implemented to fulfill a sustainability definition and vision. Ensure your communications are accurate and effective by: Q understanding how transparent you can be with your communications, Q verifying the accuracy of your statements with the people in charge of the goals and activities you are discussing, Q making sure you can support any claim you make, and Q celebrating your wins and taking credit for all you are doing. Before releasing your message, determine how updates will be managed and who will be contacted for questions and inquiries, and educate your employees on the message you want them to carry forward. Once you start communicating, don’t stop. Sustainability is a process of continual

improvement; which brings new opportunities to communicate wins. No one knows your company better than you. Challenge your company to define and act upon sustainability in a manner that encompasses all you do and drives positive economic, environmental and social change now and in

the future. Leigh Ann Johnston is part of a three-person team leading Tyson Foods’ sustainability efforts at the corporate level and is currently serving the cochair of the American Meat Institute’s Sustainability Committee. To learn more about Tyson Foods’ sustainability efforts, review the company’s online sustainability report at http://www.tysonfoods. com/Sustainability/2010/SustainabilityAt-Tyson-Foods.aspx.

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FoodSafety

The

CHALLENGES of

CIP/OPC

Clean-in-place and open-plant-cleaning systems still grapple with food safety, environmental issues, water costs and availability, and energy costs. By Megan Pellegrini

n one of the larger food recalls to date, this summer Cargill Meat Solutions voluntarily recalled about 36 million pounds of ground turkey meat on fears it was contaminated with Salmonella bacteria, possibly the drugresistant Salmonella Heidelberg strain. The company also halted production at its Springdale, Ark., plant for a few weeks until the source of the strain was discovered. The cause? Sanitary concerns, which were addressed by improving antibacterial technology in the chilling system, adding antibacterial sprays in the harvest line and requiring Springdale meat suppliers to include Cargill’s antibacterial technology in the harvest process. Indeed, that is the purpose of cleanin-place (CIP) and open-plant-cleaning (OPC) systems, which certainly play an essential role in the production process, but have remained largely unchanged for at least a decade — if not 40 to 50 years. The Cargill recall brings renewed attention to this critical process as bacteria strains become more wily and resilient.

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Photo courtesy of Kevin Keener, Purdue University

In the meantime, the meat and poultry industry continues to grapple with balancing food safety with environmental issues, water costs and availability, energy costs, and centralized, highly complex food-processing facilities with wide distribution. “Historically, processors have been more concerned that their equipment has the proper function, throughput and worker safety, and cleanability has been an afterthought in some cases,” says Kevin Keener, Ph.D., professor of food science, Purdue University, based in West Lafayette, Ind. “Because of recent outbreaks that may have been associated with equipment not being prop-

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | AUGUST 2011

erly cleaned, such as in the cracks and crevices, there is more of a movement under way — especially after the Food Safety Modernization Act was passed — to examine if machines are getting clean down to the microbial level.”

CIP vs. OPC CIP is geared toward industries that require frequent internal cleaning of their processes in closed spaces, such as in meat, dairy, beverage and brewing plants. With CIP, meat processors can clean the interior surface of pipes, vessels, process equipment, filters and associated fittings without disassembly through recirculating pipelines. A typi-

cal CIP system might include a solution reservoir, a supply pump and a return circuit. Or, a tank or other type of vessel, a spray device and some type of return device are used. As a result, the cleaning process should be faster, less labor intensive and more repeatable, with less risk of chemical exposure to employees. To enhance the effectiveness of the cleaning process, elevated temperatures and chemical detergents are commonly used, as well. OPC, on the other hand, is a manual cleaning practice, usually involving sanitizer and elbow grease, for large, open spaces. “CIP is a big investment at first, but the pumps are pretty stable and require only regular maintenance,” says Steven Goodfellow, Ph.D., director of technical services, Deibel Laboratories, based in Gainesville, Fla. “However, smaller processors generally don’t do clean-inplace, just the big ones.” If CIP is done right, it stands little chance of recontamination because it is a closed system, he says. However,

if a part does become contaminated, the bacteria will be hard to get rid of because CIP systems are not meant to be taken apart. “Most of its challenges revolve around its basic construction,” he says. “Once CIP systems are put together, processors can’t assume they are clean and sanitized, because there are still unsealed areas and cracks that product can hang around.”

Deconstructing the pieces West Liberty Foods uses both CIP and OPC methods for its operations. “Certain applications dictate whether we use CIP or OPC, but the vast majority of our plants use OPC. Anything that can generate robust cleaning water is key,” says Lee G. Johnson, Ph.D., vice president of technical services, West Liberty Foods, noting the ability to be able to dissemble and clean equipment with CIP is important. For example, West Liberty Foods uses CIP for the pipes and closed systems in its slaughter plants, he says.

To reach the nooks and crannies in its meat and ready-to-eat meat equipment, West Liberty Foods will also put the equipment parts in CIP tanks, which use heat and detergent. “Also, we put logs through slicers so there are lots of nooks and crannies in equipment that need to be scrubbed, torn apart and cleaned,” he says. “The ability to take slicing equipment apart so it can be cleaned and put back together is big for us, and will lead to continued strong food-safety results.” Johnson notes it’s also critical to fit the CIP piping and delivery systems accurately, so the pumps don’t leak, the heat is right and the pipes don’t become blocked with hard debris. “A big challenge is the fact that there isn’t one solution for meat plants so they can do the vast majority of their cleaning with just CIP,” he says. “If equipment manufacturers can figure out how to do open areas with CIP, that would save time and money.”

New cleaning methods Processors are always looking at

Verify proper cleaning techniques By Russ Gearhart and Dan Porter, contributing writers One of the most important aspects of food processing relies on the effective cleaning and sanitizing of the food facility processing equipment and associated production and non-production areas. A food processor may have the best quality ingredients and the best production skills, but without proper cleaning and sanitizing the processor would lose product quality and shelf life. Within most food-processing sanitation programs, there are three basic cleaning techniques: Open-plant-cleaning is referred to as OPC, Cleaned out of place as COP and Cleaned-in-place as CIP. OPC applications represent manual and mechanical cleaning methods used to clean the surfaces of food-processing equipment systems. These methods could include foam application, pressure wash, and bucket and brush application systems. COP applications are essentially soak tanks with recirculation pumps to move the cleaning solution through and around parts to be cleaned. This pumping action aids in the cleaning function, often enhancing cleaning results when

compared to soak tank cleaning systems. CIP applications are those where the cleaning solution, the rinses and sanitizer are pumped through the plumbing (lines), tanks and valves used during the manufacture of the product, therefore reducing the need to disassemble equipment to clean it. Each of these cleaning processes follow a basic “Sequence of Clean” which is necessary to assure food-processing sanitation programs will be top quality. This process includes the thorough removal of gross soils prior to rinsing, a pre-rinse with potable water, application of an appropriate alkaline, chlorinated alkaline, or caustic detergent, a post rinse with potable water, inspection of the area or equipment, re-clean if necessary and finally the application of a sanitizing agent to the equipment and area previously cleaned, if required or desired. In some cases a second clean may be performed prior to the sanitizer step using an acid to remove hard water or other scales that may form. This cleaning step would be followed with a rinse prior to the sanitizer application. Continued on page 80

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FoodSafety Continued from page 79 It is important to assure the correct level of cleaner and sanitizer are used in association with each of the cleaning methods. Sanitizers are commonly measured in ppm or parts per million. Application of chemicals to clean and sanitize equipment and areas follow the TACT principles: Time, Action, Concentration and Temperature. These principles apply to all basic cleaning techniques. (T)ime — reflects the time allowed for the chemical to make contact with soils and the surface to be cleaned. This could be wash time through piping, dwell time on a surface or soak time in a COP tank. (A)ction — represents the type of mechanical action used to clean a surface. Flow rate through CIP piping (a minimum of 5 feet per second is required), agitation in a COP tank, the physical action of manual cleaning, or the action required to rinse foam chemicals from surfaces being cleaned would all be example actions. (C)oncentration — suggests the proper chemical is being used at the appropriate concentration. Different concentrations are likely needed for each type of cleaning application. As an example, a high-volume CIP system would likely require a relatively low concentration where a foam application of chemical would require a relatively high concentration. (T)emperature — highlights the need for rinse application, cleaner applications and sanitizer applications to be at the correct temperature. For example, foam cleaners are normally used with ambient water temperatures, whereas COP chemicals and CIP chemicals are used at hotter temperatures. Rinse temperatures may also vary depending on method of cleaning and the soils which may be present. Use the chemical suppliers’ recommended temperatures. When troubleshooting a shortfall in a sanitation program, it is common to review the cleaning program following the TACT principles presented above. If one or more of these variables are out of line, the sanitation program may fall short of its goal. As examples: During CIP, there should be a proof of flow step, followed by rinse, a wash, a potable water rinse and if necessary or required, a sanitizing step. It should be confirmed that each of these steps are actually running, and that each are at the right temperature and for the correct duration of time. Although many of these systems are “automatic,” it should not be assumed that each step occurs correctly. It should always be assured that the correct physical piping connections have been made before a CIP cleaning process is initiated. One should never make connections and start the system without first verifying proper connections have been established. Confirmation of the times, actions and temperatures calls for observation of the system while running. In OPC applications, equipment to be cleaned should be dismantled as far as possible to help insure adequate cleaning Continued on page 82

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | AUGUST 2011

Photo courtesy of Scott Russell, University of Georgia

ways they can gain more access to their processing equipment, so they can be opened more easily during OPC. “For example, if processors could have a way to clean underneath their dicer system — by lifting it up for cleaning or clean-in-place — that would be an advantage,” says Keener. Instilling turbulence into the CIP or OPC pump lines, in theory, should increase the scrubbing action of the cleaners, thereby requiring less chemicals and water in the system, notes Keener. However, many plants don’t utilize this procedure because of the additional costs involved during installation. Electrostatic sprayers, while around since 1978, are receiving renewed attention for after sanitization methods because they use little sanitizers but coat an entire area. “It’s a more cost-effective use of chemicals, provides more coverage and is better for the environment,” says Scott Russell, Ph.D., professor of poultry processing and products microbiology, The University of Georgia. “However, chemical companies don’t want clients to use them because they use less chemicals.” Product surfaces are receiving renewed attention, as well. The European Hygienic Engineering & Design Group (EHEDG) has developed scales to measure the smoothness of equipment surfaces, due to concerns that rough areas can harbor bacteria in their cracks and crevices requiring more attention during open-plantcleaning. In addition, Russell notes new technologies are available that will transform plastic and metal surfaces into antimicrobial barriers to prevent biofilms from forming. This technology can be used in cutting boards, refrigerators, freezers and metal. However, the technology can’t be sprayed on; it must be incorporated into the product design from the beginning. So processors would have to replace equipment one by one with new

antimicrobial-treated equipment. “Companies have to see that this technology is cost-effective before they try it,” he says.

A chemical reaction The last 10 years have also seen incremental improvements in the cleaning compounds used with CIP and OPC to improve their cleaning ability and shorten the length of time needed to circulate the chemicals. Anytime processors switch to a different chemical system for cleaning and sanitizing, they run the risk of altering the processing system through corrosion or formation of biofilms, says Ronald H. Schmidt, Ph.D., retired food science and human nutrition professor, University of Florida. “However, if the equipment is manufactured according to appropriate sanitary design criteria, these effects

would be expected to be minimal,” says Schmidt. “Further, many alternative chemicals are less corrosive to equipment than the traditional chemicals.” In fact, for the past 20 to 30 years, food industry cleaning suppliers have worked on developing more environmentally friendly detergents and systems to minimize the environmental impact of cleaning and sanitizing through reducing effluent load (BOD and pH) and by decreasing the use of chemicals that are less environmentally friendly (such as phosphates, nitrates, sodium salts and chlorine), he says. “Single-phase or single-cycle CIP detergents are now being marketed that are designed to replace the more traditional alkaline/chlorine-based products to remove fats, minerals, and proteins in one wash cycle,” says Schmidt. “In addition to lowering the chemical discharge, such detergents also shorten the clean-

ing process and save on water usage.” Many innovations in the design of cleaning systems have been developed, as well. They reduce the overall effluent load through chemical recovery systems, improving and redesigning CIP systems so they use less water and improve cleaning efficiency. “These systems use engineering principles and evaluation methods that focus on the mechanics of the system through more efficient pump systems, piping design systems, automatic valve systems with improved sequencing and improved water flow and control, and the use of vortex breakers,” says Schmidt. In recent years, there has been increased use of food product recovery systems where appropriate, he says. Such systems remove much of the residual food product in the system prior to cleaning, thus lowering the cleaning

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FoodSafety and sanitizing load and allowing for the use of less water and chemicals. However, disposal of the recovered product may be an issue. “Depending upon the situation, recovered product may be used in rework or reprocessing, byproduct utilization or animal feed,” says Schmidt. Improved monitoring of the product stream using electrical conductivity or optical methods has also resulted in less water waste in cleaning systems. As the CIP and OPC system manufacturers continue to make incremental improvements to their systems, it’s important to remember the role employees play too. “Equipment may function well, but if employees can’t clean it and the end result negatively impacts the company reputation, then the long-term viability of the company will be damaged,” says Keener.

Continued from page 79 is performed. As these cleaning methods are not automatic or mechanically controlled, it is necessary to verify visually that the necessary steps are being performed, in the correct sequence, at the correct temperatures and concentrations. If equipment systems to be cleaned can be safely run during cleaning this may aid in the cleaning process. For example, during foam-cleaning of conveyors, cleaning agents may penetrate the soils hidden in the components of the conveyors more effectively if the conveyors are operating. COP operations — although somewhat mechanical — are not in most cases automatic. Therefore when troubleshooting a shortfall in a COP system, it is important to check temperatures and chemical concentrations. It is also important to insure that the flow of the solution in the tank is reaching the equipment surfaces to be cleaned. To achieve the best cleaning results possible, routinely monitor the TACT principles listed above. Independent of the basic cleaning procedures in use — CIP, COP or OPC — it is important to follow label directions. This is especially true when using sanitizing solutions. When in doubt ask your chemical supplier for guidance. Russ Gearhart is Process System Specialist with Diversey’s Inc. Sector Expert Group for Diversey Inc., and Dan Porter is Senior Scientist & Global Applications Expert for Diversey Inc. For more information, they can be reached at [email protected] or [email protected].

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TechPackaging

From silver bullet to silver lining The expectations of sustainability in packaging applications have changed as the economy has soured and limped along. By Chip Bolton, J.H. Bolton Communications LLC

I

f you look at the landscape of sustainable packaging and meat processing, you will see quite an evolution over the past four or five years. Not so much in technology advancements, but in a more enlightened and reasoned view of the broader economic value that sustainability initiatives can have on business absent packaging formats constructed from renewable or compostable materials. Early on, according to a senior packaging manufacturing source, many meat processors were looking for real breakthroughs in materials that were sustainable. Now, most realize that there are no silver bullets, and sustainability is a much more complex proposition.

The easiest steps — and this by no means diminishes their impact — have been to go after low-hanging fruit by reducing energy consumption in their processes, thinning down their packaging materials and trying to redesign packages to take up less space during storage and distribution. One company has moved away from a paperboard sleeve on a lidded tray to a printed top-web.Yet another has moved to a thinner shrink film which enables them to reduce sealing temperatures, use less material and have fewer roll changeovers, because thinner material means more footage on the same roll. Further evidence is the sense of increasing awareness among processors about the sustainability benefits of protecting their products from damage or spoilage, thus keeping more from entering the waste stream. The relative benefit of extending shelf life for an extra two days can greatly outweigh a packaging weight reduction, say, of 10 percent to 20 percent, according to this same packaging manufacturer. The sort of packaging technologies that deliver here are traditional ones like enhanced sealability, more robust gas barrier properties or unique package designs that can reduce material volume or portion products. Those traditional technologies are also being examined in another way, says a product development veteran with 30 years of experience in the food industry. Some

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processors are looking to modify or change packages made currently from multi-layer materials — which would carry an SPI recycling code of 7 — to those that are more recycling friendly such as polypropylene or polyester. Certainly this would create another marketable point to communicate to shoppers. The critical caveat here is that in doing so the modified package maintains the performance characteristics required for its application, a task easier said than done in some cases. Three years of recession and glacially sluggish recovery have left meat processors in a mood where they are less likely to invest in new capital or accept higher material costs when it comes to packaging. However, costsaving programs are alive and well, with many companies working to improve yields and energy efficiencies to improve their bottom lines. Ironically, in scouring their packaging costs for any efficiency they can find, they have helped to change the expectations of sustainability to include a demonstration of economic value, not just environmental value. Chip Bolton is a principal at J.H. Bolton Communications LLC, with more than 20 years experience in the food packaging industry. For more information, contact him at (864) 525-3494, or chpbolton@ gmail.com.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

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Latest and greatest on display Process Expo promises to be a new technology showcase for the entire food industry. The food-processing industry is so vast, that dozens, if not hundreds, of trade shows, have been established to accommodate all of its sectors. It can be troublesome for large companies that may have multiple operations that cover the industry. This November, however, Process Expo 2011 will bring the entire industry together to see the newest equipment, supplies and services. Sponsored by the Food Processing Suppliers Association, Process Expo is expected to draw more than 10,000 attendees from around the world. They will all gather in the South Hall of Chicago’s McCormick Place to learn about the latest trends, see demonstrations of the latest food processing and packaging equipment and technology and address the most pressing issues affecting the marketplace. Along with the meat, poultry and seafood industries, attendees representing the snack, beverage, packaging, confectionary and dairy industries will be in attendance. More than 350 exhibitors, representing more than 200,000 square feet of exhibition space, will be there as well. In addition to the show Áoor, there will be more than 30 hours of educational programming, including a track dedicated to Process Expo’s attendees from Latin America. “Manufacturing Solutions: Practical Responses to Food Industry Challenges” will focus on key issues of concern in the food and beverage industry, and solutions that can be incorporated into an ongoing operation today. Additionally, the Exhibitor Spotlight Theater will feature short technical workshops from many of the Process Expo exhibitors, covering a wide variety of topics of interest to food processors.

Process Expo, November 1-4 Where: McCormick Place, South Hall, Chicago, IL Exhibit hours: Tues.- Thurs.: 9am – 5pm; Friday: 9am – 2pm Exhibitors: More than 350 Attendees: More than 10,000 expected Exhibit proÀles, pages 87-95

AmTrade Systems Inc.

Ashworth Bros. Inc.

Innovation is your future - Amtrade along with our German based partner Schroeter Technologie, can be a large part of this future. We supply the most innovative, highest quality machinery in the industry. Amtrade´s product line: Hot – Cold – Green - Service Ovens, Bake units – Chillers, Drying rooms – Scrubbers, Afterburner systems – and all full range of Services For Process Expo show Amtrade´s show display focuses on emission control. We offer a range of emission reduced smoke generators and exhaust cleaning equipment, beside our range of smoke houses and chillers. New: SMOKjet RF, a high power friction smoke generator and the CLEENjet RWK, a modiÀed wet scrubber, latest generation, for pollution control. Visit us on booth 4812 and enjoy our hospitality.

Ashworth invented the Àrst spiral over 40 years ago and is now the world’s only manufacturer of both metal and plastic spiral belts, offering customers the best belting solutions for their speciÀc requirements. For over four decades, we’ve pioneered belt advancements that maximize throughput while minimizing life-cycle costs, and have been granted more patents than any other spiral belt manufacturer. Ashworth belts featured at Process Expo will include the super-strong Omni-Pro®, the USDA-accepted plastic Advantage belt, and the drop-in replacement for self-stacking spirals, ExactaStack. In addition, Ashworth will display examples of their straight-running Cleatrac and woven-wire belts. Learn how to increase capacity and improve efÀciency from The Conveyor Belt Experts at Process Expo Booth #1016.

AmTrade Systems Inc. 13720 Wayne Road Livonia, MI 48150 (734) 522-9500 Fax: (734) 522-9549 www.amtrade-systems.com Process Expo Booth #4812

Ashworth Bros. Inc. 450 Armour Dale Winchester, VA 22601 (800) 682-4594 Fax: (540) 662-3150 www.ashworth.com Process Expo Booth #1016

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Beacon Inc. Beacon Inc. offers more than 60 years of experience in the process of designing and manufacturing stainless steel processing racks that will work for each processors speciÀc requirement. Beacon has engineered trucks and screens to process a wide range of products and weight loads, from jerky to hams and everything in between. Beacon has probably custom engineered and built more unique racks than any supplier in the industry. Our design process includes; gathering the correct information, designing the most efÀcient racks, supplying detailed engineering drawings, working through the details and possible changes, and then manufacturing the perfect rack based on all this critical customer interaction. Whether a customer is looking for two or 200 trucks, Beacon gives each customer high-quality service throughout the design process which results in all of our customers getting equipment that gives them maximum yields at the best possible cost. Beacon Inc. 12223 S. Laramie Alsip IL 60803 (708) 544-9900 Fax: (708) 544-9999 [email protected] www.beaconmetals.com Process Expo Booth #134

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CSB System International Success is a Matter of System – Maximizing ProÀts with CSB-System Software Solutions With more than 33 years of experience, CSB-System is the leading provider of innovative software solutions for the protein industry. Our industry speciÀc fully integrated solutions provide our global client base with long-lasting competitive advantages by increasing efÀciency, reducing costs and maximizing proÀts. It is our unparalleled capabilities relating to Traceability & Recall Management, Recipe Management, Yield Management, Costing and Gross Margin Analysis that emphasizes our focus on the protein industry. We are committed to providing functionality for the entire enterprise, including Scale, Labeling & Scanning, Inventory Management Systems, Livestock Solutions and Enterprise Resource Planning. Take advantage of our expertise – contact us in order to learn more about our state-of-the-art software solutions for the protein industry. CSB-System International Inc. USA 625 PlainÀeld Road, Suite 322 Willowbrook IL 60527 (800) 852-9977 [email protected] www.csb-system.com Process Expo Booth #2449

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

FOSS FOSS develops and produces analytical instruments that improve production efÀciency, product quality and proÀtability. As the leading producer of analytical solutions to the Food and Agricultural industries, FOSS offers solutions for on-line, at-line, and bench analysis of ingredients, in-process production, and Ànal products. In-process solutions include: ProFoss™ - a near infrared (NIR) process analysis system that allows food and feed producers to gain tighter and more proÀtable control of products in the production process. MeatMaster™ is the intelligent way to carry out meat analysis and optimize your meat production. It can scan up to 22 tons per hour of fresh, frozen or packed meat and determine fat content, meat contamination and weight with a high accuracy rate. Visit booth # 3615 to see for yourself!

FOSS 8091 Wallace Road Eden Prairie MN 55344 (952) 974-9892 www.foss.us Process Expo Booth #3615

Fristam Pumps USA Fristam Pumps USA manufactures high-performance, high-purity stainless steel pumps, blenders and mixers. Fristam’s booth features the new FKL A positive displacement pump series with clean, rounded exterior; split-style gearbox for easy access to bearings and shafts; and customizable portto-port dimensions for easy drop-in replacement of other PD pumps. The FKL A is built for no-disassemblyrequired “True CIP.” Its balanced rotors, large diameter shafts, and a heavy-duty gearbox make it durable and reliable. Additional products on display: Q Powder Mixer for quick and efÀcient blending of dry and wet ingredients into a Áuid stream. Q FS shear blenders for inline mixing. Q FL II series PD pumps for gentle product handling. Q Easy-maintenance FPR series pump with front loading seal. Q Heavy-duty FP series centrifugal pump. Q High pressure pumps. Q FZX series self-priming pump for CIP return/aerated products. Fristam Pumps USA 2410 Parview Rd Middleton WI 53562 (800) 841-5001 www.fristam.com/usa Process Expo Booth #2116

GEA Convenience-Food Technologies

All you need for a world of changing tastes GEA Convenience-Food Technologies (formerly CFS) specializes in performance focused solutions for the food industry. From a single machine or packaging material to a complete production line for the preparation, marination, processing, slicing and packaging of primarily, poultry, Àsh, seafood and cheese based products. Bringing Value to our customers Everyday Q The BRAND NEW CFS Fresh Retail Injection Line’s marination target accuracy offers a standard deviation of less than 1 giving a unbeatable payback on your investment. Q The CFS GigaSlicer has been developed with the highest hygienic design and tooled for precision quality, and the highest production rates on the market. Q The traditional powerhouse PowerPakNT has a new tool change over application making Áexibility easier and more efÀcient. Come see us at Process Expo booth 431. GEA Convenience-Food Technologies 8000 N. Dallas Pkwy Frisco TX 75034 (800) 388-2601 Fax: (214) 618-1200 www.cfs.com Process Expo Booth #431

Grote Co. Celebrating 40 years in business, Grote will display its latest developments in slicing and depositing technology at Process Expo 2011. Showcased equipment includes the Slicer/Applicator 530E, Waterfall Topping Applicator, and Horizontal Bread Cutter. Grote’s industry leading Slicer/Applicator 530E features numerous design improvements that greatly enhance both sanitation and performance. Notable changes include a remote enclosure for placement of all electronics outside the main slicer body, sloped and hermetically sealed framing, stainless steel bearings, sanitary leveling feet, and full 6-inch stroke capability. Grote’s popular Waterfall Topping Applicator has also been recently redesigned to meet today’s highest standards in sanitation and cleanliness, while retaining several unique design features which deliver optimal product distribution over a wide range of IQF toppings. The 2-lane Horizontal Bread Cutter is Grote’s newest slicer. It is ideal for cutting a wide variety of fresh breads and breakfast rolls, and easily integrates into existing sandwich assembly operations. Grote Co. 1160 Gahanna Parkway Columbus OH 43230-6615 (614) 868-8414 [email protected] www.grotecompany.com Process Expo Booth #1406

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Handtmann Inc.

Harpak-ULMA

Process Expo will host the global launch and Àrst public demonstrations of Handtmann’s new 400 links/minute Natural Casing Automation system featuring seamless integration of robotic orientation and loading functions with Handtmann’s VF stuffer and high speed PVLS 125 revolving head/paired nozzle linker. Handtmann will also be demonstrating its Coex MFD system with precise portioning and perfect distribution of co-extruded inner and outer elements for products like meatballs and croquettes. Additional displays include the Dual Horn continuous stufÀng, linking and hanging equipment, the Handtmann Burger Former, and the Handtmann HVF series that has revolutionized whole muscle stufÀng and portioning. Handtmann products enable traditional old world quality with new economy precision, delivering added value through high operational accuracy with unmatched consistency, improved control over product quality and portioning, and the next generation of system management and tracking capabilities. Handtmann delivers industry leading accuracy with broad spectrum efÀciency that dramatically reduces residual waste while using less power, water and labor.

With today’s extraordinary demand for packaging excellence, Harpak-ULMA stands alone. Our unique experience allows us to offer completely integrated packaging and handling systems. HarpakULMA offers solutions for all your packaging needs - from simple, single components to highly complex, automated, fully integrated packaging lines. Our team of experts systematically reviews the individual needs of each customer to develop cost effective, efÀcient and superior packaging solutions. Harpak-ULMA is the North American distributor of G. Mondini tray sealers, ULMA primary packaging equipment, and RAMA secondary packaging machinery. Our capabilities include packaging equipment for the food and non-food industries including: Tray Sealing, Flow Pack, H/F/F/S, V/F/F/S, Skin Pack, Side Seal, Stretch Wrap, Shrink Wrap, Blister, Robotics, Meal Assembly, Cartoning, Retail Ready, Sleeving and Case Packing. HarpakULMA is a full service supplier offering customer installation, training and ongoing technical support.

Handtmann Inc. 28690 N. Ballard Drive Lake Forest, IL 60045 (847) 808-1100 or (800) 477-3585 Fax: (847) 808-1106 www.handtmann.com Process Expo Booth #1802

Harpak-ULMA Packaging LLC 175 John Quincy Adams Rd. Taunton MA 02780 (800) 813-6644 [email protected] www.harpak-ulma.com Process Expo Booth #602

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Hoegger Food Technology Inc. Hoegger designs and manufactures process machinery utilized in the meat and food industries. We offer innovative system solutions for bacon, various other meat form pressing and in-package continuous cooking/chilling process lines for sausage products, cooked ham, turkey breasts, menu components, convenience foods, etc. Expert personnel support our clients with application consultation, customer service, and assistance during product and process development, either at the customer’s facility or at our in-house laboratories. YIELD is PROFIT Our state-of-the-art bacon and meat presses maximize yield, minimize waste and produces a great looking result. Stop by at Process Expo to discuss your process needs and challenges. Come see our full machine line up and talk to our application experts. Uncompromising FOOD SAFETY in the Bag The continuous in-package cooking/chilling process by Hoegger ensures the highest degree of safety, product quality, and long shelf life of the product, as well as high economic efÀciency. Hoegger offers a completely automated system solution. We focus on our customers´ beneÀts and are only satisÀed when our customers recommend our services to others! Visit us at Process Expo in Booth 2231. Hoegger Food Technology Inc. 322 Holly Lane N., Ste. 10 Minneapolis MN 55447 (763) 233 6930 www.hoegger.com Process Expo Booth #2231

Hollymatic Corp.

Materials Transportion Co.

Mepaco

From grinding to cutting to tenderizing to forming to food safety, Hollymatic has quality equipment for the meat processing industry. They are at Process Expo to provide cost-effective solutions for all of their customers. Hollymatic Grinders feature output rates that range from 3000 lbs/ hour up to 9900 lbs/ hour. Various horsepowers and options enable processors to choose a model that’s just right. The Hi-Yield Meat Saw optimizes power, reducing energy costs up to 11%. It also offers significant safety features with a Quick Stop Brake that stops the blade within 1 second of shut-off to dramatically reduce the risk of injury. The Tender-Rite Tenderizer offers power, safety, efficiency, and a competitive price to make it a real profit center for all processing applications. Hollymatic has a variety of Food Formers with capacities from 1200 patties per hour to 7800 patties per hour. Hollymatic will be exhibiting at Process Expo with their sister companies: NuTEC, Rollstock, and Former Associates. It’s a “4 of a Kind” event that you don’t want to miss. If you stop at each one of the companies exhibiting at Booth #2840 and collect a different Ace from each company, you can enter a raffle to win a new iPad. You’ll want to participate in this event!

The experienced team of engineers, designers and manufacturers at Materials Transportation Co. have set the standard for quality, durability and increased productivity in the food processing industry for over 60 years. Our Food Processing Solutions maximize customer production and proÀts. The MTC SmartCooker is a state-of-the-art, continuous batch cooker that provides cost effective processing with consistent, savory results! And, the newest member of our family, the MTC HLEC-S is a unique hydraulic dumper that minimizes contaminants in the dump zone by utilizing a two-stage carriage to separate pallets from cardboard boxes during the dump cycle. Come see for yourself. Visit us at Booth 4837 during PROCESS EXPO 2011 to learn how our industry leading line of Food Processing Solutions can maximize your production process and increase your bottom line!

Materials Transportation Company. We Provide Solutions.

As pioneers in the meat and food processing industries, Mepaco specializes in processing solutions for grinding, blending, cooking, and material handling challenges. Its comprehensive service and product offerings incorporate many pieces of standard machinery, system design and integration along with enhanced sanitary Ànishing and custom fabrication. At the 2011 Process Expo, among other things, Mepaco will be exhibiting its ThermaBlend™ line of cookers that features superior cooking, cooling, and blending characteristics. Constructed by ASME CertiÀed Welders, ThermaBlend delivers long lasting reliability even after years of stress from large-scale cooking and cooling applications. Mepaco will also be exhibiting its 420V Continuous Vacuum Stuffer. The 420V pulls and maintains full vacuum while it gently agitates the product in its vacuum chamber to expose more area to deaeration, resulting in greater density and yield. It also prepares the product for gas or vacuum packaging with vastly improved color and shelf-life. In addition to the ThermaBlend and 420V, the company will have Grinders and Mixer-Blenders on hand at its booth.

Hollymatic Corp.

Materials Transportation Co.

600 E. PlainÀeld Rd. Countryside, IL 60525 (708) 579-3700 Fax: (708) 579-1057 www.hollymatic.com Process Expo Booth #2840

P.O. Box 1358 1408 S. Commerce Temple TX 76503 (800) 433-3110 mtcworldwide.com Process Expo Booth #4837

Mepaco

200 W. Industrial Drive Beaver Dam WI 53916 (920) 356-7323 www.mepaco.net Process Expo Booth #1031

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Odenberg Inc. Odenberg has been delivering Sorting, Peeling and Process Analytics innovations to the fresh and processed food industry for over 40 years and will feature the new QVision in-line Fat Analyzer at Process Expo 2011, Booth 2619. Its unique and cost effective way of combining transÁection and nearinfrared measurements brings precision and sets a new standard for in-line analysis. Both fresh and frozen meat can be measured at any grind size. QVision is compact, easy to integrate into existing lines and allows customers to realize large savings through reduced lean giveaway, improved raw material control and elimination of “out of spec” fat claims. Odenberg can help you simplify and potentially automate your process control. Odenberg is now part of the world’s largest sorting group, Tomra Sorting Solutions.

Odenberg Inc. 4038 Seaport Blvd West Sacramento CA 95691 (916) 371-0700 www.odenberg.com Process Expo Booth #2619

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Patty Paper Inc. Over 50 years ago, Patty Paper Inc. (PPI) began converting large rolls of waxed paper into small squares to separate meat patties. Today, PPI offers a wide variety of waxed, coated, and printed papers for many uses including separating meat, poultry, cheese, bakery items, and deli foods. Its complete line of 100% FDA approved converted papers includes patty paper interleave, deli waxed interfold paper, picking paper, sheeted waxed paper, bulker or roll stock paper, steak paper, and meat board. Everything about PPI is 100% FDA approved. The company has helped raise the food safety bar when it comes to converted paper. Where most patty paper producers use string and cardboard to package their patty paper stacks, PPI uses a patented FDA approved individually wrapped paper packaging system. Individually fully wrapped packages keep each stack of interleaving paper clean and sanitary until it is used for interleaving. In addition, the individual sheets are protected from environmentally introduced contamination.

Patty Paper Inc. 1955 North Oak Drive Plymouth IN 46563 (574) 935-8439 www.pattypaper.com Process Expo Booth #3354

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Provisur Technologies Provisur® Technologies offers the industry’s broadest platform of automated grinding, mixing, separating, meat recovery, forming and slicing equipment through its Beehive®, Cashin®, Formax® and Weiler® family of brands. This year’s exhibit highlights new innovations from raw material to Ànished product in a solutions-driven display. Weiler® will display its Dominator® 14 Grinder, OMNI V™ 1107 Multi-Grinder and the new VersaGrind™ Pump Grinding System with AccuPump technology. Beehive® will bring its BeeMax™ Modular System that produces different meat textures and classiÀcations with minimal waste, capital expense and low operating costs. Formax® Forming will highlight its Maxum700® and advises guests to be on alert for a major surprise. Formax® Slicing will exhibit its PowerMax3000™, PowerMax4000™ and the new CashinEDGE™ Multi-Slicer with precision drive, 14.5 inch throat and blade speeds up to 2000 rpm. See us at the Process Expo Booth #3723.

Provisur® Technologies Inc. 9150 191st St. Mokena IL 60448 (near Chicago) (708) 479-3500 [email protected] www.provisur.com Process Expo Booth #3723

QMS International See us at our Booth #860 South Hall to see the new MKiii Servo Drive Siebeck Jet 2000 Tying Machines The MKIII is the all new 21st-century tying machine, featuring: Q Wear-free AC Servomotors Q Automatic reset of knotting unit and ring Q Smart Motion Controller with LED displays Q Ties up to 63 strings/min Q Selector switch for 1,2,3,4 cross and continuous tying See the Tying Machine for roasts and poultry, combine high performance with excellent reliability to offer maximum productivity. What it does: The Siebeck JET 2000 comes in a semi-automatic version and is a tying machine perfect for many poultry tying applications. Why it’s different: By eliminating the need for workers to tie poultry by hand, the machine can result in signiÀcant labor and cost savings. Why you should check it out: Cost savings, labor savings and health and safety reasons.

Reiser Reiser will introduce numerous new Vemag stuffers and linking solutions at Process Expo. Reiser will demonstrate the new Vemag FSL210 sausage linker, a single machine that combines sausage portioning, linking and link cutting. At the touch of a button, the preprogrammed FSL210 automatically adjusts to produce sausage links of any length, diameter or weight. It is the perfect solution for easily producing a wide variety of superior looking sausage products – all with clean cuts and closed ends. Also on display will be a similar Vemag FSL211 that is ideal for sausage portioning, linking and hanging applications. The new Vemag LPG209 highspeed sausage linker will also be demonstrated. The LPG209 features twin rotating linking horns and an automatic casing loading magazine. It automatically loads collagen casings, and with a quick changeover, allows semi-automatic loading of natural casings.

Remco Products Inc. A family-owned business since 1985, Remco Products has developed its presence as a trusted supplier to the food processing, pharmaceutical, jansan, safety, and material handling industries and provides a range of color-coded quality plastic products. With today’s increasing focus on hygiene and cross-contamination issues, Remco has taken the approach of proactive product development to help companies comply with stringent HACCP regulations and guidelines. The color-coded tools from Remco are made from FDA-compliant materials and ISO-certiÀed, providing the ultimate step in quality assurance and safety for the various industries. Remco’s wide selection of products includes polypropylene shovels, scoops, scrapers, kart tubs, and mixing paddles in addition to a line of color-coded metal detectable products. Remco also offers Vikan brooms, brushes, squeegees, pails, and handles.

QMS International Inc.

1833 Folkway Dr Mississauga ON L5L 2X1 Canada (905) 820-7225 Fax: (905) 820-7021 [email protected] www.qmsintl.com Process Expo Booth #860

Reiser

Remco Products

725 Dedham Street Canton MA 02021 (781) 821-1290 Fax: (781) 821-1316 www.reiser.com Process Expo Booth #2602

4735 W. 106th Street Zionsville, IN 46077 Phone: 317-876-9856 Fax: 800-585-8619 www.remcoproducts.com Process Expo Booth #2848

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Rollstock Inc. Process Expo attendees are invited to visit Rollstock’s Booth #2840 to learn more about the company’s line of packaging equipment. One of the pieces of equipment featured at their booth will be its RI200 Wash-Down Rollstock Machine. These machines are available in Àve standard web widths from 285 mm to 459 mm. Wider web widths and cut-offs are available upon request. The company will also have information on its new RC-300 Rotary Chamber Machine available. This machine features a 304L stainless steel modular frame with the ability to accept a multitude of chamber conÀgurations, sealing proÀles, and sealing widths up to 24 inches long. The RC-300’s patented constant temperature sealing system allows for the capability of sealing through the thickest bags, through contaminants, and through excessive folds and wrinkles. Rollstock will also have information available at the show on their 12 ft. and 16 ft. Rollstock models as well as its Zipper Packaging Machine. Rollstock will be exhibiting at Process Expo with its 3 sister companies: Hollymatic, NuTEC, and Former Associates. It’s a “4 of a Kind” event that you don’t want to miss. If you stop at each one of the 4 companies exhibiting at Booth #2840 and collect a different Ace from each company, you can enter a rafÁe to win a new iPad! Rollstock Inc. 1728 N. Topping Kansas City MO 64120 (888) 314-2152 www.rollstock.com Process Expo Booth #2840

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Select Technologies Inc. Select Technologies Inc. is a full-service food plant equipment systems integrator. STI designs, builds and installs equipment to streamline production line layouts for process, material handling and plant utility systems. Capabilities also include ammonia refrigeration services, electrical UL508 panel shop, PLC automation and IT integration. This year’s booth will include the premier display and demonstrations of a Heneken tumbler, macerator and spice mixer. Henneken designs and manufactures custom high quality food processing equipment. Distributed worldwide from Germany, it is now available in the U.S. exclusively through Select Technologies. The booth will also include Advanced Food Equipment information. AFE provides freezer, cooler and steam cooker equipment and repair services. AFE’s refrigeration equipment is designed and manufactured based on CSA, USDA and OSHA standards.

Select Technologies Inc. 8093 Graphic Drive NE Belmont MI 49306 (616) 866-6700 Fax: (616) 866-6770 www.select-technologies.com Process Expo Booth #5214

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Spartan Chemical Co. Inc. Spartan Chemical Co. is a manufacturer of quality maintenance and chemical specialty products to meet the needs of professionals. For over 55 years Spartan has earned wide recognition for its high-quality, high performance cleaning products. Spartan offers a broad line of cleaners, degreasers, CIP (clean in place) cleaners, sanitizers, drain treatments and appropriate application equipment speciÀcally designed to assist the prevention of food-borne illness. All products are extensively Àeld-tested to meet the ever-changing needs for improved sanitation in the Food Industry. Spartan distributors and Regional Managers can give you an overview on how to design and implement Hazard Analysis and Critical Control Points Systems. We will be happy to recommend the appropriate cleaners and sanitizers as well as update you with relevant regulatory standards. To learn more, visit us at www. spartanchemical.com.

Spartan Chemical Co. Inc. 1110 Spartan Drive Maumee OH 43537-0110 (800) 537-8990 or (419) 531-5551 Fax: (419) 536-8423 www.spartanchemical.com Process Expo Booth #2641

Tipper Tie Inc.

Treif USA Inc.

Tipper Tie is a leading developer and manufacturer of clip closure systems for use in processing and packaging applications in the food industry. Tipper Tie clipping systems provide a safe, secure clip closure to all types of sausage and chub-shaped products, as well as bagged and netted products. Tipper Tie will showcase its SwiStick XXL Double Clipper. The SwiStick XXL automatically portions, clips, string loops and hangs extra-long sausages directly onto smoke sticks to reduce product waste and operator intervention. This automated sausage hanging system is perfect for high-speed production of long, heavy sausages. Tipper Tie will also showcase its RS4204AB Automatic Double Clipper. The operator and maintenance-friendly RS4204AB is the Àrst automated double clipper to offer consistently high speeds of up to 50 cycles per minute, doubling production without sacriÀcing product quality.

Are you looking for better cutting solutions? Do you need to increase production without sacriÀcing quality? Are you looking for easier ways to exceed sanitary and hygiene regulations while still maintaining proÀts? Do you want to improve employee safety on the cutting lines? At TREIF USA Inc. we continuously work with our clients to solve some of these questions, and many other challenges and needs. For us, 60 years in the business isn’t something we say, it is something we use to provide you with cutting solutions that improve your production and quality. This is why we are an international leader producing portion cutting, dicing and slicing machines… Solutions! At TREIF USA Inc. everything revolves around food cutting and we are passionately devoted to this and our customers. At TREIF USA our Àrst goal is customer satisfaction!

Tipper Tie Inc.

Treif USA Inc.

2000 Lufkin Rd. Apex NC 27539 (919) 362-8811 or (800) 331-2905 Fax: (919) 303-3272 www.tippertie.com Process Expo Booth #2212

230 Long Hill Cross Road Shelton CT 06484 (888) 77-TREIF (87343) Fax: (203) 929-9949 [email protected] www.treif.com Process Expo Booth #3823

Wire Belt Co. of America Wire Belt, the leading developer of open mesh stainless steel conveyor belts, has been keeping your lines running for over 60 years. Our conveyor belts are extensively used for breading, battering, frying, blanching, cooking, coating, dusting, and cooling. Wire Belt’s entire line of belting products are accepted by the USDA NSF/ ANSI/3-A hygiene standards. This is the only acceptance that can assure you that you have the cleanest, safest conveyor belt available. Wire Belt’s latest innovation CompactGrid™ conveyor belt is engineered speciÀcally to replace heavier balanced weave belts and difÀcult to clean plastic modular belts. Engineered with 70% open surface area, CompactGrid conveyor belt provides optimal performance in processes where product coating, drainage, and liquid or air circulation are factors. To learn more about Wire Belts complete line of products, including our CarrySmart conveyors, please stop by Booth #1155. Wire Belt Co. of America

154 Harvey Road Londonderry NH 03053 (603) 644-2500 [email protected] www.wirebelt.com Process Expo Booth #1155

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TechShowcase Turkey hock/neck cutter Jarvis manufactures the Model CPP pneumatically powered hock and neck cutter for turkey, goose, duck and ostrich. Jarvis’ CPP, the most durable, trouble-free hock and neck cutter available, is constructed from rugged, corrosion-resistant materials for optimum hygiene and easy maintenance. The CPP does not use springs. A pneumatic blade closing/ opening procedure operates the blades, ensuring no down time due to spring failure. All air pressure is converted into cutting force. Jarvis Products Corp.: (860) 347-7271 or visit www.jarvisproducts.com

Bacon Packaging

Rotary Chamber Machine

Multivac has introduced its R 595 system for efÀcient, precision packaging of bacon. One machine version, with a footprint of approximately 16 feet, will be equipped with a one-track tooling. The second, which will be equipped with a two-track tooling, will have a footprint of approximately 23 feet. This machine generates an output of 120 packs/minute. The forming station is placed within the machine, offering ample loading area for manual loading despite the limited footprint.

Rollstock’s new RC-300 Rotary Chamber Machine features a 304L stainless steel modular frame with the ability to accept a multitude of chamber conÀgurations (widths and lengths) and sealing proÀles (single, double or custom seal impressions) and sealing widths up to 24 inches long. The RC-300’s patented constant temperature sealing system allows for the capability of sealing through the thickest bags, through contaminants, and through excessive folds and wrinkles.

Multivac Inc.: (816) 891-0555 or visit www.multivac.com

Rollstock Inc.: (888) 314-2152 or visit www.rollstock.com

Fryer Heat and Control’s Breaded Products Fryer fries coated and uncoated seafood, poultry, meats, vegetables and other prepared foods. It delivers higher output in the same or less Áoor space than an existing direct-heated fryer, because cooking oil is heated outside the fryer using an external heat exchanger. The fryer and heat exchanger are sized separately. Product throughput determines fryer size, while heat exchanger size is dictated by the heat load – for present and future production. Heat and Control Inc.: (510) 259-0500 or visit www.heatandcontrol.com 96

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

Intervention Cabinet New Intervention Cabinets from Hollymatic help protect meat, poultry, Àsh, and vegetables from pathogens and provide safer Ànished products for consumers. Guardian Intervention Cabinets feature wash-down 316 stainless steel, a wash-down 230-volt, 3-phase, stainless steel gear box, a variable speed Intralox conveyor belt, top and bottom spray coverage using Àve nozzles and an accurate, user-friendly chemical mixing pump assembly. They are available in two sizes. Hollymatic: (708) 579-3700 or visit www.hollymatic.com

Savory Flavor “Flavors from the Kitchen” by Red Arrow recreates homecooked and chef-prepared Áavors that capture the true essence of cooking methods. The range of authentic Áavors includes: grill, roast, char, sauté, caramelize and fry. Red Arrow’s newest addition to their Flavors From the Kitchen, Grandma’s Natural Pot Roast Flavor, is reminiscent of a slowly cooked, juicy pot roast. This beefy Áavor captures the true nuance of tender roast beef with characteristic browned notes.

Conveyor Dynamic Conveyor Corp. will unveil the new DynaClean conveyor system at PackExpo 2011 in Las Vegas. DynaClean conveyors are easy to clean and offer Áexibility in conÀguration and reconÀguration not possible with traditional stainless steel conveyors. DynaClean conveyors are ideal for food and other applications where cleanliness and sanitation are required. Offering a conveying solution that is sustainable and environmentally friendly, the layout and conÀguration can be changed when food processing or packaging needs change.

Red Arrow Products Co. LLC: (920)769-1227 or visit www.redarrowusa.com

Dynamic Conveyor Corp.: (800) 640-6850 or visit www.dynamicconveyor.com

Lamps Shat-R-Shield has expanded its line of shatter-resistant compact Áuorescent lamps, now offering a broader choice for customers looking for energy efÀciency and safety. The new selection includes CFL PARs, Globes, ReÁectors and higherwattage Twists. If accidentally broken, virtually all glass, phosphors and mercury are safely contained within the clear and tough, skin-tight plastic coating. Shat-RShield’s safety coating is optically clear and is the only silicone coating that blocks over 97% of damaging Ultra Violet light. Shat-R-Shield: (800) 223-0853 or visit www.shatrshield.com

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TechShowcase

Lubricant Tested for performance, consistency and compliance, PristineFG foodgrade lubricant for rotary compressors is a long-lasting synthetic lubricant that maintains food product quality and increases equipment performance. Sullair’s PristineFG outperforms traditional mineral oils, extends equipment life and minimizes consumption, all while complying with current FDA and USDA H1 regulations. It has been formulated to provide enhanced lubrication at high and low temperature variations and under extreme conditions. Furthermore, PristineFG has received Kosher and Halal approval. Sullair Corp.: (219) 879-5451 or visit www.sullair.com

Refrigeration

Stretch Wrapper ITW Muller introduces the latest addition to its Octopus line of automatic rotary ring stretch wrappers- the Octopus 505 AL. The 505 AL is ideal for food and beverage manufacturers looking to increase productivity without compromising cost. An upgrade from the Octopus 303, the 505 AL is still compact but allows for the stretch wrapping of larger loads. In addition, its simple design and Áexible network increases its overall versatility. ITW Muller: (800) 628-6787 or visit www.itwmuller.com

Freeaire Refrigeration has innovatively realized technology that allows cold outside air to be used for inside cooling, reducing energy consumption in refrigeration by cutting component run-times 50 to 90 percent. Freeaire manufactures energy-efÀcient commercial refrigeration systems for walk-in coolers, freezers and cold storage warehouses. Every Freeaire refrigeration system has the patented electronic Cooler Controller, a powerful computer that maximizes efÀciency by operating each component of a conventional refrigeration system only as much as needed. Freeaire Refrigeration: (802) 496-5205 or visit www.freeaire.com 98

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Salt Replacement Ingredient LycoRed introduces LycoRed SANTE, a patented and natural tomato concentrate designed to successfully enhance taste and Áavor, in place of artiÀcial Áavor components or Áavor enhancers. SANTE can be used for salt taste enhancement and reduction of expensive, Áavor components in food products. LycoRed SANTE can be used to enhance Áavor and thereby reduce the amount of salt added to a product. LycoRed SANTE is available in liquid form or as a free-Áowing powder. LycoRed: (866) LYCORED or visit www.lycored.com

Hot Dog Grill C. Cretors and Co. introduces its Stackable Hot Dog Grill. Available to accommodate all Cretors grills, the stacking unit integrates the grills into a single unit, doubling production capacity while occupying minimal counter space. Cretors Stackable Hot Dog Grill increases cooking capacity by allowing two grills to be stacked in the space of one. As opposed to other grills which expand horizontally across a counter, the stacking feature allows users to expand grilling surfaces vertically. C. Cretors and Co.: (773) 588-1690 or visit www.cretors.com

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Robots Alvey Robotics from Intelligrated, operating on industry-standard controls, enable customers to deploy efÀcient and repeatable robotics solutions that seamlessly integrate with other line equipment. Alvey robotics system capabilities include EOATs (end of arm tools), case unscramblers, automated pallet or sheet dispensers, infeed conveyors for single or multiple lines, full-load pallet discharge conveyors, sortation solutions, advanced PLC control systems, vision systems as well as stretchwrapper integration. Intelligrated: (877) 315-3400 or visit www.intelligrated.com

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TechShowcase Washer Compactor The Duperon Washer Compactor is a simple, non-batching process unit that efÀciently cleans and compacts screenings of less than 4 inches at rates of up to 60 cu. ft/hour. The core of the compactor’s simplicity is found in its dual auger system, which utilizes thermal-mechanical dynamics to enable absorption of grease into the debris’ naturally occurring Àbrous materials. Additionally, the positive displacement employed by the dual augers ensures that what comes in, goes out. Duperon: (989) 754-8800 or visit www.duperon.com

Batching Controller Mettler Toledo has introduced the new IND780batch stand-alone batch controller which combines advanced batching control technology while adhering to the ISA SP-88 Batch Standard. IND780batch optimizes batch processes with consistent, accurate material transfers, to minimize material waste, improve batch quality, and yield increased proÀts. It is a powerful and Áexible stand-alone terminal for single or multi-scale batching applications. Multi-material automatic batching control handles up to 28 automatic materials with recipe-speciÀc control. Mettler Toledo: (614) 438-4511 or visit www.mt.com/industrial

Fittings Stainless steel transition Àttings are now available for connecting Viega’s ProPress system to existing piping systems in commercial and industrial facilities. The transition Àttings enable installers to connect directly from either welded pipe systems or grooved pipe systems. The stainless steel transition Àttings are made from either high quality 304 or 316 stainless steel and come with an EPDM sealing element. Six sizes enable connections to both welded pipe systems and grooved pipe systems. Viega: (866) 766-7805 or visit www.viega.com

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Supplier News Birko, a leader in providing food safety solutions to the protein industry, announced a deÀnitive agreement to acquire Chad Co., a Kansas-based manufacturer specializing in automated washing and pasteurizing systems for meat harvesting and processing operations. Chad will become Chad Equipment, LLC, a Birko company. Birko will be combining its current equipment division into Chad Equipment, LLC, headquartered in Olathe, Kan. “We are delighted to be adding Chad’s equipment expertise to the Birko portfolio of food processing and safety capabilities,” said Mark Swanson, CEO of Birko. “This provides an exciting opportunity for our customers as two of the best known

food safety companies in the protein industry team up to offer integrated solutions in both chemistry and equipment.” Under the terms of the agreement, Chad Co. President Mike Gangel will stay on as Chad’s president for an extended period of time. “We are thrilled about this opportunity to team up with Birko,” Gangel said. “Our harvest and processing equipment line blends well with Birko’s chemical dispensing equipment and will give customers a comprehensive resource for their equipment needs.” Birko has also launched a new corporate website, The Birko Advantage, a total integrated food safety solution of chemistry, equipment and technology. “The Birko Advantage is a revolution in food safety,” said Kelly Green, owner and chairman of the board. “We’re building on our legacy of providing innovation through green/sustainable chemistry and customized equipment, all to help customers meet HACCP and SSOP standards and maximize

their return on investment.” The website can be viewed at www. birkocorp.com. The Birko Advantage can be viewed at www.birkocorp.com/birkoadvantage.

Mepaco is now represented by Sulmaq (Guapore´, RS) in Brazil. Founded in 1971, Sulmaq is a well-known, highly respected company that offers complete solutions for slaughter, deboning, and further processing throughout Latin America. In partnering with Sulmaq, Mepaco is proud to be represented by such a strong name in the industry, Mepaco stated. Sulmaq has a Àrm commitment to quality, reliability, and customer service.

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TechShowcase Middleby Corp. has acquired the Maurer-Atmos smoking and processing equipment, headquartered in Reichenau, Germany. With this latest acquisition, The brands of Middleby Food Processing Equipment Group include Alkar, Cozzini, Danfotech, Maurer-Atmos, MP Equipment and Rapidpak. “We are certain that with the high quality and reputation that Maurer-Atmos has had for many years combined with the Middleby commitment, we will support and satisfy the needs of our global customer base,” said Ivo Cozzini, group president of sales and marketing, and Magdy Albert, president of manufacturing and operations. Scott Seymour has joined Marel as the central territory sales manager in the Fresh Meats Division. He will be responsible for developing new equipment and software sales and for serving Marel fresh meats customers in the central region (Iowa, Minn., Mo., Mich., Southern Ill. and Southern Ind.). In 1988, he joined Townsend Engineering where he served the company in several sales related positions over a 15-year period. After leaving Townsend, Scott operated his own company for a few years before joining Reiser as a territory sales manager. He worked for Reiser for four years. “We are thrilled that Scott is joining our team and are conÀdent that his industry knowledge, experiences and relationships will translate into increased sales and satisÀed customers,” noted Kent Sliffe, VP of Fresh Meat Sales.

Multivac has acquired Spain’s Mobepack Sistem S.L., a transaction which substantially expands the company’s market position on the Iberian Peninsula. Terms of the purchase agreement provided ownership of Mobepack Sistem S.L. to be transferred to Multivac Packaging Systems España. Mobepack employs approximately 80 staff members, all of whom will be integrated into the Spanish distribution and service business of Multivac Spain. The manufacturing capacity of Mobepack Sistem will continue to be used within the Multivac group of 102

Provisur Technologies will come to the Process Expo highlighting the capabilities of its Beehive, Cashin, Formax and Weiler family of brands. In doing so, this important exhibit will bring forth the broadest platform of automated grinding, mixing, separating, meat recovery, forming and slicing equipment. And as a partner with completely integrated solutions from raw material to Ànished products, Provisur states that its ability to maximize future opportunities through ingenuity and advanced technology makes this year’s exhibit a must see. The company will be exhibiting at Process Expo Booth #3723.

companies. “The management and staff of Mobepack Sistem welcome this investment by Multivac, the market leader, and we are convinced that Mobepack Sistem can continue fully developing its potential within the Multivac group of companies,” said Francisco Monente, the company’s previous owner. Monente will continue running Mobepack as it is integrated into Multivac Packaging Systems España, and will thereafter be joint chief executive ofÀcer of Multivac Spain. “Mobepack has a good market position on the Iberian Peninsula. We are pleased to be able to welcome such a competent partner into our group, as it empowers us to offer our clients in Spain and Portugal even better service,” added Emilio Hernández, CEO of Multivac Spain.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | SEPTEMBER 2011

The Mobepack acquisition has also provided Multivac with distribution authority for Weber slicing technologies on the Iberian Peninsula. Multivac and Weber have collaborated on more than 1,500 automated slicing and packaging installations worldwide. Foodmate US Inc., the North American distributor for Netherland-based Foodmate B.V., has named Paul Breure as its technical services manager. In his position, Breure uses his technical expertise to assist the company’s sales managers and customers. He oversees sales engineering, project management and new product implementation. Having worked for several large poultry

processing equipment companies in the U.S. and Europe over the last 20 years, Breure has a thorough knowledge of processing plant operations. He has served in many capacities including project manager, service manager, and international Àeld technician. The National Poultry & Food Distributors Association has announced its scholarship winners for 2011-2012. Every year, NPFDA awards scholarships to four outstanding students who are enrolled full-time pursuing an agriculture, poultry or food science (related) degree. The recipients for this year are: Q Michelle Janik, Oregon State University,

Animal Science/Poultry/ Pre vet– Albin S. Johnson Memorial Scholarship Q Philip Wise , Pennsylvania State University, Agricultural Sciences - William Manson Family Memorial Scholarship Q George Ethan Kilcrease- Poultry Science/ Pre-Vet, Auburn University- Alfred Schwartz Memorial Scholarship Q Amy Marie Vansa- Poultry Science, Texas A & M - NPFDA Scholarship Q Sheilena Brookshire- University of Georgia – Avian Biology– Alternate The American Meat Science Association (AMSA) and the Canadian Meat Science Association (CMSA) are both involved in organizing several conferences of mutual interest to each other’s memberships. As part of a new co-operation agreement, members from both associations are encouraged to attend these conferences. “Attending each other’s conferences is a

great way to increase communication and opportunities for collaboration” says Benjy Mikel, AMSA president. One such conference is the 58th International Congress of Meat Science and Technology, or ICoMST 2012, in Montreal. “We are very proud to be hosting ICoMST 2012 in Canada and look forward to seeing many AMSA members in Montreal next August” says Brian Sullivan, CMSA president. Information on ICoMST and other meat science meetings can be found on both the AMSA (www.meatscience.org) and CMSA (www.cmsa-ascv.ca) web sites. Some of these include: Sept. 20-22, 2011, AMSA Pork 101, Iowa State University, Ames, Iowa Oct. 6-7, 2011, Canadian Meat Council (CMC) Technical Symposium on Pathogen Reduction, Toronto, Ontario Oct. 18-20, 2011, AMSA Pork 101, Oklahoma State University, Stillwater, Oklahoma

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John Bauer, president and CEO of Basic Food International, has been appointed to the U.S. Agricultural Advisory Committee, which resides under the direction of the U.S. Secretary of Agriculture in coordination with the U.S. Trade Representative (USTR). Bauer and other appointees will perform duties on a consultancy basis and advise the U.S. Secretary of Agriculture and the U.S. Trade Representative on issues concerning Agriculture and Trade Policy. Bauer says, “This appointment is certainly an honor for me and I will devote my energy and experience to fulÀll its potential. This is the second time I have been called to serve our country with the Àrst being to serve in World War II in the Military Intelligence Service of the U.S. Army.” American Pasteurization Company (APC) has appointed Scott R. Kossoris, CPA, to chief Ànancial ofÀcer. In this role, Kossoris will develop Ànancial analyses and models that help gauge and forecast overall business growth. Additionally, Kossoris will be engaged on a day-to-day basis, evaluating the company’s business models and helping to facilitate key business discussions. “I was looking for a business partner who brings both Kossoris Ànancial and business sensibilities to our leadership team,” said Justin Segel, CEO of APC. “With Scott’s diverse background – that includes operations management, Ànance and food industry experience – he adds an important dimension to our team as we prepare for a period of aggressive growth. His experience not only equips him to provide Ànancial leadership, but brings a new perspective on our overall business decisions.” APC is the Àrst company in the United States to offer high pressure processing (HPP), a post-packaging pasteurization technique, on a commercial tolling basis to the food manufacturing industry. The Board of Directors of Bar-S Foods elected Warren Panico to serve as president and chief operating ofÀcer. Warren will report to Chairman & CEO Tim Day and will gradually assume all responsibilities for the day-to-day operations of the company and its seven brands. He has a proven track record and extensive experience as a senior executive at Bar-S Foods for the last 14 years. In his past roles, Warren was responsible for managPanico ing the operations and distribution functions, and more recently, for overseeing the sales and marketing activities. “Warren’s appointment is an important step to ensure that our organization is properly structured for the future with sound leadership succession in place,” said Day. “We are certain that Warren’s vast experience and capabilities will prove invaluable in this new position.”

PROVISIONERONLINE O .COM Check our website for updates and more Industry News, Supplier News and Tech Showcase.

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Ajinomoto AmTrade Systems, Inc. Ashworth Bros., Inc. Beacon, Inc. Biro Manufacturing Company Budenheim USA, Inc. Cargill CSB-System International, Inc. Danisco USA Inc. Diversey Douglas Machines Corp. Eriez Formax / Provisur Technologies FOSS North America Framarx / Waxstar Fristam Pumps USA GEA Convenience-Food Technologies (Formerly CFS) Grote Company GPI USA Handtmann Inc. Harpak-ULMA Packaging LLC Henry & Sons Inc. Hoegger Food Technology, Inc. Hollymatic Ingredients Solutions, Inc. James V. Hurson Associates Inc. Kemin Marfood USA Materials Transportation Company MEPACO, A Division of Apache Stainless Equipment Corp My Clear Opinion Odenberg OSI OYSTAR North America Patty Paper Inc. Process Expo Purac QMS International Reiser Remco Products Rochester Midland Corporation Rollstock Sandvik Select Technologies Spartan Chemical Company, Inc. Spraying Systems Co Thermo Fisher ScientiÀc Tipper Tie Treif USA, Inc. UPEMI Weber Inc. West Liberty Foods Wire Belt Company World Technology Ingredients

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PROCESSOR INDEPENDENT

SM

SERVING SMALL AND MIDSIZE MEAT, POULTRY, AND GAME PROCESSORS

PUBLISHER

Also publishers of: Beverage Industry, BrandPackaging,

Dave Lurie

PRINT, EVENT AND INTERNET ADVERTISING Dave Lurie

Candy Industry, Dairy Foods,

CUSTOM MEDIA

[email protected] • (248) 593-0337

Flexible Packaging,

Rick Parsons

Food & Beverage Packaging,

[email protected] • (248) 593-0337

Dave Lurie

[email protected] • (248) 593-0337

[email protected] • (407) 302-7952

SINGLE COPY SALES/ BACK ISSUES

[email protected] • (415) 387-7784

[email protected] • (248) 405-4061

[email protected] • (630) 962-0094

Ann Kalb

REPRINTS

Jill L. DeVries

[email protected] • (248) 244-1726

Wayne Wiggins Vito Laudati

CLASSIFIEDS

Diana Rotman

[email protected] • (847) 405-4116

Reaching an average qualiﬁed circulation of 25,500 copies. Source: December 2010 BPA Circulation Statement.

Food Engineering, Independent Processor,

BNP MEDIA II, L.L.C

Prepared Foods, Private Label Buyer,

155 Pfingsten Road, Suite 205 Deerfield, Illinois 60015 (847) 405-4000 Fax: (847) 405-4100

Industria Alimenticia, Meat & Deli Retailer, Refrigerated & Frozen Foods, Refrigerated & Frozen Foods Retailer, Snack Food & Wholesale Bakery

GPI USA. More than you expected.

ANTIMICROBIALS All-natural, clean-label systems to improve food safety and extend shelf life.

FOOD GUMS Improve marinade retention, increase yields, reduce purge, add texture, replace fat, lower sodium.

SEASONINGS Flavorings, seasonings, and spice extractives to add flavor and taste.

ANTIOXIDANTS All-natural, clean-label fruit and green tea extracts add “healthier” ingredients.

At GPI USA, we’re surprising a lot of people in the industry. Most processors know us for our outstanding line of hydrocolloids. But, did you know we also supply a wide range of all-natural, clean-label, multi-functional flavoring ingredients, antimicrobials, antioxidants, and contract services? Let GPI USA help improve your product. Contact us today!

GPI USA 931 Hill Street Athens, GA 30606

Toll Free 888-GPI-USA9 [email protected] www.GPIglobal.com

Creativity, Synergy, Success!