The National Provisioner February 2011

Automatically more productive ! powerful and dynamic

FCA 160

NEW ! A milestone in clip technology ! Automatic, self-regulating process: the world‘s most productive automatic double-clipper First automatic double-clipper with centralized lubrication: maximum reliability and service life Even faster: 160 cycles per minute Even more flexible: calibres of 38mm up to 160mm New voiding separator and new clip shape: short sausage shoulders, more slices per sausage

System solutions

The SAFETY-CLIP System

Visit us at IPE Booth #4355

innovative · reliable · leading

Poly-clip System Corp. · 1000 Tower Road, Mundelein, IL 60060 · P h o n e ( 8 4 7 ) 9 4 9 - 2 8 0 0 · Fax (847) 949-2815 · Email: [email protected] · 1-800-usa-clip (800) 872-2547 · Visit our website: www.polyclip.com

*FullPages_m1012.indd 16

11/24/10 8:30:20 A

INGREDIENTS & FORMULATIONS

Phosphates improve quality 18 | Donna Berry discusses the benefits phosphates have on meat and meat products.

32

COVER STORY

The spice of life Cargill’s Rumba brand uses merchandising, marketing and unique packaging to offer variety and specialty meats to under-served multicultural consumers.

10 | Regulations & Legislation: Are ‘undeclared allergen’ recalls really necessary? 12 | Fight for Food Safety: You are what you wear.

ProvisionerOnline.com

4

Daily MarketVideo

Read Us Online

ProvisionerOnline.com teams up with Urner Barry to update the market trends and conditions in this dynamic, informative daily video.

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

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

SPECIAL REPORT

Annual Sausage Report 22 | Linking comfort and taste.

Departments Editor’s Journal ............ 8 Guest Commentary ...... 14 Protein Problem Solvers .. 56 Tech Showcase ............ 62 Classifieds ................... 72 Ad Index...................... 78

Contact Us PHONE (847) 405-4000 FAX

(847) 405-4100

MAIL

155 N. Pfingsten Suite 205 Deerfield, IL 60015

February 2011

Volume 225 Issue 2

Tech

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

CONTRIBUTING THIS MONTH Dan Emery

PROCESSING TECH |42

Meaningful Solutions

Robotics & Vision Systems To design a truly successful system, processors must expand their thinking beyond viewing robotics and vision systems simply as labor-replacement tools.

John E. Johnson JBS

Huston Keith Keymark Associates

Lynn Knipe

SPECIAL REPORT

FOOD SAFETY

PACKAGING TECH

Ohio State University

52 | Meat and poultry processors are improving their sanitary equipment design with built-in cleaning and processing practices.

54 | What looked like

58 | The fluidity of

a real decision in the donning/doffing compensation battle has become unclear once again in early 2011.

MAP/overwrap packaging requires vigilance and teamwork to stay on the cutting edge.

CONTRIBUTING THIS MONTH

THE NATIONAL PROVISIONER (ISSN 0027-996X) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $161.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $198.00 USD (includes GST & postage); all other countries: $211.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2010, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices.

Gary McMurray Georgia Tech Research Institute Dan Murphy Meat Industry Hall of Fame Mark Reed Border Management Strategies Steve Valesko Butterball LLC

POSTMASTER: Send address changes to: THE NATIONAL PROVISIONER, P.O. Box 1080, Skokie, IL 60076. CANADA POST: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Bleuchip International, P.O.Box 25542, London, ON, N6C 6B2. CHANGE OF ADDRESS: Send old address label along with new address to THE NATIONAL PROVISIONER, P.O. Box 1080, Skokie, IL 60076.

Barbara Young The National Provisoner

FOR SINGLE COPIES OR BACK ISSUES: contact Ann Kalb at (847) 405-6499 or [email protected]

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

5

Do You Know Where That String Has Been? (Competitor’s Paper)

Didn’t think so. And it’s now touching every single piece of patty paper in that stack. Yuck.

Everything About Hollymatic Patty Paper is FDA and USDA Compliant Every sheet. Every wrap. Every box. No strings attached. We think it’s just safer. Don’t you?

708-579-3700 www.hollymatic.com/np

www.ProvisionerOnline.com Group Publisher > Peter Havens [email protected] • (847) 405-4055 Publisher/Midwest Sales > Dave Lurie [email protected] • (248) 593-0337

editorial

Editor-In-Chief > Andy Hanacek [email protected] Editor > Sam Gazdziak Editor emeritus > Barbara Young This month’s contributors > John Butts, Christine Hurckes, Dennis Johnson, Megan Pellegrini, Shawn Stevens Art Director > Mary Ann Lawrence

print, event & web marketing Sales (Southeast/East Coast) > Rick Parsons [email protected] • (407) 302-7952 Sales (Great Plains/West Coast) > Wayne Wiggins [email protected] • (415) 387-7784 Sales (Business Development) > Gary Campbell [email protected] • (440) 227-8377 Advertising/Production Manager > Gail Porter [email protected] • (847) 405-4104 Classified Sales > Diana Rotman [email protected] • (847) 405-4116

MeatProcessingXchange event Gina Caruso [email protected] • (952) 224-8541 Fax - (952) 736-9362

Food Safety Summit

Emily Patten [email protected] • (847) 405-4030

reprints

Jill L. DeVries [email protected] • (248) 244-1726

audience development Audience Development Coordinator Teresa Owens • [email protected] Corporate Fulfillment Manager Alison Illes Audience Audit Coordinator Carolyn M. Alexander

For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] www.provisioneronline.com

list rental For postal information: Contact Rob Liska at 800-223-2194 x726 [email protected] For email information: Contact Shawn Kingston at 800-409-4443 x828 [email protected]

BNP Corporate Directors

Co-CEO Taggart E. Henderson Harper T. Henderson Mitchell L. Henderson Publishing Timothy A. Fausch Publishing John R. Schrei Corporate Strategy Rita M. Foumia Information Technology Scott Kesler Production Vincent M. Miconi Finance Lisa L. Paulus Creative Michael T. Powell Marketing Holly Banks Directories Nikki Smith Human Resources Marlene J. Witthoft Clear Seas Research Beth A. Surowiec Events & Conferences Emily Patten BNP Media Helps People Succeed in Business with Superior Information

“The patented tight curve in the GYRoCOMPACT TC Freezer makes high capacity freezing possible in tight spaces.” Who has space for gigantic freezers in plants where there are already equipment traffic jams? Processors need significantly more capacity but in a smaller footprint and that’s where the GYRoCOMPACT M10 TC Freezer comes in. Its 40” belt expands on the outside and collapses on the inside to create a tight radius curve. Add to this an integrated self-stacking belt system creating an enclosed product zone which provides the most efficient and hygienic system on the market today. What’s in it for you? Up to 40% greater capacity in the same footprint, longer run-times, less downtime and turnaround time, increased throughput and more trouble-free production. Call Lee Clarkson to reserve the Tech Center. 419-627-4319

We’re with you, right down the line.™ www.jbtfoodtech.com

Steve Radke on the Frigoscandia™ GYRoCOMPACT® M10 Tight Curve (TC) Spiral Freezer

Editor’sJournal

Breaking up is hard to do

S

ometimes, splitting up is the best move for all involved. In the case of Sara Lee Corp., and its Jan. 28, 2011, announcement that it will split into two separate, publicly traded companies — one focused on the North American foods business and the other focused on the international beverage and bakery business — obviously the result won’t be known for years to come. Yet, on its face, the move makes sense, and, as James Crown, chairman of the board of Sara Lee Corp., said in a company release, it’s “a logical step” following the divestiture of the North American bakery, the household and body care businesses. This statement certainly isn’t far from the truth. After all, when Brenda Barnes took the reins as president and CEO of the corporation in 2004, she launched the company into a five-year transformation plan designed to sharply focus and turn around the fragmented, decentralized business into which Sara Lee had grown. As time went on, Sara Lee shed business after business, and Barnes officially stepped down in the fall of 2010 after suffering a stroke that spring. Today, for all intents and purposes, there were two businesses left — the aforementioned international business and the North American foods division, dominated and propelled by the iconic Sara Lee, Jimmy Dean, Hillshire Farm and Ball Park meat brands. A quick whirl around the news, business and financial sites on the Web brings about a general consensus that this is indeed a logical step. The general market community appeared to be OK with the move at presstime, particularly since, on the day of the announcement, Sara Lee stock rose 0.7 percent while the rest of the market indexes recorded healthy losses. Many analysts believe that the move makes sense but is not a sign that the two new companies won’t entertain acquisition offers. The breakup of these two businesses, in fact, may make them more attractive individually to potential suitors. Weeks worth of news reports state that two parties placed bids on the corporation prior to its breakup, one of those parties headed by Brazilian meatpacker JBS — bids that Sara Lee found to be unacceptable. Whether this breakup will make either part more attractive than the whole to potential suitors — and whether the new Sara Lee (the North American food business will retain the name) will accept those flirtations — remains to be seen. However, if the new Sara Lee “stays single,” this breakup could be the best thing for its bottom line, behind a very sharp, focused strategy to back up several iconic U.S. brands that should fly high with the right support. The talent is certainly on board at the Downers Grove, Ill., headquarters — we’ve seen it first-hand here at The National Provisioner. With the right strategy from new CEO Marcel Smits, next year at this time we could be reporting on the fantastic decentralization of Sara Lee and the amazing turnaround it spurred.

Our

Family

of Products

Independent Processor A supplement to The National Provisioner, publishing every two months.

Provisioner Prime Weekly eNewsletter

provisioneronline.com The industry’s only BPA-audited website offers a digital edition as well as updated industry news that you can read anywhere.

Twitter Follow us at www.twitter.com/ natprovisioner.

Facebook Check out our Facebook page at www.facebook.com/ NationalProvisioner.

ANDY HANACEK [email protected]

8

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

Looking for the most reliable, first-rate source of liquid food ingredients? Welcome to hog heaven. Hawkins always delivers what you need, when you need it. Our customers know they can rely on us — no matter what size they are — to deliver what we promise, every day with every order. They appreciate our innovative approach, unbeatable quality and unmatched service. And they know we always strive to provide the best possible price. We’ve invested in people and facilities, including our newest plant in Centralia, Illinois. And we’re committed to being one of the nation’s foremost food ingredient suppliers.

products. We often alter and test different blends until we find the specific solution our customers require. If you want a world class resource for your liquid food ingredient supply, talk to Hawkins first. Find out more about our unique UltraLac formulation along with the rest of our high quality products.

Once you experience our relentless focus on providing the best service, you’ll understand why customers stay with us. For example, we don’t simply offer three or four major We bring so much more to the table

To find out more about Hawkins and our products, please call 1-800-328-5460 today. Or visit us at www.hawkinsinc.com

Regulations&Legislation

Are ‘undeclared allergen’ recalls really necessary? By Dennis Johnson

A

quick review of the FSIS current recall list shows that there is a significant number of recalls relating to undeclared allergens. In some cases, the wrong packaging was used; in others, suppliers had changed ingredients, but the change was never communicated to the processor so that its production/labeling staff could update the product labels or refuse to accept the “new” ingredient. The one common thread is that each and every one of these recalls was preventable. The basic notion is quite simple to state but seemingly difficult to implement — the product formulation must match the label. Given the continuing recalls for undeclared allergens, one would expect that FSIS will issue another policy to charge inspectors with verifying an establishment’s ingredient/label control program. The agency did this once before with FSIS Notice 45-05. As many of you remember, that notice led to numerous disputes as to the perceived potential for cross-contamination of allergens during processing. As a result, folks lost sight of the core issue, which is still haunting us today: Establishments are applying labels that do not declare all ingredients used in the product — those directly added by the establishment and/or those included as a component of a purchased ingredient. Some components of a written program to control the labeling of products with allergens could include:

10

■

Review label stock and discard “old” labels with incorrect ingredient statements — when a formula changes, destroy obsolete labels or remove them from the regular label-storage area so there is no way someone can accidentally put them into production

■

Restrict label access — limit the employees able to draw labels out of inventory. Too often line employees will run into the label room when a line runs out of labels and will grab labels that look right, but are incorrect.

■

Review purchased ingredients — are all the components of the ingredient on the finished product label?

■

Provide a structure for product labeling —

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

develop a checklist for R&D formula development and modifications to ensure all ingredients are on the final label. ■

Be careful that suppliers are not changing ingredients without notice — verify incoming shipments to ensure the ingredient label as received matches the label on file.

■

Pay attention — when products are being run, someone should verify that the labels being used match the formulation batch sheet. Do not assume the label is correct or that an old formulation batch sheet has not been placed into use from someone’s locker.

Monitor/Verify — periodically audit yourself to make sure the system is indeed working as intended. Recalls are inevitable, sometimes things simply happen. That said, many of the current recalls dealing with undeclared allergens could have been and should have been prevented. ■

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.

Balance food safety and shelf life with clean labels

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

FightforFood Safety

You are what you wear By Shawn K. Stevens

A

ppearance can be everything. Ever since grade school, the clothes you put on in the morning had a direct impact about how you felt about yourself and, in many instances, how others felt about you. Now that we’ve grown up, not much has changed. Whether you’re dressing for the next interview, picking the perfect suit for a sales pitch, carefully selecting (as in my case) the best ties for a lengthy trial, or getting ready (after work) for an exciting date, we all recognize that the clothes we wear make a difference. Our apparel affects our attitude, our perspective and, in many instances, our performance.

Besides looking good, however, the clothes you choose have other More implications as well. In the food On apparel, industry, there are a number of see page 54 unforeseen hazards that can affect your products. In addition to welldocumented risks associated with incoming raw materials and environmental hazards, improper clothing can create potential problems as well. For this reason, the federal regulations make it clear that proper employee hygiene, sanitation and clothing is critically important to any good foodsafety system: Aprons, frocks, and other outer clothing . . . must be of material that is disposable or readily cleaned. Clean garments must be worn at the start of each working day and garments must be changed during the day as often as necessary to prevent adulteration of product and the creation of insanitary conditions. (9 C.F.R. 416.5.) Although the directive sounds exceedingly simple, there is more to food safety than simply ensuring that your clothes are “clean.” Food companies should ensure that, at the beginning of each production day, uniforms and garments are “hygienically clean.” According to the CDC, this

means they have been treated to reduce “microbial counts to a level free of bacteria, viruses and other disease-producing organisms.” This can be achieved by selecting vendors with validated protocols to ensure proper detergents are being applied and adequate temperatures are being reached. In addition to being clean, garments should be properly designed. Pockets, which are never recommended, can collect contaminants and become difficult to clean. Moreover, garments and frocks should never have buttons, which can harbor bacteria or fall off, creating additional hazards. And remember, never wear uniforms and garments outside of foodprocessing areas. So, next time you step onto the production floor, take pride in how you look. And, never forget, whether referring to your people or products, you are (quite literally) what you wear. 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.

Water Saving Washers Hide-on Carcass Washers Researchers believe that most likely the first point of cross contamination to beef carcasses is when the hide is removed. Now comes the next generation of hide-on carcass washers. The new HoCW-6000 Series system uses the mechanical action of patented whips to accomplish this washing process. ~ Another water saving washer ~ US Patent 7,387,565 - US & Foreign Patents Pending

Split Carcass Washers In plant production, brush technology has been proven to be more effective than just water in cleaning the split carcass, especially the neck area. This System removes blood clots and bone dust while greatly reducing water usage. US Patent 7,458,886

Head & Tongue Washers

US Patent 7,467,994

Saving as much as 30 million gallons a year, this system has been used to clean heads and tongues. See the before and after photos on right. FSIS has issued a letter of “no objections” for its use in FSIS Establishments.

Before

Call For An In-Plant Visit

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

After

GuestColumn

The Brazilian venture

I

n recent years, Brazilian companies have made key acquisitions of U.S. companies, especially in the agricultural business sector, and as red-blooded Americans, this may raise concerns for some. But let’s examine these developments objectively. The Brazilians have invested their currency in the U.S. at a time when many of our companies and industries desperately need help, and our own banks and financial institutions have been very conservative in their lending practices. Brazilian companies, supported by their banks and their government, have stepped up to preserve American jobs and our ability to continue to run our operations and grow our business.

Investments by foreign firms played an important role in last year’s recovery. With the domestic companies and investors de-leveraging and hoarding cash, foreign direct investment is vital to fund growth and expansion. Perhaps Wall Street bankers should begin to learn some Portuguese phrases. Brazilian meatpacker Marfrig agreed to acquire Keystone Foods for $1.25 billion in June 2010. As a result, the Brazilian firm has now become a key supplier to American fast-food chains like Subway and McDonald’s. According to Thomson Reuters, there have been eight transactions since October 2010 involving Brazilian firms purchasDan Emery, Meaningful Solutions ing U.S. companies and/ Editorial Board or assets from U.S. comMember panies. There are likely to be more. In July 2007, we saw JBS, the giant Brazilian meatpacker, lead the way with the acquisition of Swift for $1.4 billion. InBev, the Belgian-Brazilian beer company, acquired Anheuser-Busch in 2008. By fall of 2009, we saw JBS in action again with the purchase of Pilgrim’s Pride for $800 million. Brazilian acquisitions haven’t been limited to the meat industry, however — U.S. oil fields, chemical companies and financial institutions all have been sold wholly or in part to Brazilian businesses. Agriculture is truly a global business and we need to manage this business accordingly. Part of the reality of our current recession is the U.S. transition to being a service economy. One of the biggest remaining manufacturing sectors is agriculture. The U.S. will be counted upon by a growing world

eb

14

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

Brazil population to be a key worldwide food supplier. But being the bread basket for the world is an opportunity and a responsibility. Brazil, Australia, Argentina, China, Russia and other nations with millions of acres of farm land will all be key players in feeding the world’s population as well. This is good news for American agriculture including the protein sector for generations to come. In 2010 our own government mandated more than 4.6 billion bushels of corn to be converted into ethanol, creating an imbalance in supply and driving corn prices toward the record high 2008 levels. Brazil has done an excellent job converting its sugar cane into ethanol, thus releasing pressure on its energy and agricultural sectors. Our own government treats U.S. companies with suspicion and mistrust. Conversely, the Brazilian government has collaborated with its business sector to advance their cause around the world. We should select leadership in our own country that supports businesses as well as picks our world allies carefully. Dan Emery has 25 years experience in the food industry, including 15 as vice president of marketing at Pilgrim’s Pride. He is directing Meaningful Solutions, a company founded to assist clients in solving problems.

Danisco is your complete source of solutions for the complex challenges facing meat manufacturers: sodium and fat reduction, increasing yields, improving texture and advancing food safety. From antioxidants to hydrocolloids, antimicrobials to fiber, Danisco delivers more innovative solutions than anyone in the industry. To learn more about our products and how we can help, contact Danisco today at 800.255.6837 ext. 3421.

Telephone: (1) 800-255-6837 Fax: (1) 913-764-9157 www.danisco.com © 2010 Danisco USA Inc.

NewProducts

Lloyd’s adds sauceless meats to lineup Lloyd’s® Barbeque has launched a new line of sauceless smoked meats — authentic, premium meats that are slow smoked for 9-10 hours using real hard woods such as hickory to highlight their unique flavors. Lloyd’s Woodfire Barbeque meats are a start to a great-tasting meal, providing consumers the opportunity to add their favorite sauce to make it their own. For more than just BBQ, these versatile meats are great in tacos and salads, and on pizzas and more. They are available in 12-ounce packages of pulled pork and pulled chicken varieties. www.lloydsbbq.com

Saffron Road brand debuts at Winter Fancy Food Show American Halal Company, Inc. introduced a new premium, all-natural, halal-certified food brand, Saffron Road, January at the Winter Fancy Food Show in San Francisco. Saffron Road’s initial four products are Chicken Tikka Masala, Chicken Biryani, Lamb Saag, and Lamb Vindaloo. Each entree is made from only the finest all-natural ingredients, including pasture-raised lamb and Certified Humane chicken, which are never given any antibiotics or hormones. www.saffronroadfood.com

Jimmy Dean’s newest breakfast bowl features ham Jimmy Dean has expanded its D-lights line of breakfast options, with a new Breakfast Bowls variety featuring ham. Jimmy Dean D-lights offer a morning meal with 300 calories or less and between 15 and 23 grams of protein per serving, and they are microwavable and ready in less than three minutes. Jimmy Dean D-lights are available in seven varieties, including three breakfast bowl options and four breakfast sandwich options. Each contains less than half the fat of the leading breakfast sandwich and bowl, are portable, single servings and can be found in the frozen breakfast section at grocery stores across the country. www.jimmydean.com

Midamar launches halal air-chilled, antibiotic-free, organic chicken Midamar Corp., Cedar Rapids, Iowa, is introducing Halal Air Chilled, Antibiotic-Free and Organic Chicken. The chickens are chilled during production with pure, cold air that is circulated throughout the birds. Eschewing the common water-chilling procedure eliminates the possibility of chickens absorbing the water/chlorine mix, which can artificially inflate the fryer’s weight, the company notes. Birds also are raised in unconfined settings and are fed a vegetarian diet of corn and grain. The chickens are slaughtered in accordance to Islamic law (individually blessed, hand-cut and completely eviscerated). www.midamar.com

16

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

*

Av N ai ow la bl e!

% Sa O ve FF a n Yo A ur dd Fi itio rs n tO a l rd er

15

Now a Self-Stacking Belt That Won't Break Your Bank Replace your existing self-stacking belts with Ashworth’s NEW ExactaStack™  Drop-in Replacement - Available in all widths including wide belt, tier heights, and mesh configurations for both spliced-in sections and complete belt replacements. No system drive modifications required  Turn Key - Expert technical support and full turnkey installation from the belting experts who invented spirals  Made in the USA - for fast deliveries and cost savings 1-800-682-4594 to register your Self-Stacking Belts and receive * Call 15% OFF your first ExactaStack order! − Limited Time Offer ™

Increase Capacity & Improve Efficiency - Contact Ashworth Today Ashworth Bros., Inc. +1-800-682-4594 | Ashworth Factory Service +1-866-204-1414 [email protected] | www.ashworth.com

Ingredients&Formulations

Phosphates serve to improve meat quality By Donna Berry

here’s a great deal of confusion about the term “natural” when it comes to food and beverage marketing, as product developers have been given very little guidance from federal authorities regarding its use. At best, the FDA disqualifies some ingredients from being called natural, as they have been deemed artificial or synthetic. The meat industry is a step above many others, as USDA provides this definition as it pertains to meat: A product containing no artificial ingredient or added color and is only minimally processed (a process which does not fundamentally alter the raw product) may be labeled natural. As a scientist, I find it very confusing that marketers of uncured hot dogs will label them as natural, but meat manufacturers who inject a roast with a marinade based on ingredients derived from nature will stay away from the term. I have no desire to debate the term or its use, but I would like to provide some facts about the use of phosphates in meat products — fresh and processed, cooked and raw.

T

18

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY FEBRU RUA ARY 201 20 2011 1

Application Ham, Corned Beef

Bologna, Hot Dogs, Sausages Roast Beef Reduced-Sodium Meats

Ingredient Sodium Tripolyphosphate, Sodium Tripolyphosphate/Sodium Hexametaphosphate Blends Sodium Tripolyphosphate, Tetrasodium Pyrophosphate, Sodium Acid Pyrophosphate Sodium Tripolyphosphate, Sodium Hexametaphosphate Potassium Tripolyphosphate , Tetrapotassium Pyrophosphate

Phosphate Function Maintain meat juiciness and shelf life

Emulsion stabilization; cure color development Maintain meat juiciness and shelf life Maintain meat juiciness and shelf life Source: Phosphate Forum of the Americas

From ore to ingredient For starters, phosphorus is No. 15 on the Periodic Table of Elements. It plays a major role in the human metabolic system, including bone growth and health, and energy-transfer systems. (Remember adenosinetriphosphate, or simply ATP, from high school biology?) This is why phosphorus is an essential mineral, one we need quite a bit of. The Daily Value is 1 gram per day. One of the ways we obtain our daily requirement is by consuming foods naturally high in phosphorus, such as dairy, legumes, meat and nuts. Another source is the phosphate ingredients used in all types of foods, from baking to beverage to beef. Phosphate ingredients are typically available as salts and produced by neutralization of phosphoric acid with a metal element such as calcium, potassium and, most commonly, sodium. Phosphoric acid (one phosphorus atom with four oxygen atoms) is made from phosphorus ore by a variety of methods, all of which rely on both chemical and physical processing. Remember, we need phosphorus in our diet and we cannot eat ore. Processing is necessary to turn inedible ore into a functional and nutritional food ingredient.

Why add it to meat? By adding phosphates during the mixing or grinding of processed meats or the injection or tumbling of fresh, raw products, manufacturers hope to achieve a number of results. The most desirable is retention of moisture, which equates to higher yield. Phosphates can also preserve color and flavor, improve juiciness, assist with freeze/thaw stability and reduce oxidation, thereby extending shelf life.

Let’s Cook Something Up Together

There is nothing more satisfying than a delicious meal featuring the savory goodness of pork, poultry, seafood or beef. Our scientists are dedicated to finding new ways to maximize the potential of meat products. You provide the challenges and we’ll provide the solutions. Call Technical Assistance at (866) 631-7394. Call Innophos Customer Service today at (800) 243-5052 to place your order. ◆ BAC-N-FOS® ◆ CURAFOS® STPP* ◆ Kena® 22-4 ◆ Kena® FP-28

◆ ColorSure ◆ LEM-O-FOS® ◆ OptiBalance ◆ CURAVIS® 250 ◆ VersaCAL® ◆ CURAVIS® 350 ◆ OptiBind ® ◆ StabilColor ◆ CURAVIS SO-LO 93 ◆ Taterfos®

*For distribution only in the United States, Mexico, Canada, Japan, and New Zealand. The CURAFOS® mark is a registered trademark of Innophos, Inc. in the United States, Mexico, Canada, Japan, and New Zealand.

Innovate with Phosphate™ ◆ Innophos.com

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

19

Ingredients&Formulations Phosphates are frequently added to curing solutions and cured product formulations, as in addition to the benefits already identified, the water-retention attribute reduces shrinkage (moisture loss) and purge (cook-out) of fermented and cured comminuted products during further processing. Phosphates also improve the stability and uniformity of the cure color. Encased meat emulsions, such as bologna and hot dogs, must maintain integrity during processing and cooking. Phosphates can enhance stability by influencing viscosity and pH, as well as assisting with protein extraction so that when cooked, the protein readily coagulates to form a gel that stabilizes the encased meat’s matrix. Pyro (two phosphate units) and tripolyphosphates (three units) extract soluble protein molecules from meat the best.

20

phosphates or potassium phosphates, instead of using complex chemicals names. Marketers must decide for themselves just how natural it is to improve the quality of meat. And here’s one last point to ponder. Phosphates help control acid-based balance in mammals. Some say that the addition of phosphates returns meat to its natural state after the animal has been slaughtered, because food-grade phosphates can duplicate the function of an animal’s native ATP. Is that natural or supernatural?

In conclusion FDA has not labeled phosphate ingredients as natural or artificial. Further, USDA allows approved phosphates to be collectively labeled as sodium

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

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.


, Ê9"1Ê  

*,"
/6 ÊÊÊÊÊÊUÊœœ`Ê->viÌÞ UÊ9ˆi`Ê“«ÀœÛi“i˜Ì ÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊUÊ-œ`ˆÕ“Ê,i`ÕV̈œ˜ ÊÊÊÊUÊ
Ê >ÌÕÀ>Ê>Liˆ˜} UÊ-…iv‡ˆviÊ ÝÌi˜Ãˆœ˜

WITHOUT IMPACTING FLAVOR? Call us today at 877-221-8558 Or visit www.wtiinc.com

THE NATIONAL PROVISIONER’S 2011 SAUSAGE REPORT

LINKING

&

comfort

taste

Photos courtesy of Johnsonville Sausage

The sausage category is holding its ground, largely due to gains in breakfast and fast-food sales. By Megan Pellegrini

S 22

ausage may have the dollar menu at McDonald’s to thank for its resilience last year. Savvy breakfast eaters could find sausage biscuits, burritos and McMuffins at their local drive-throughs, and other fast-food and quickserve restaurants (QSR) — including a surprising rebound from pizza restaurants — offered

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

more low-priced options. Like most other food categories, sausage sales were flat overall, notes Gary Karp, executive vice president, Technomic, a food industry consulting and research firm based in Chicago. But the category held its own thanks to the continued popularity of the breakfast meal

Small applications still require

big solutions.

Now you can produce sausages in natural casings that are identical in weight, length and diameter. The Vemag Robby is the ideal small vacuum stuffer for producing fresh sausage in natural casings. Combine the Robby with the LPV802 Length Portioning Device to automatically link sausages with exact weight, exact length and exact diameter. The TM203 allows you to cut strings of sausage into individual sausages quickly and precisely – an economical solution for increasing production.

725 Dedham St., Canton, MA 02021 • (781) 821-1290 • www.reiser.com

Leading the food industry in processing and packaging solutions.

THE NATIONAL PROVISIONER’S 2011 SAUSAGE REPORT occasion — during the week at fastfood and full-service restaurants and at home over the weekend. “It’s a consumer-preferred ‘comfort food’ product that’s good-tasting and is an economical protein product that is easy to cook,” he says. “It has tremendous menu flexibility as it can be made in different flavors, shapes and sizes to fit uses from biscuit-size, English muffin-size to roll-size patties and various-sized breakfast and lunch links.” Going forward, Karp says the same themes of convenience and flavor will be popular for the sausage category, with the best opportunities to be found with breakfast items, as well as continued efforts to get regional (such as bratwursts) and ethnic (like Polish, Italian, etc.) links on more plates. The latest chef survey Refrigerated Breakfast Sausage/Ham Top 20 Brands from the National RestauTotal sales in U.S. supermarkets, drug stores and mass-merchandise outlets (excluding Wal-Mart, rant Association (NRA), club stores and gas/c-stores) for the 52-week period ending Dec. 26, 2010. “What’s Hot in 2011,” reveals that local and hyper$ Sales Percent Change Dollar Unit Sales Percent Change local sourcing will be Brand (in millions) vs. Year Ago Share (in millions) vs. Year Ago among the hottest trends on 1 JIMMY DEAN 258.0 16.05 27.45 82.9 13.35 restaurant menus this year. 2 BOB EVANS 110.7 (7.61) 11.78 30.3 (16.36) For sausage, this means 3 PRIVATE LABEL 86.0 7.51 9.15 33.2 0.23 restaurant items may be 4 JOHNSONVILLE 82.5 8.44 8.78 25.2 6.38 artisan (made in-house by 5 TENNESSEE PRIDE 48.9 (5.43) 5.20 16.6 (10.98) the chef), such as at Vancouver’s Medina Café. 6 FARMER JOHN 26.5 (5.82) 2.82 18.6 (7.37) The Center for Culinary 7 TAYLOR 18.1 (5.84) 1.93 5.9 (12.37) Development classifies arti8 ECKRICH SMOK Y LINKS 17.9 (6.28) 1.90 7.1 (7.82) san sausage as just entering 9 OWENS 17.0 (22.80) 1.81 4.6 (34.53) stage one (out of a possible 10 JENNIE O TURKEY STORE 16.7 6.13 1.77 4.7 0.24 five) of its trend-mapping 11 HATFIELD 15.5 (9.59) 1.65 5.8 (13.95) process — by cropping up 12 PURNELL OLD FOLKS 14.1 (8.49) 1.50 4.6 (10.88) in fine-dining restaurants 13 FARMLAND 13.2 2.56 1.40 7.7 (3.42) before it makes its way to more mainstream accep14 CUMBERLAND GAP 9.4 (12.10) 1.00 2.3 (12.96) tance, says Kara Nielsen, 15 NEESES 9.3 11.00 0.99 2.6 8.60 trendologist, Center for Cu16 WILLIAMS 9.2 1.59 0.98 2.9 (7.78) linary Development (CCD), 17 SWAGGERTY 8.4 9.16 0.89 1.6 2.88 based in San Francisco. 18 JAMESTOWN 7.5 0.74 0.80 4.3 (8.29) “Artisan sausage allows 19 RAPA 7.4 (3.18) 0.78 3.0 (2.47) for more experimenting 20 CLIFTY FARMS 6.6 6.65 0.70 1.6 7.88 with flavors, and there is a Total category 940.1 2.37 100.00 318.0 (2.91) segment of consumers who will appreciate its quality, Source: SymphonyIRI Group, a Chicago-based market research firm

24

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

www.riscousa.com

I am Raring toGrow RS 105: Primary Technology Available for Small Scale Processors Main Features: • Higher Versatility for all Meat Production • Patented Risco Long Life Vane Product Pump for Superior Quality Products • Precision Portioner • Easy to use Microprocessor Control • Possibility to Connect the Filler to a Wide Range of Risco Accessories and Systems to Meet any Present and Future Production Requirements.

The RS105 continuous vacuum filler is an extremely complete versatile machine; ideally suited for small to medium producers. This model includes all the technology of the larger models utilized by larger producers and the result is a compact, reliable, and user friendly machine. The flexibility of the filler permits easy changeover to different kinds of products and programs during the production time.

Risco USA Corporation 60 Bristol Drive | South Easton, MA 02375

|

Tel: 508 230 3336

Risco: Solutions for Moving you Forward

|

Fax: 508 230 5345

|

[email protected]

THE NATIONAL PROVISIONER’S 2011 SAUSAGE REPORT flavor and local sourcing,” she Refrigerated Dinner Sausage Top 20 Brands says. Total sales in U.S. supermarkets, drug stores and mass-merchandise outlets (excluding Wal-Mart, club stores and gas/c-stores) for the 52-week period ending Dec. 26, 2010. Ethnic-inspired breakfast items, such as chorizo, also $ Sales Percent Change Dollar Unit Sales Percent Change cracked the NRA’s top 20 of hot (in millions) vs. Year Ago Share (in millions) vs. Year Ago trends, with gourmet sausage 1 JOHNSONVILLE 371.8 7.32 19.47 92.0 7.78 (98), sausage in general (140) 2 HILLSHIRE FARM 333.7 10.43 17.48 108.3 10.86 and breakfast sandwiches (183) 3 PRIVATE LABEL 202.7 2.79 10.62 59.5 (2.92) rounding out the top 200. 4 ECKRICH 99.2 1.49 5.20 32.6 4.25 “Both consumers and food5 AIDELLS 41.8 11.62 2.19 7.2 13.08 service operators are looking 6 PREMIO 35.8 15.71 1.87 10.1 15.64 for new flavors and products that can deliver versatility for 7 SHADY BROOK FARMS 35.2 4.72 1.84 10.0 4.26 many meal applications,” says 8 BAR S 34.1 4.42 1.79 9.0 (0.48) Gary Kolling, director of food9 AL FRESCO 30.5 11.39 1.60 6.6 13.44 service, Johnsonville Sausage, 10 CAROLINA PRIDE 23.6 1.29 1.23 8.9 (0.66) based in Sheboygan Falls, Wis. 11 JENNIE O TURKEY STORE 23.4 3.23 1.23 5.7 2.48 “We have seen that in even 12 HILLSHIRE FARM LIT’L 22.4 6.44 1.17 6.8 8.79 more intensity in foodservice, BEEF SMOKIES as operators are consistently 13 JOHN MORRELL 16.9 (8.13) 0.88 8.8 7.86 looking for products that can 14 CONECUH 15.5 13.05 0.81 3.7 6.62 bring intense flavor to their 15 BUTTERBALL 15.3 15.98 0.80 6.0 22.17 customers.” Johnsonville offers a variety 16 BOB EVANS 15.0 (20.46) 0.78 4.0 (25.83) of flavors to retail consumers, 17 EARL CAMPBELL 13.2 3.41 0.69 3.8 4.87 such as Grilling Chorizo, Four 18 NEW YORK STYLE 11.3 0.29 0.59 3.0 (0.31) Cheese Italian Sausage, Wis19 FARMER JOHN 11.1 4.91 0.58 2.4 (0.34) consin Cheddar Breakfast Sau20 SMITHFIELD 10.8 (24.44) 0.57 3.7 (28.32) sage Links and Bold Jalapeno & Total category 1,909.4 2.33 100.00 551.2 1.47 Cheese Smoked Sausage. Source: SymphonyIRI Group, a Chicago-based market research firm Chicken sausage processors have also rolled out quite a few flavors to mainstream conTop markets sumers the past few years, including for dinner mango, artichoke, jalepeno peppers sausage and other spices, beyond the popular apple and spinach-and-feta cheese varieties. Another foodservice trend, says $91 million sales Kolling, is the use of sausage expanding across the entire menu and dayparts. Sausage is extremely versatile and can be paired with upscale $85 million sales toppings, as well as being the featured ingredient in dishes across the entire menu. “Due to the flavor that sausage brings to a menu, the mindset of how $56 million sales sausage can be used is evolving,” he says. “We are consistently working Source: SymphonyIRI, 2010 with operators on new product and menu ideas, and include appetiz-

Los Angeles New York Chicago

26

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

DeWied REAL Casings Outweigh the Competition!

Competition

DeWied REAL® Casings

Do your casings match up to REAL standards? DeWied REAL® Casings are produced to a consistent, guaranteed standard for: >> Superior Consistent Quality >> Accurate Caliber Control >> Greater Production Efficiency/ Yields Do your casings match up to REAL standards? We provide a full detailed casing analysis of any of your Natural casings.

Call DeWied Now to Take the DeWied REAL Challenge! Visit us online at www.dewied.com or email, [email protected]

To Order, Call Toll Free at 1-800-992-5600 or 210-661-6161

THE NATIONAL PROVISIONER’S 2011 SAUSAGE REPORT Refrigerated Frankfurters Top 20 Brands

Total sales in U.S. supermarkets, drug stores and mass-merchandise outlets (excluding Wal-Mart, club stores and gas/c-stores) for the 52-week period ending Dec. 26, 2010.

Brand

$ Sales (in millions)

Percent Change vs. Year Ago

Dollar Share

Unit Sales (in millions)

Percent Change vs. Year Ago

118.1

1.18 (8.01)

1

BALL PARK

343.0

0.27

20.10

2

OSCAR MAYER

286.5

(6.48)

16.79

105.2

3

BAR S

156.6

3.36

9.17

135.0

2.62

4

HEBREW NATIONAL

139.6

8.49

8.18

37.1

17.06

5

NATHAN

101.8

1.61

5.96

25.8

4.10

6

PRIVATE LABEL

87.5

(7.78)

5.13

48.8

(11.07)

7

GWALTNEY

41.4

(1.28)

2.43

29.8

(2.68)

8

OSCAR MAYER SELECTS

29.0

NA

1.70

11.5

NA

9

LOUIS RICH OSCAR MAYER

21.2

1.78

1.24

9.2

4.34

10

SABRETT

20.5

3.73

1.20

4.8

11.94

11

BRYAN

19.4

(3.62)

1.14

9.5

(6.65)

12

ECKRICH

19.2

(9.29)

1.13

10.1

(8.13)

13

FOSTER FARMS

17.0

(9.58)

1.00

8.2

(4.60)

14

JENNIE O

16.8

(2.38)

0.98

10.2

(0.35)

15

FARMER JOHN

14.7

9.08

0.86

8.4

18.00

16

JOHN MORRELL

13.7

(11.84)

0.80

10.2

(13.67)

17

BAR S TASTY DOGS

12.9

(3.68)

0.76

11.4

(5.25)

18

KAYEM

12.0

4.39

0.70

2.0

1.25

19

DIETZ & WATSON

12.0

(6.36)

0.70

2.3

(7.38)

20

CAROLINA BRIGHT LEAF

11.8

20.06

0.69

2.9

15.79

1,706.5

0.14

100.00

731.5

(0.84)

Total category Source: SymphonyIRI Group, a Chicago-based market research firm

ers, sandwiches, wraps, entrées, salads, soups, sides, pizza and more during breakfast, lunch, dinner and late night.” Both foodservice operators and retailers have been incorporating sausage into convenient, portable breakfast bowls, pizza, burritos and sandwiches. “Sausage as a side seems to be diminishing in importance, in my opinion, but it’s showing up in breakfast bowls, pizza and the frozen-food section,” says Nielsen. “From our point of view, the flavor of sausage and bacon is still an important part of breakfast but is being incorporated in new ways, such as with the one-stop shopping aspect of breakfast bowls.” Certainly, most breakfast bowls in QSR and retail include sausage with eggs, cheese and potatoes. Bob Evans’ Border

28

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

Whatever you need...

Whatever it takes. CFS Consumable Parts CFS Customer Support is committed to keeping your machines up and running. From our 24/7 help desk to assist you maintenance personnel, to the superb knowledge of our parts hotline staff, CFS will decrease your downtime and adds to your bottomline. CFS specializes in the re-tooling and upgrading of machines and stocks only genuine CFS replacement parts that are compatible with our machines.

Place your order today at www.na.cfs.com or 800.388.9487

THE NATIONAL PROVISIONER’S 2011 SAUSAGE REPORT Top 10 Sausage Brands in foodservice Brand name

Number of items

Bob Evans

27

Old World

11

Zenner’s

11

Nathans Famous

9

Vienna Beef

4

Hill Country

1

Maple Leaf

1

Carando

1

Oscar Mayer

1

Sugardale

1

Scramble omelet (smothered in sausage, fries, cheeses and sauces), Jack in the Box’s Hearty Breakfast Bowl and Jimmy Dean D-lights Turkey Sausage Bowl are just a few of the options available to consumers, notes Nielsen. “People realize a savory breakfast with protein is the best way to start the day,” she says. “While sausage has a higher fat factor, donuts and pastries provide empty carbs that aren’t as filling.” Although the economy may be affecting consumers’ purchasing decisions regarding anything seen as an indulgence or extra, sausage may buck the trend with its new artisan or nostalgic offerings, says Nielsen. “It’s an exciting time for consumers who appreciate hand-quality and strong flavors,” she says.

Sample from Q4 2010; Source: Mintel Menu Insights

Average Price Per Unit

Average price per unit in U.S. supermarkets, drug stores and mass-merchandise outlets (excluding Wal-Mart, club stores and gas/c-stores) for the 52-week period ending Dec. 26, 2010.

Top 5 Restaurant Segments featuring Sausage Restaurant Segment Family/Midscale

Number of Items 1,493

Quick Service Restaurant

841

Casual Dining

745

Fine/Upscale/Gourmet

342

Fast Casual

252

Sample from Q4 2010; Source: Mintel Menu Insights

Current avg. price per unit

Category

Actual change vs. year ago

Refrigerated Breakfast Sausage/Ham

$2.96

$0.15

Refrigerated Dinner Sausage

$3.46

$0.03

Refrigerated Frankfurters

$2.33

$0.02

Source: SymphonyIRI Group, a Chicago-based market research firm

Top 15 Menu Items featuring Sausage Menu Item Dish Pizza (All)

Number of items 1,135

Top Major League Baseball venues for sausage sales

Sandwich (All)

725

910,000 sausages

Meat (All)

478

The Milwaukee Brewers’ Miller Park

Pasta (All)

309

Calzone (All)

165

Entree Combination (All)

144

376, 650 sausages

Egg (All)

143

New York Mets’ Citi Field

99

Salad (All)

104

North America Southwestern/Tex-Mex

85

Baked Goods (All)

62

Seafood (All)

54

North America - Cajun

63

Soup (All)

50

North America - BBQ

52

Burrito (All)

40

North America - Southern

20

Rice (All)

37

Asian - Chinese

10

Wrap (All)

25

Mediterranean - Greek

12

Skillet (All)

21

Mediterranean - French

4

Toppings

20

Top 10 Cuisine Types featuring Sausage Cuisine Type

Number of items

Mediterranean - Italian

2,126

North America Traditional American

1,163

Mexican

Sample from Q4 2010; Source: Mintel Menu Insights

30

Sample from Q4 2010; Source: Mintel Menu Insights

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

325,000 sausages Chicago White Sox’ U.S. Cellular Field Source: National Hot Dog & Sausage Council’s sausage consumption survey, 2010

With 99.86% on-time delivery, we keep lines running. Flat-Flex®

CompactGrid™

Eye-Flex®

Flat-Flex XT®

Flat-Flex® Conveyor Belt:

CompactGrid™ Conveyor Belt:

t t t

t t t

Easily cleaned to high hygiene standards Large open area up to 86% Available in stainless steel and carbon wire

More open area provides optimum cleaning ability Lower belt mass offers increased efficiency Grid pattern provides optimal product support

Eye-Flex® Conveyor Belt:

Flat-Flex XT® Conveyor Belt:

t

t t

t t

To suit many industrial applications including recycling and waste handling Available for cooking, cooling, baking and other food processing applications Can be fitted with cross flights, side guards and chains

t

Provides Xtra Strength and Xtra Support Enables superior distribution of product weight across the width of the belt Low belt mass translates into lower power consumption, saving you money

Wire Belt Company of America, 154 Harvey Road, Londonderry, NH 03053 5&-

t
'"9
 &NBJM
TBMFT!XJSFCFMUDPN
t
8FCTJUF
XXXXJSFCFMUDPN ISO 9001:14001 Registered Company

CoverStory

Carl Hermreck, vice president of Pork Sales and Marketing, and Tammy Shaw, vice president of Beef North American Sales and Marketing, of Cargill Meat Solutions, display some of the Rumba brand’s products in the company’s test kitchen in Wichita, Kan.

32

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

spice The

of life

Cargill’s Rumba brand uses merchandising, marketing and unique packaging to offer variety and specialty meats to under-served multicultural consumers. By Andy Hanacek, editor-in-chief Photos by Vito Palmisano

T

o be a pioneer, it takes a boatload of courage. To be a successful pioneer, it takes courage plus insight and innovation — along with, in some cases, a little bit of luck. When it comes to serving the needs of the multicultural meat consumer, Cargill Meat Solutions stands as the latest pioneer in an under-served segment of the meat case. Rumba is the first brand of its kind in its segment, providing fresh beef and pork variety cuts to African-American, Asian-American and Hispanic-American shoppers across the country.

Follow the trail Today, one out of three consumers in the United States is multicultural — HispanicAmerican, African-American or Asian-American — and the U.S. Census Bureau projects that by the year 2050, nearly half of the population will be multicultural (according to U.S. Census Bureau Projections, June 2007). Furthermore, these three groups are growing 2.9 times faster than the total U.S. population. Buying-power estimates within these population segments are very strong, with Hispanic-Americans expected to have $1.4 trillion in buying power by the year 2013, African-Americans $1.2 trillion, and Asian-Americans $752 billion (according to The Multicultural Economy, Selig Center for Economic Growth, Terry College of Business, 2009). For Cargill, these prognostications — combined with the company’s own market research on the meat case — demonstrated a real opportunity to step in, innovate and take command of the market. Tammy W. Shaw, vice president of Beef North America Sales and

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

33

CoverStory and experienced so much success that Cargill made the decision to extend the brand into pork. In fact, Rumba has logged double-digit year-overyear growth since the program was launched in June 2007, according to the company. Carl Hermreck, vice president of Pork Sales and Marketing, Cargill Meat Solutions, believes in the possibilities for the brand’s continued growth. “This is not just a variety meats program — beef has expanded into muscle cuts, and we’re going to do the same thing in pork,” he says. “The brand has a lot of power and strength, and I think you can expand the product line to more muscle cuts.” Indeed, Cargill believes Rumba has the potential to generate more than $100 million in annual sales over the next five years. Much of that strength and potential builds off the research, explains Shaw, but Rumba draws further inspiration from one group that has been involved from Day One. “Within our own company, in our own facilities, we have a very ethnically diverse group of employees,” she says. “We realize what a huge resource our employees are, and we have asked them, to tell us what we needed to do.”

Expansion exploration

Cargill Meat Solutions corporate chef Chad Schafer (left) gives Andy Hanacek, editor-in-chief of The National Provisioner, details on how multicultural consumers prepare their traditional meals using specialty meat cuts that the company’s Rumba brand offers.

Marketing, Cargill Meat Solutions, says that convergence of data gave Cargill the background it needed to commit to creating the Rumba brand, which launched its first beef items in 2007. “Our consumer research told us that there was an opportunity there, in this space in the meat case that, in the past, had been filled with products that 34

were frozen and sometimes difficult to deal with in the back room,” she explains. “Here was an opportunity to offer these products fresh and in a package that is clear, so that consumers can see the product and know what they’re purchasing.” Within two years, Rumba’s beef products became the category leader

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

As the brand looks for ways to expand, it will continue to tap into the bevy of research and its own employees’ knowledge, says Meredith McGowan, Rumba brand manager. “In developing the brand, we took products into the multicultural consumer’s home and we asked them to prepare the product in front of us and give us feedback,” she adds. “So through interviews with them in their homes, we learned about other products they consumed and prepared also.” One of the solutions Rumba is able to bring to consumers comes in the form of its newest product, its timesaving tripe. McGowan states that typically tripe would take four hours to cook, but Rumba’s time-saving tripe cooks in less than one-and-a-half hours, without any additional

CoverStory “Our consumer research told us that there was an opportunity there, in this space in the meat case that, in the past, had been filled with products that were frozen... .” — Tammy W. Shaw, Cargill Meat Solutions

InfraLab At-Line Meat Analyzer FAT/LEAN MEASUREMENT IN 10 SECONDS! ■ Measure Fat, Moisture & Protein Accurately ■ Save Time and Money with Rapid Analysis ■ Secure, Passcode Protected User Access ■ Full Data Logging ■ USB & Ethernet Connectivity ■ Designed for the SEE InfraLab ON OUR Process Environment BOOTH 2504 AT THE AMI SHOW 2011

Based on over 40 years of experience manufacturing NIR measurement systems for the foods industry, our latest InfraLab is the most cost-effective rapid meat analyzer you can buy. Ask us for an on-site demonstration! The Measure of Quality™

www.ndcinfrared.com/meat NDC Infrared Engineering Inc., 5314 N. Irwindale Ave., Irwindale, CA 91706 Tel: 626 960 3300 Email: [email protected] 36

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

ingredients. “Consumers today are more crunched for time than ever before,” she says. “This innovative product allows multicultural consumers the chance to prepare their families’ favorite traditional dishes much more quickly.” Another step Rumba took toward putting its research into action came from the inclusion of specialty muscle cuts on the beef side — those that target the multicultural markets Rumba serves. Beef features such cuts as hanger steak, inside skirt and outside skirt, among others, and pork will soon follow into the segment, says Donna Lin Niles, Rumba pork brand manager. “We’ve been growing very quickly just in terms of variety cuts,” she explains. “But we see our progression going the same way beef has grown beyond variety meats and into specialty meats and muscle cuts, and convenience products.”

Winning over retailers Convenience stands as one very important aspect for the entire line, from its packaging and extended shelf-life to its overall ease-of-use for the consumer. The total package Rumba offers has taken it to more than 5,000 locations from coast to coast, and is something Lin Niles says really hits the mark for their retail partners. “We often hear retailers describe it as a program, which is not what they get from their frozen bulk offering,” she adds. “So the retailers know that when they’re buying the package, they’re getting a lot more than just meat or case-ready meat. They’re getting all the services that we provide to them.” Rumba enters the partnership with each retailer stocked with strong demographic data on that retailer’s neighborhood, and backed by products that are attractive in their presentation, shelf-life capabilities and convenience. McGowan relays that according to Rumba’s research, 8 of 10 multicul-

Kevin Kroeger, a lab technician for Cargill Meat Solutions, runs a test in the company’s test lab in Wichita, Kan.

tural customers shop at a mainstream retailer, but only about half of them buy their meat at that mainstream retailer. “Whereas the multicultural consumer would have normally gone to an ethnic grocer, such as a carnicería to buy their meat, we provide the mainstream retailer a product that the multicultural consumer will pick up from their meat case,” she says. Those benefits, however, make the most sense for a mainstream retailer, Rumba’s primary target, explains Lin Niles. “That’s where the brand benefits kick in,” she says. “If a consumer is shopping at a mainstream retailer, they’re going to see the quality, the packaging, the freshness of Rumba, whereas a carnicería or Asian market merchandises differently.” Cargill Meat Solutions took a courageous leap into this variety-meats vacancy several years ago, planting its flag first in this territory of the market. Thus far, Rumba has been able to reward the company by improving the

“I Stand Behind All Our Patty Paper and Interleaving Products.” Larry Czaszwicz Jr.

President/Owner

s'REATSELECTION

CUSTOMSIZES s/RDERSMATCHEDTO YOURNEEDS s,OWMINIMUMS

s7ORLD CLASSCUSTOMER SERVICE sv3UPERIORv'-0 CERTIlCATION

3224 Butler Avenue South Chicago Heights, IL 60411 0F [email protected] www.framarx.com

Interleaving the worlds of meat, poultry, dairy, baking, and specialty products

4OLL&REE #ALLTODAYANDEXPERIENCETHE Framarx/WaxstarDIFFERENCE

framarx ® waxstar ™

”Our goal is to astonish you with great service. Let me know how we’re doing.” - Larry

Interleaving The World

We’re proud to be part of your quality products

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

37

CoverStory product offerings, using Cargill’s market research and demographically targeted merchandising. Pioneers such as Rumba always have the courage to strike first — it’s the very essence of being a pioneer. However, if the pioneer doesn’t have the proper insight or is unable to innovate, competitors eventually

erase the pioneer’s lead. With the strength of Cargill Meat Solutions’ research and experience behind it, Rumba appears poised to maintain its position as the leading provider of fresh variety meats to the multicultural population.

Pinpoint targets During his visit to Cargill Meat Solutions’ Wichita, Kan., offices, Andy Hanacek, editor-in-chief of The National Provisioner, sat down with Meredith McGowan, Rumba brand manager, and Donna Lin Niles, Rumba pork brand manager, to discuss the intricacies of Rumba’s targeted multicultural demographics and how the brand uses that information to innovate and improve its offerings. What follows is a portion of the interview: Hanacek: Does Rumba’s data point to any gravitation of the brand’s consumers toward any specific products or cuts? For example, do your African-American consumers prefer a particular cut that the Asian-American demographic does not?

Quickdraft knocks problems out of the park! Like a powerful cleanup hitter, Quickdraft Engineered Solutions and Venturi Technology come through for you, blowing both exhaust and conveying problems out of your plant.

(330) 477-4574

Lin Niles: Tripe, for example, is an interesting product because it appeals to multiple groups in some way, but the recipe or application is completely different. So with Vietnamese consumers in the Asian-American segment, they have a rice noodle soup named “pho,” in which the tripe is thin-sliced and eaten as part of the pho. It’s not part of the broth. But with Hispanic consumers, menudo uses pork feet as well as tripe, but the tripe is sliced into squares and is a big part of the soup — it’s actually the star of the soup.

[email protected] quickdraft.com

McGowan: So, as far as

Increase Incr In c ea cr ease se Pro Productivity Produ duct ctiv ivit ity y an and d Reduce Redu Redu Re duce ce Maintenance M Mai aint nten ena ance Both Exhaust and Systems. fforr B fo oth hE xhaust h a nd Conveying Conveying on Sys ste tems.

Exhaust

Conveying

0‰  h‰h’KdQ‰  K in Air Stream

0‰`mh’A‰hh9‰IAŠ•   9 I Š 0‰h‰Š„‰h‰dK„ŠA„

0‰ NK`KdŠA‰hhIŠhm‰ Grease Buildup

1hŠ‰„‰Š‰h1A„„‰”mh‰‰0‰‰ N•‰kB[Ž—7‰Ž—k—‰‰0‰‰hhŠY‰gkk—‡k 38

McGowan: A lot of the products will overlap into all three consumers groups we target, but when the consumers prepare the dishes, the recipes are what make the products their own, specific to their culture.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

certain consumer groups consuming more of any item, tripe is a good example. Hispanics really love tripe, and Argentinian consumers will buy a lot of the sweetbreads; Asian consumers buy a lot of the pork products; and for African-Americans, oxtail is a good seller. Lin Niles: Also with the pork items, a lot of these applications are not for stewing or eating them as the center-of-the-plate item, but they’re flavorings. So you’ll see them added to greens or stews to add that certain flavor that you can’t get from anything else. Hanacek: Are there any other product trends on the pork side that show up in Rumba’s data? Lin Niles: Again, it depends on the group. Asian-Americans really love cuts like the feet or the ears. Those have certain cooking applications.

Donna Lin Niles (left), Rumba pork brand manager, and Meredith McGowan (center), Rumba brand manager, discuss with Hanacek the convenience Rumba is bringing to market with its time-saving tripe product.

The ears are kind of like a braised barbecue pork ear, and they’re sliced very thin. The ear has the skin on top and the bottom, and the center is kind of crunchy. The feet, you’ll see that there are several applications, but they can be braised as well and eaten just off the bone that way. With African-

Americans, the tendency is toward hocks, jowls and fatbacks, and those are often used as flavorings or stews. You’ll see them with collard greens or cooked into a stew. Sometimes feet are cooked with greens as well. With the Hispanic segment, it really varies by consumer group, but I would say fried pork fatback skins — the chicharrones — are popular. But you also see neck bones cooked into stews and served over rice, or some consumers may turn them into tacos, because they’re meaty. Hanacek: So based on the demographic data you have, you’re able to tailor the product mix to each individual store based on those trends that you see, right? McGowan: We are able to tailor that product mix toward the demographic data we have, and that’s part of the overall solution that we offer the retailer.

Bacon Hanger Specialists! BH-400

BH-300-CT

BH-600 Patent #5,938,522

Beacon has the largest inventory in the industry. With over 50,000 combs of different styles in stock, Beacon can supply your plant with the best Bacon Hanger for your processing needs. By manufacturing our Bacon Hangers in large quantities we are able to supply quick delivery at a very competitive price.

BH-401-S Patent #7,182,686 B2

OUR PRODUCT LINE INCLUDES: • Standard eight and ten prong designs • Mechanical puller styles • “Shorty” combs to be used with longer bellies • Hook reinforcement bar designs to reduce hook breakage • CT combs designed to easily catch the CT muscle during combing • Special Bacon Hangers for unique applications

For more information visit our web site at: www.beaconmetals.com or call toll free 800-445-4203.

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

39

MORE information. MORE resources. MORE ways to do your job better.

FREE

Webinar

Sponsored by

Renovation Mythbusters Thursday, March 10 | 2:00 - 3:00 p.m. EST Major food and beverage expansion projects often start with the preconception that a Greenfield plant is needed to achieve desired performance goals. This preconception is based on some pervasive myths: • MYTH #1: Too many compromises have to be made with renovations/expansions or Brownfield conversions. • MYTH #2: Renovations are too risky, costly and take too long. • MYTH #3: Few suitable Brownfield properties can be renovated for food and beverage production. Featuring real-world examples, the latest Food Plant of the Future webinar from Hixson, one of the leading design and engineering firms in North America, dispels some of these common misconceptions. Join us as we discuss the benefits and drawbacks of renovating/expanding and Brownfield development to help you determine which option best fits your plant expansion needs.

Live Q&A with attendee-submitted questions will follow.

Don’t miss this exciting opportunity! Register for FREE at

webinars.provisioneronline.com Can’t attend live? Register and watch on-demand.

TechProcessing ROBOTICS/VISION SYSTEMS

Step outside ‘labor replacement’ box To design a truly successful system, processors must expand their thinking beyond viewing robotics and vision systems simply as labor-replacement tools. EVERY FOOD-PROCESSING PLANT TODAY IS LOOKING FOR NEW ways to automate their process. It seems the most common method of justifying any robotic or automation project (including inspection) is labor replacement. You cannot start any conversation with a system integrator or a representative of a plant without someone bringing up the question, “How many people will this system replace?” The question is not intrinsically wrong, but it does bring with it a fair number of assumptions, and it constrains the problemsolving ability Gary McMurray, Georgia Tech Research of everyone on Institute the team. While Editorial Board this approach Member can yield some positive benefits for the company, it is missing the larger potential benefits of automation — including higher throughput, safer product and more efficient utilization of natural resources. When the starting point for any discussion about automation begins with the labor replacement question, this immediately puts a box around the manual worker, and all solutions are based on replicating exactly what the person would be doing while trying to do it better. There is no opportunity to ask if an automated

eb

42

Photos courtesy of Georgia Tech Research Institute

Gary McMurray and Matt Marshall, a Ph.D. candidate at Georgia Tech, observe the actions of a robot arm used for rehang of chickens after they pass through the chiller, at GTRI’s facility.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

WEBER INC. 10701 N. Ambassador Drive Kansas City, Missouri 64153 Phone: (816) 891-0072 Fax: (816) 891-0074 www.weberslicer.com e-mail: [email protected] We proudly support the missions of

WORKS FASTER. WORKS FOR LESS. NEVER TAKES A SICK DAY. Hire your next competitive edge – Weber Twin Pick Robotics. Designed to virtually eliminate human contact with sliced products, Weber’s innovative Twin Pick food robotics deliver blazing speed, precision placement and reduced labor costs – every working day.

Come see Weber at the WISCONSIN CHEESE INDUSTRY CONFERENCE April 13-14, 2011 La Crosse Center Booth #50 La Crosse, WI and PROCESS EXPO ‘11 Nov. 1-4, 2011 Booth #5231 Chicago, IL

Talk to our Weber applications specialists and learn how Weber Twin Pick robotics can become your competitive edge in the decade ahead.

Key to these advantages is an integrated camera system able to instantly recognize the position of each sliced portion. Using this visually acquired information, picking and placement is then accomplished with great speed and dexterity. Portions of almost any shape or size can be rotated to your desired angle and accurately placed into any desired configuration of packages and trays. Trouble-free operation and easy-to-accomplish sanitation combine with your labor cost savings to assure a rapid return on your investment.

Scan to view video. Get the free app at http//:gettag.mobi

Weber Pick & Place Robotics are designed to work efficiently with all major lines of packaging equipment and help processors take full advantage of the extra slicing throughput built into every high speed Weber Slicing System.

1-800-505-9591

TechProcessing We must no longer be accepting of a process that is 60 years old, but look for new methods to process food that facilitate and enable automation as well as food safety.

NEWPORT NEWS, VA

TM

COLD STORAGE WAREHOUSING AND QUICK FREEZE CAPABILITY.

TIPPMANN HAS BOTH!

Check out Interstate Warehousing in Newport News, Virginia, equipped with our new QFR Zone™ to handle your quick freezing needs. Immediate Availability • 355,000 square foot multi-temperature facility • Import/Export USDA Inspection Room • Capacity to quick freeze 15-17 loads per day, with room to grow • 15 divisible rooms • Public storage space AND lease options available Get in the Zone!

9009 Coldwater Rd. Fort Wayne, IN 46825

(260) 490-3000 [email protected] www.tippmanngroup.com

• QFR Zone™ technology uses improved airflow for more efficient freezing • Available for your freezer, too! (new construction and/or existing building)

TIPPMANN HAS THE SPACE YOU NEED AND THE INCREDIBLE QFR ZONE™ TO FREEZE ANY PALLETIZED PRODUCT. FAST. 44

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

system can do more than just this one task; if the process can be changed to facilitate automation; or what data is required to do the task and what other tasks need the exact same information? The basic product flow and process for a poultry plant has not dramatically changed from the manual process used by Jesse Jewell in the 1940s and 1950s. This inability to change the process has lead to several unintended consequences. The addition of each robotic system to replace the manual worker almost without fail increases the footprint of the work cell. This is a big expense to the company. It has also created islands of automation where each cell functions as a completely independent entity. The addition of each independent piece to the line only increases the overall complexity of the system, and this leads to more potential failure points and more cost. Finally, improving the throughput of a single cell in the production chain will only incrementally improve the throughput of the entire system. This concept was at the heart of Dr. Goldratt’s Theory of Constraint. To achieve the radical change in the system, you must redesign the system. Is labor replacement the right measure to justify robotics? It is a component, but in order to truly capture the value of robotics, the plants must be looking at the entire system. A simple example (and I agree, a somewhat naïve example) of this is the dishwasher. If you were designing a robot to replace the manual dishwasher, then you would probably start by trying to design Rosie from the Jetsons. However, we know that the modern dishwasher has been tremendously successful, and it looks nothing like a human worker. It achieves the goals of the work, but the process is completely different. Let me use an example from some of my own work in this area to show how this thinking can lead you down

What if reduction of E.coli O157 could start at the source?

E. Coli Bacterial Extract vaccine1 with SRP® technology, from Pfizer Animal Health, is the first and only vaccine approved by the USDA to reduce the amount of Escherichia coli (E. coli) O157 pathogens in the intestines of cattle. Call 800-733-5500 to learn more.

1 This product is conditionally licensed. Effi cacy and potency test studies are in progress. All brands are the property of their respective owners. ©2010 Pfizer Inc. All rights reserved. SRP10012

TechProcessing

A washdown-ready robot places raw product into trays.

the wrong path. For years at GTRI, we have looked at automating the rehang of the birds after the chiller. We looked at industrial robotic arms and we looked at novel fixed automation concepts that utilized advanced imaging for controls. Each of these systems went to great length (and floor space) to solve the problem by looking to directly replace the manual worker. While our systems were technically successful, none of them really solved the problem in a manner suitable to the processing companies. We have now taken a step back and looked at the process including the chiller. The key questions are now: Why did you let go of the bird in the first place, and how do you get the proper cooling of the bird while still maintaining control of the bird? As you can see, the real problem was upstream to the rehang task — not

Hang up your gloves. A better way to wash and sanitize scale parts is right at your fingertips! Presenting the Douglas Model 1536-SPW. Meet today’s high standard for cleanliness and sanitation at the push of a button with this versatile, highly effective washing and sanitizing system. Installed in a pit or used with a ramp, this walk-in type batch washer cleans scale parts such as weigh and feed buckets, chutes, funnels, feed pans and other detachable items. This powerfully efficient machine also features pre-programmed wash times and a digital display that monitors key performance criteria and service requirements. And with a typical wash/rinse cycle of just 5 minutes, clean-up is quick and economical!

C ALL 800-331-6870 for pricing, literature and specifications on a model suited to your needs. 2101 C ALUMET ST. • C LEARWATER, FL 33765 • (727) 461-3477 (800) 331-6870 • FAX(727) 449-0029 • www.dougmac.com 46

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

NE

JARVIS NOW HAS W W E N ROBOTS FOR THE KILL FLOOR!

Jarvis offers technologically advanced robots for: •

Hog head dropping

•

Brisket opening (hogs)

•

Aitch bone opening (hogs)

•

Forequarting (beef)

•

Hock cutting (beef)

Model JR-50 Head Dropper Robot with Jarvis’ 3HD-1R Head Dropper

Model JR-50 Hock Cutter Robot with Jarvis’ 30CL-1R Hock Cutter JARVIS PRODUCTS CORPORATION

View additional equipment information at our website!

33 Anderson Road, Middletown, CT 06457 Tel: (860) 347-7271 Fax: (860) 347-9905 E-mail: [email protected] http://www.jarvisproducts.com

Please visit us, Booth 1524 at AMI’s WWFE 2011 in Chicago, April 13-16

TechProcessing

An automatic casepacker places shrink-wrapped trays of product into shipping containers.

the rehang task itself. When the post-chiller rehang problem is posed from this new system-oriented point of view, you can also begin to see how other problems can be solved at the same time. If you can maintain control of a bird through the chiller, then you can also track an individual bird all the way through the process. This means that a single bird from a grower could be tracked through deboning, and yield and product quality could be traced all the way through the system. This could have a significant impact on food safety as well. This is, of course, just one simple example, but it shows how easy it is to get trapped into this labor-replacement box. How should we automate the back end of a poultry-processing plant? It would be simple, and I think wrong, to begin replacing

Metal Detectors & X-Ray Inspection

Eriez’ New Vibratory Inspection Conveyors Our new Dual Inspection Vibratory Conveyors offer precise product control and uniform coverage giving hand inspectors easy visual recognition of imperfect product or foreign objects.

Features include: • Vibratory action rotates and flips product • Easy visual inspection • Precise product control • Reduced noise • Safe operation with no rotating parts or lubrication • Sanitary wash down • “Green” low energy consumption

Vibratory Screeners

Magnetic Separators

FREE!

Vibratory Selection Guide & How-to-Use Brochures

Visit eriez.com Call 888-300-3743

every person with a robot. Why do we have to touch the product so many times after it is removed from the bird? It is touched at trimming, manually placed on a conveyor for marination, replaced on a conveyor for cooking and freezing, and then manually loaded into a tray. Can we redesign the system to eliminate the need to handle it all these times as opposed to trying to design robots to perform each of these tasks? I think so, and I would be willing to bet that the integrated system design would require less floor space and improved throughput. The task of automating a plant is something that should be a team effort between the plant, the system integrator and the equipment companies. Each partner needs to play an active role in the design process. The plant representatives need to challenge the designs and process. The system integrators and equipment companies need to fully understand the process and actively look for ways to address the system needs. The research community has a role in this process as well, and it is one that I think has not been fully accepted by the academic community. It is the job of the academic community to envision the future and develop the new processes or systems. We must no longer be accepting of a process that is 60 years old, but look for new methods to process food that facilitate and enable automation as well as food safety. We must begin to envision a new future for the industry that provides a path forward to completely automate the entire production process. In order to achieve this lofty goal, we must challenge the accepted norms and look for new ways of doing things. If we can do this, we can work with the equipment companies and industry to provide a product that is reasonably priced and safe for the consumers, and also allows the industry to produce a reasonable profit.

The task of automating a plant is something that should be a team effort between the plant, the system integrator and the equipment companies.

Your life. Your future. Your decision.

"O
POMJOF
EVBMEFHSFF
NBTUFST
QSPHSBN
GPS
XPSLJOH
QSPGFTTJPOBMT Choosing a graduate school is tough, but the quality of our program makes it easy. t

5XP
EFHSFFT






t
.4
JO
BHSJDVMUVSBM
FDPOPNJDT from Purdue University






t
.#"
GSPN
*OEJBOB
6OJWFSTJUZ









,FMMFZ
4DIPPM
PG
#VTJOFTT t


QFSDFOU
POMJOF t


'JWF
POFXFFL
SFTJEFODJFT t


NPOUIT

DSFEJU
IPVST t

/P
UIFTJT
PS
EJTTFSUBUJPO t

*EFBM
GPS
XPSLJOH
QSPGFTTJPOBMT

“Earning two degrees at once is a powerful combination. The focus on both agriculture and general business broadened my knowledge of the agriculture industry while exposing me to real-world experiences from my MBA classmates. There are many online MBA programs, but none offers the same combination of academic rigor and convenience as the Purdue-Kelley MS-MBA.” Jennifer Araujo Protocol Analyst–Technology Development, Monsanto

#FGPSF
ZPV
EFDJEF
öOE
PVU
NPSF
BU

w w w.age con.purdu e. e du / a g r ibusiness Contact: Luanna DeMay (765) 494-4270 [email protected] Purdue is an equal access/equal opportunity university.

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

49

TechProcessing

Freezing systems’ efficiency on fast track By Andy Hanacek, editor-in-chief Freezing systems remain one of the key systems in food production overall, and in the protein-processing industry, the challenges processors and other companies face in this realm hit from many angles. From sustainability to maintenance and worker safety, issues abound for processors. To get a fresh perspective on freezing systems, The National Provisioner discussed the topic with Steve Tippmann, executive vice president of Tippmann Group / Interstate Warehousing, a family-owned and operated refrigerated distribution and warehousing company headquartered in Fort Wayne, Ind. Q: In this world of sustainability and energy management, how have freezing systems adjusted in recent years? What technologies have emerged to help ease the high-costs of freezing products and keeping them frozen? Tippmann: In the last three years, we have reduced our KWH consumption (per cubic ft) close to 30 percent system-wide, and we are freezing more pounds of product today than three years ago. Our new QFR Zone™ freezing system (pictured) operates at 30 percent to 50 percent less power than traditional blast freezers. We are installing state-of-the-art lighting systems (LED) with motion detection and monitoring, and controlling our refrigeration systems so they operate at peak efficiency. Our systems regulate the suction pressure by monitoring the temperature requirements throughout the warehouse — this keeps the suction pressure at the highest pressure which is the most efficient operating condition. Variable speed or frequency drives (VFD) have increased their operating 50

Courtesy of Tippmann Group / Interstate Warehousing

efficiency more recently.We are now installing them on the fans of condensers to enable the lowest head pressure with the least fan horsepower. Every aspect of the design is critiqued to ensure we have the proper insulating values and absolute vapor seals throughout our facilities. Q:What are the primary challenges you find in maintaining your freezing systems, to keep them at that peak efficiency? Tippmann: So much can be gained in the operation of our warehouses that we have started an audit program both for our own (Interstate Warehousing) facilities along with some of our construction customers.We audit all aspects of the refrigeration, electrical, fire protection, safety, sanitation and overall warehouse condition to ensure peak operating performance. Q: Are there any significant differences in the way protein products are stored frozen versus other frozen-food products? If so, what are they? Are there certain freezing systems processes that lend themselves better to freezing (and frozen storage) of protein

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

products? Tippmann: [Serving] the breadbasket of the world, we freeze and ship commodity priced products worldwide. It is a competitive industry and the most efficient producer wins. Added-value products tend to be frozen in unit or case quantity, and commodity-priced proteins are typically frozen in pallet quantity. Tippmann has developed a pallet freezing system that reduced the utility consumption by up to 50 percent. In addition to the utility savings, the labor cost and overall product-quality improvements reduce the overall cost substantially. Q: Finally, what further improvements need to be made in freezing systems, from your perspective, and do you see those changes coming on the horizon, or will they take a quantum leap to get there? Tippmann: Utility rates have been increasing at double-digit rates for the past three years. In the last three years, we have seen the most significant improvements in utility consumption in our industry, as our rates increase; I believe our design changes and new ideals will be cost-justified.

Ross S Series

The advantages of Ross Tray Sealers come in every shape and size. Join other satisfied Reiser customers that trust Ross tray sealing equipment to protect the integrity of their product. Specially designed to produce modified atmosphere packages (MAP), the Ross high-impact seal bar system ensures the highest quality seals every time. Reiser offers a full line of Ross tray sealers to match any packaging requirement. Reiser is your solution – put us to the test. For more information, call Reiser at (781) 821-1290.

Ross Inpack A10

725 Dedham Street, Canton, MA 02021 • www.reiser.com

Leading the food industry in processing and packaging solutions.

SpecialReport

Streamlining sanitation Meat and poultry processors are improving their sanitary equipment design with built-in cleaning and processing practices. By Megan Pellegrini

I

n the 1990s, a meat-plant employee entering a work station might have to use a decontaminating foot wash. Now, plant employees have to navigate a boot-scrubbing system, put on personal protective equipment (PPE) such as gloves, masks and goggles, and their movement is restricted to prevent any contamination. Certainly, meat and poultry processors have made tremendous improvements to their sanitary standard operating procedures (SSOPs) in the past 10 years, and continue to develop new methods to control foodborne illnesses through sanitary plant design. “Plant designs have become much better in regard to the cleanability of the entire envelope instead of just the functionality of the building and equipment,” says John E. Johnson, general manager for a JBS-Swift case-ready facility, Greeley, Colo. These changes are largely due to the 2003 U.S. Department of Agriculture’s Food Safety and Inspection Service’s (FSIS) interim final rule requiring federal establishments producing certain readyto-eat (RTE) meat and poultry products to take steps to reduce the incidence of Listeria monocytogenes contamination, and document (and verify) their control measures. “The extra emphasis and regulatory concern from the government and increased public awareness pushed the meat industry to improve its equipment and facility design,” says Lee Johnson, Ph.D., vice president of technical services,West Liberty Foods, based in West Liberty, Iowa. As a result, the design of equipment and facilities has improved so that equipment is now easily accessible and cleanable to a microbiological level, which is 52

building layout to prevent crosscontamination and control forklift traffic, says Johnson. “We’ve redesigned our plant traffic flow to better cater to our RTE products, with one side of our plant devoted to RTE slicing and packaging lines, which have their own individual slicing ‘cells,’” says Johnson. The West Liberty Foods’“cells” are well-known for their complete isolation from the surrounding environment to prevent cross-contamination. Employees enter wearing clean, full-body suits. Product casings are first treated with foodgrade antimicrobials before entering the cell. And each cell has its own drain (to dispose of copious amounts of floor sanitizer) and air-handling system (to filter out airborne Listeria and ambient air).

Retrofitting older plants Photo courtesy of Christopher Raines

further documented with SSOPs that regulate dry cleaning, pre-rinsing, foaming, scrubbing, rinsing and visual inspection. In addition, the post-processing environment undergoes the same scrutiny.

Sealing off contaminants “Regarding improvements in facility construction, we [also] know so much more now about the need to separate raw from RTE and air controls to reduce condensation — and even building materials have improved to increase life expectancy and therefore require less maintenance,” says Joe Stout, former global director of product protection and hygienic design for Kraft Foods Inc. and current president of Commercial Food Sanitation, LLC, based in Chicago. Today,West Liberty Foods’ team, for one, is focusing on how to design its

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

According to John Johnson, probably the biggest challenge for plant designers is retrofitting older plants to meet today’s more rigorous standards, with more work still needing to be done in this area. “It is easy to build green-field plants and is oftentimes cheaper than trying to retrofit an older plant with new designs. Constraints on floor space, non-compatible materials, older infrastructures — for example, plumbing, pneumatics, etc. — are a high hurdle,” he says. Today’s more modern plants are designed to adapt to new equipment, notes Christopher Raines, Ph.D., assistant professor of meat science, department of dairy and animal science, The Pennsylvania State University, based in University Park, Pa., and their designers also factor in Listeria’s well-documented obstinacy. “The challenges for RTE meat products in older establishments will probably get more difficult,” he says, with very small plants facing the largest obstacles.

By the book Since 2003, the Washington, D.C.based American Meat Institute’s (AMI) 11 Sanitary Design Principles for Facilities has been a handy reference for meat processors looking to upgrade their facilities and avoid food recalls. Here is another look at the trusty guidelines:

Photos courtesy of Lee Johnson

“Often, they are able to obtain a grant of inspection for fresh product but not RTE product.” The recent Food Safety Modernization Act may also put more pressure on smaller plants in particular as it requires more documentation and records of sanitary handling of food, says Stout. In addition, all plants managers need to be aware of “sandwiches” — an area where two pieces of equipment material meet, are not hermetically sealed and cannot be dissembled for cleaning, notes Stout. “A good example seen too frequently is conveyor rails — either side or bottom support or guide rails — that are made of slotted UHM and pressed into a stainlesssteel channel,” he says.“These create perfect ‘sandwiches,’ as they are an area where moisture can harbor without being reached with detergents, mechanical action or sanitizers.” Freezers also pose cleaning challenges, although they have come a long way in recent years and can be purchased with clean-in-place (CIP) capability and fully welded panels. “However, there is still too much moisture which collects at the in-feed and exit points, which has the potential to form condensation,” says Stout.“There are formulas that can be used to figure out the dew points that would minimize this. It may mean an extension on a freezer to gradually allow temperatures to calibrate, other dehumidification techniques that could be employed or both to get this under control.”

Automating cleaning systems Lee Johnson says that processors will only continue to improve sanitary equipment design and automation in cleaning and processing practices. “I see meat plants becoming more like aseptic filling and canning operations where processes are less reliant on manual activities and more and more CIP systems and automated cleaning equipment are built into the design of the facilities,” he says. Automated cleaning systems eliminate the human variability factor associated with manual cleaning practices, such as the traditional foam and mechanical actions used to remove soil, and training challenges on proper cleaning procedures, says Stout. Raines says that CIP processing equipment will become even more streamlined. “Advancements are being made with antimicrobial packaging systems — which is antimicrobial activity beyond an ingredient — such as bioactive packaging films,” he says.“More antimicrobial processes such as HHP [high hydrostatic pressure treatment] and ingredients, especially ‘natural’ ones, will be explored.” Plant designs will only become more flexible with their utilization of materials and the functionality of the design, notes John Johnson. “The envelope in which equipment is used will be more dynamic and not rigid to only accommodate one type of processing,” he says.

■

Establish distinct hygienic zones in the facility to reduce the transfer of hazards from one process or area of the plant

■

Control the movement of personnel and materials flow to reduce hazards

■

Prevent and control the accumulation of water inside the facility

■

Control room temperature and humidity to prevent microbial growth

■

Design, install and maintain HVAC/refrigeration systems serving process areas to ensure room air flow and quality are controlled

■

Provide site elements (such as exterior grounds, lighting, grading and water management systems) to facilitate sanitary conditions

■

Design and construct all openings in the building envelope (such as doors and fans) to enable easy cleaning and inspection, and prevent insects and rodents from entering

■

Provide interior spatial design that promotes sanitation

■

Design building components and construction to prevent harborage points through sealed joints and no voids, and use durable materials.

■

Design and install utility systems to prevent contamination

■

Provide proper sanitation systems to eliminate chemical, physical and microbiological hazards

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

53

FoodSafety APPAREL

Donning/doffing dogs processors What looked like a real decision in the donning/doffing compensation battle has become unclear once again in early 2011. By Andy Hanacek, editor-in-chief THE LONGSTANDING ARGUMENT OVER WHETHER PROTEIN-PROCESSING employees should be paid for the time spent donning and doffing protective apparel, or personal protective equipment (PPE), continues as the industry awaits definitive legal guidance on the issue. Donning and doffing time has been a sticking point for many in the industry over the years, resulting in battles and lawsuits over whether employees should be paid for such time or not. In 2010, the issue of donning and doffing appeared on a faster track toward a definitive resolution, but a Minnesota appeals court once again brought uncertainty to the table in January 2011. The U.S. Department of Labor (DOL) requires that employees be paid for this time, yet processors certainly can’t predict the enforcement of this requirement, especially in dealing with some of the lower courts’ decisions. In June 2010, Tyson Foods and the U.S. government reached an agreement in regard to DOL allegations that Tyson was required by federal law to pay its workers overtime compensation for donning and doffing times. Tyson, which paid out $500,000 to resolve the claims against it, denied any wrongdoing on the matter and said this case was an example of “an ongoing, nationwide legal debate over what types of activities are compensable under the Fair Labor Standards Act.” At the time, in its own release, Tyson said this agreement “could serve as a model for the way some workers in the poultry industry are paid.” 54

Photo by Vito Palmisano

However, though the DOL requirements now seem clear, cracks in the law appear to be surfacing. On Jan. 18, 2011, the State of Minnesota Court of Appeals ruled in favor of Jennie-O Turkey Store in a similar donning-and-doffing-related lawsuit filed by current and former Jennie-O employees. The employees claimed that timekeeping methods at Jennie-O did not fully capture the time required to don and doff mandatory apparel, which resulted in the underpayment of their wages in violation of their contracts and the Minnesota Fair Labor Standards Act (MFLSA). In this particular case, the court sided with Jennie-O, stating that under MFLSA, employers are required to pay overtime wages only after an employee works at least 48 hours (unlike the Federal Fair

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

Labor Standards Act, which requires only 40 hours to earn overtime), and that the workers’ compensation already “significantly exceeded the compensation required under the MFLSA.” Furthermore, the court said, the workers could not provide enough evidence that they and Jennie-O had any kind of agreement, verbal or otherwise, that they’d be compensated for donning and doffing times. This ruling simply muddies the waters of the donning and doffing issue on the heels of the Tyson agreement and other earlier court rulings and settlements in recent years. In order to avoid lengthy litigation, processors should study their donning and doffing compensation structure and begin to solve the issue within their own organizations.

ProteinProblemSolvers

Cargill’s Fresno facility fights pathogen with innovative hide-on-carcass wash CARGILL HAS COMPLETED PROJECTS TO EXPAND its already extensive foodsafety efforts at its Fresno, Calif., beef-production facility, having spent $4.2 million to install a hide-on-carcass wash. The wash closely resembles a “car wash for cattle,” in which the hides of animals are scrubbed with spinning bristles and a mild bromine solution that kills bacteria at the beginning of the harvesting process. This process helps better ensure removal of dirt and debris while washing the animal’s exterior, thereby minimizing the potential for contamination from bacteria that potentially pose a health risk to humans. Used in concert with numerous food-safety measures already in place and aimed at reducing bacteria such as E. coli O157: H7, the hide-on-carcass wash provides Cargill’s Fresno facility with another tool to reduce, and potentially eliminate, these randomly and naturally occurring bacteria. “People expect safe food, and Cargill’s Fresno beef facility prides itself on producing safe, fresh, quality meat products,” said John Niemann, vice president and general manager. “It’s the meat that families of our 830plus employees eat, and it’s the meat millions of additional consumers eat, so we work hard to deliver the safest products possible to all of our retail and foodservice customers.” Water used for the hide-on-carcass wash process is treated and reclaimed using cutting-edge wastewater-treatment technology. “We are sensitive to regional water needs in California and the Central Valley, and feel it is important to

56

Photos courtesy of Water Management Resources (WMR) and Cargill

ensure any water we use at our beefprocessing facility is properly treated, [is] reused for other purposes and meets water quality and environmental standards when it is discharged,” explained Niemann. He added that the company’s respect for natural re-

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

sources and the need for conservation are fundamental to Cargill’s values and part of the organization’s cultural DNA. The hide-on-carcass wash is a collaborative effort between WMR (Water Management Resources) and Cargill. Using resources from both companies allowed Cargill to install a highly innovative, unique piece of equipment that could become the benchmark for the industry after all final adjustments were made. Installation and testing of the hide-on-carcass wash was completed in late September and packaging line renovation work was recently completed. Established in 1939, the business located at the Cargill site in Fresno eventually became Beef Packers Inc. Cargill purchased the Fresno beef facility in 2006. The 60-acre facility currently harvests cattle during one shift Monday through Friday, with certain types of meat production and packaging taking place on multiple shifts during the week.

WE’VE 8K?BJ
THE

TOP EQUIPMENT & TECHNOLOGY SHOW FOR THE

Meat Industry

NOVEMBER 1-4, 2011 – CHICAGO McCormick Place – South Hall The NEW PROCESS EXPO provides prime access to the latest processing developments from around the globe. Progressive meat producers and marketers – like you – are coming to Chicago to see: š

D[m
[gk_fc[dj
\hec
j^[
mehbZÊi
b[WZ_d]
ikffb_[hi š

9kjj_d]
[Z][
j[Y^debe]o š

El[h
*+&
[n^_X_jehi
%
'&"&&&!
Wjj[dZ[[i š

(/
[ZkYWj_edWb
i[ii_edi
\eYki_d]
ed
\eeZ
iW\[jo"
ikijW_dWX_b_jo
WdZ
ej^[h
_iik[i
W\\[Yj_d]
oekh
cWha[jfbWY[
(in English and Spanish) Come join us at the top.

THE GLOBAL FOOD EQUIPMENT AND TECHNOLOGY SHOW™

REGISTER TODAY at mmm$cofheY[ii[nfe$Yec | 703.761.2600 ©2011 FPSA

TechPackaging

The

maze of

MAP technology The fluidity of MAP/overwrap packaging demands means processors and retailers must remain vigilant and work together to stay on the cutting edge. By Elizabeth Dressler, Mountain States Rosen MODIFIED-ATMOSPHERE PACKAGING (MAP) TECHNOLOGIES have the ability to provide incentives and opportunities for processors and retailers to positively affect their bottom line. However, product presentation as well as consumer acceptance are the primary factors that affect final decisions on packaging selection. Given the dynamic nature of MAP technologies and the demand for improved packaging and better product shelf life, processors must stay on top of MAP trends and be able to help the retailer stay in step with these demands. When dealing with specialty products such as lamb and veal, it is particularly important that case-ready technology offerings assist retailers in a multitude of areas. 58

THE NATIONAL PROVISIONER SIONER | PROVISIONERONLINE.COM PROVISIONEERO ON ONL NLINEE.C .CO OM | FEBRUARY FEEBRRUA ARRY Y 20 2 2011 011

Photo by Vito Palmisano

Active Packaging Works to Keep Your Product Fresh Multisorb’s intelligent Active Packaging safeguards your product from the harsh effects of distribution and storage; not only guaranteeing that your product reaches the customer looking fresh, colorful and appetizing, but that your product smells and tastes as good as it looks. Whether your concern is oxidation, moisture control, spoilage and aging, or EDFWHULD0XOWLVRUEKDVDQ$FWLYH3DFNDJLQJVROXWLRQWR¿W\RXUQHHG

Visit us at Meat Expo – Booth 1400, and Annual Meat Conference – Booth 512

www.multisorb.com | +1 716.824.8900

TechPackaging h

Photos by George Motz, courtesy of Mountain States Rosen

According to Joe Dibenedetto, Diben d special projects manager for Mountain States Rosen (MSR), “controlling shrink and inventory levels — for margin management as well as offering product variety and consistency in the case — driving return sales and customer satisfaction, are successes that can be directly influenced by MAP technologies.” Dibenedetto also believes that as technology continues to evolve, retailers will rely more on the manufacturer’s technological expertise and understanding of the retail business in order to help them succeed. “We have personnel with extensive retail management backgrounds as well as those on the production side of our 60

business,” Dibenedetto explains. “This blend of personnel allows us to effectively link production to retail needs with knowledge of package styling, cutting specifications, product presentation and cost-management strategies.” Going forward, the survival and growth of small to mid-sized manufacturing companies will likely depend on how they differentiate themselves from their competition. The ability to offer experience, technological knowledge and diversity in product will be essential in the future for specialty-item processors such as Mountain States Rosen. MSR realizes lamb and veal, while key components of a well-rounded meat program, often make up a smaller percentage of sales. Therefore, MSR must

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

continue to find new ways to support the retailers and distinguish their products from others in the case to ultimately drive sales. Processors must provide insight into technologies and advances that keep retailers on the cutting edge to meet the expectations of their customers. Paul McCauley, director of operations at MSR, considers “sustainable, cost-effective packaging that offers extended shelf-life and reduced waste as the highest priority for the foreseeable future.” That being said, there are plenty of challenges to these priorities. Defining sustainability is tricky; tying technologies that are continuously evolving to economics and consumer acceptability make for abstract answers. Furthermore,

Paul McCauley, director of operations at MSR, considers “sustainable, cost-effective packaging that offers extended shelf-life and reduced waste as the highest priority for the foreseeable future.”

there is a regional twist to packaging technologies, which plays an important part in case-ready packaging offerings and trends. In similar fashion to most companies with national distribution, MSR has identified differences in packaging preferences between regions and retailers within those regions. For example, certain geographic regions prefer the overwrap format with the mother-bag that provides a fresh backroom look. These same regions are

looking to stay with this technology but make it more sustainable, possibly by adding biodegradable trays, or decreasing total packaging waste. Another region tends to focus on decreased packaging waste by eliminating the tray, at the same time obtaining extended shelf-life through roll-stock or vacuum-sealed packaging formats. “Staying abreast of the changes and managing diversification of technology offerings must become a high priority

for all manufacturing companies,” says McCauley. There is no question, as packaging technologies and trends continue to develop and grow, so will the processors in order to keep up with the demands of their customers. For more information, contact Elizabeth A.W. Dressler, M.S. of West Spear Consulting, a Technical Services & Marketing Business, at (303) 246-0807 or west.spear.consulting@ gmail.com.

Automatic Vacuum Packaging Equipment

Purchase Factory Direct! Simple and reliable machines that offer the lowest cost of ownership in h/f/f/s packaging. Tremendous Values & Quick Delivery Model No. RA200 RI200 RZ200

Length 111⁄ 2 ft. 16 ft. 18 ft.

Description Starter Machine Standard Machine Zipper Machine

*1 year or 1 million cycle warranty on all machines

888-314-2152 Made in the USA

1728 N. Topping Avenue • Kansas City, MO 64120 816-455-8055 • Fax 816-455-8469

VISIT US AT AMI - BOOTH #2419

TechShowcase

Packaging Multivac demonstrated “saddlepack” packaging as its key highlight at the IPE show. Saddlepack packaging is available in a variety of configurations and provides multiple hermetically sealed package compartments connected by perforated film. Processors benefit from the highly efficient and hygienic loading process made possible with horizontal thermoform packaging technology. They are also able to move much larger volumes of product in a SKU while maintaining and even improving brand identification. Multivac Inc.: (800) 800-8552 or visit www.multivac.com

Gowns PolyCo gowns are engineered for quick and easy “donning and doffing.” VR Multi-Use Gowns and PolyWear SingleUse Gowns are designed to replace traditional aprons and sleeves. With more extensive coverage of the employee, PolyCo gowns have demonstrated to provide greater protection for both the employee and the food chain. In addition to improving employee productivity by saving on garment changes, elimination and replacement of aprons and sleeves can contribute to the reduction of inventory costs. PolyConversions Inc.: (888) 893-3330 or visit www.polycousa.com

Former Speed, product consistency and versatility are key to NuTEC’s 710 Forming Machine. The 710 provides excellent weight control and gentle product handling for a variety of products from beef to vegetables. It can form hamburger patties, meatballs, skinless sausage links, and many more items. The 710 Forming Machine operates with minimal wear and maintenance. NuTEC supports the machine with factory direct service and a one-year parts warranty. The 710 is operatorfriendly and easy to use. NuTEC Mfg.: (815) 722-2800 or visit www.nutecmfg.com 62

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

OBITUARY

Former Tyson CEO Don Tyson dies Donald John “Don” Tyson, who turned his family’s Arkansas chicken company into one of the largest industrial meat and poultry producers in the world, has died of cancer at age 80. Tyson became president of the company in 1966 and served as CEO and chairman from 1967 to 1991. He officially retired from the company in 1995. The son of the company’s founder and the father of its current chairman, grew into a world protein leader under Tyson’s management. The Wall Street Journal notes that he was credited with bringing industrial scale to chicken farming. Annual revenue rose under his watch to more than $10 billion from about $50 million a year. “Don was known by all to work hard, but also to play hard,” said Tyson CEO Donnie Smith. “He was famous the world over for his ‘No Bad Days’ outlook on life, and well known for telling everyone that ‘I don’t have time to have a bad time.’ Don’s passing will be mourned by all who knew him, especially his family, his countless friends, and business leaders and associates in Arkansas, across the country and around the world.” Through most of the 1950s Tyson worked with his father to grow the family business, then known as Tyson Feed and Hatchery, supplying feed and baby chicks to local poultry producers in Northwest Arkansas. In 1958 the company became “vertically integrated” by building its first chicken processing plant in Springdale, with Tyson overseeing the construction and then becoming its first plant manager. The company continued to grow through the 1970s and 1980s with Don Tyson leading a series of acquisitions including Val-Mac, Lane Poultry and the 1989 purchase of Holly Farms, which more than doubled the size of the

company and made it the largest poultry producer in the country. After ending his active dayto-day involvement with the operations of Tyson Foods Inc., Tyson continued to serve as a consultant and on the company’s Board of Directors, and was also the managing general partner of the Tyson Limited Partnership (TLP). With his death, the TLP will maintain effective control of Tyson Foods Inc., with management of the TLP residing with a small group of Tyson family members, former Tyson executives, and trusted confidants of Don Tyson. “My sisters, my children, Barbara Tyson and I are truly saddened by the loss of our father, as are many, many friends, business associates and Tyson team members,” said John Tyson. “He was a true visionary who led Tyson Foods from a small regional chicken company to a multi-billion dollar food processing enterprise. He will be missed by everyone who knew him.” The National Chicken Council, which named Tyson a “Pioneer of the Industry” in 2004, issued a statement calling him a “titan of the modern chicken industry.” “From the beginning of his leadership of his company, he saw the future of the industry and worked to make his vision a reality,” the statement continued. “He was a pioneer in moving beyond commodity chicken to valueadded products and in the development of new products and international markets. Don Tyson was a key figure in transforming the industry into the powerhouse it is today. Not only his family and his company have suffered a loss, but the entire industry as well.” Sources: Wall Street Journal, ArkansasOnline. com, Tyson Foods Inc., National Chicken Council

TechShowcase

Grinder

pH Kit

Able to grind everything from fresh product to frozen blocks, Weiler’s OMNI V offers rugged reliability and durability. It eliminates all requirements for changeover and quick speed adjustments, so operators can optimize production quality and volume with fresh or frozen applications even in demanding work environments. The OMNI V includes independently controlled feed screws and Weiler’s Balanced Flow Technology, which promises more efficient handling during grinding, while offering consistent particle definition, improved texture and superior product quality.

Mettler Toledo introduces the FiveGo pH Food Kit, a portable pH measuring instrument designed for use in the food and beverage industry. FiveGo instruments all feature storage capacity for up to 30 measurements, including automatic endpoint recognition and calibration with automatic buffer recognition. Operation is easy and intuitive with dedicated buttons for starting and ending a measurement and for saving and accessing measurements and the latest calibration data.

Provisur Technologies Inc.: (708) 479-3500 or visit www.weilerinc.com

Mettler Toledo: (614) 438-4511 or visit www.mt.com

Material Handling Ship more product per load with Rehrig’s weight, space and cost saving Slip Sheets.

Come see us at the AMI Tech Fair Booth #510

Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets. Impervious to moisture, high tensile strength plastic provides added tear resistance making them the perfect replacement for fiber or corrugated sheets, as well. Available in standard or custom sizes, Rehrig Slip Sheets provide superior slide resistance, keeping goods securely in place. Manufactured from nearly 100% recycled material, each sheet is also 100% recyclable. Beyond the sale, Rehrig can help you develop a customized re-use or buy-back program, further lowering your average cost per trip. Phone: (800) 546-4993 Email: [email protected] Web: w w w.rehrigpacific.com

Call us for more information about: Tier sheets, Liner sheets, Layer sheets, Cap sheets, Divider sheets, Pallet pads and Separator sheets

A FAMILY TRADITION OF GROWTH, SERVICE AND INNOVATION

64

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

©2011 Rehrig ig Pa a cific c Company

Give Your Heavy Pallets the Slip.

If leading edge manufacturing and automation technologies are your priorities, save the date for the food industry’s PREMIER CONFERENCE in 2011.

SAVE the DATE APRIL 3-6, 2011 The Ritz-Carlton, Palm Beach, Florida

WHO SHOULD ATTEND:  O Vice Presidents of Operations  O Plant Managers  O Vice Presidents of Engineering  O Plant Maintenance Managers  O Plant Engineers  O Directors of Engineering  O Owners and Presidents

FEATURED SPEAKERS INCLUDE: Peter Hock, Senior Director of Continuous Improvement, ConAgra Foods; Al Koch, Director of Engineering—Global Biscuit, Kraft Foods Nabisco; Peter Monkeiwicz, Vice President of Operations, Kayem Foods, Inc.; Bob Palczewski, Engineering Director, Celebration Foods; Alex Posada, Project Engineer, Campbell Soup; Diane Wolf, Global Vice President, Safety and Environmental Sustainability, Kraft Foods; Ed Delate, Vice President Global Engineering and Corporate Social Responsibility, Keystone Foods, Peter Takacs, Manager, Quality Assurance. Spoetzl Brewery

 O Sustainability Directors

ALL NEW AGENDA FOR 2011 TO INCLUDE:  O Project Economics: Getting Paybacks on Your Plant Automation Projects  O Overall Equipment Effectiveness Across the Enterprise  O Implementing a Powerful Corporate Social Responsibility Plan  O Developing Quality Systems in Food Plant Operations  O Quantifying Your Energy Inputs  O Improving Packaging Line Efficiency Via Robotics, Machine Control and Changeover Speed

PRODUCED BY

WWW.FOODAUTOMATIONCONFERENCE.COM

TechShowcase Scissors AirShirz pneumatic scissors from Bettcher Industries increase worker productivity while reducing muscle fatigue in turkey gizzard harvesting and gizzard opening operations. With its fixed bottom blade design, AirShirz scissors provide a clean, accurate intestine cut, as well as easy piercing to split and open the gizzard. AirShirz scissors require approximately 90% less muscle activity to operate and achieve up to 127% greater worker productivity over manual scissors. AirShirz scissors are available in two grip designs. Bettcher Industries: (440) 965-4422 or visit www.bettcher.com/gizzard-splitting

Salt Blend Cargill new Premier Light Salt 50/50 is a blend of food-grade potassium chloride and sodium chloride that provides 50 percent less sodium than regular salt. The blend can be used as a direct replacement for salt in processing applications where sodium reduction is desired. The blend maintains many of the functionalities of regular salt and can be used for processed meat and poultry products; cheese; seasoning blends and more. Cargill Salt: (888) 385-7258 or visit www.cargill.com

Flooring Primer Dur-A-Flex offers Dur-A-Glaze MVP (moisture vapor protection) moisture mitigation primer for its line of resinous flooring products. The new epoxy-based primer effectively reduces moisture vapor emissions in concrete slabs, allowing resinous floor systems to be installed on concrete slabs as soon as five to seven days after being placed. It is also ideal for existing concrete floors where moisture vapor emissions exceed the allowable limits for epoxy floor installations. Dur-A-Flex: (800) 253-3539 or visit www.dur-a-flex.com

Loading Dock Management 4SIGHT Yard and Dock Management System integrates a facility with intelligent software to monitor, schedule, and communicate trailer movement, load assignment, and loading dock status in a simple, easy-to-use interface. 4SIGHT bridges the gap between warehousing and transportation, thereby alleviating common logistics problems. This system combines RFID, GPS and sensor technologies to provide companies with real-time yard and loading dock visibility, enabling them to improve trailer coordination and turn time management. 4Front Engineered Solutions: (866) 691-1377 or visit www.4sightsolution.com 66

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

Freezer Air Products’ Freshline DM tunnel freezer is a flexible cryogenic freezing solution that allows manufacturers to process both individually quick frozen (IQF) and flat or trayed products in a single machine. This can result in maximum uptime and can lead to optimum efficiency. The dual-mode freezer can offer significant capital savings and improved product quality when processing a variety of poultry items, including diced and sliced products, wings, filets, cutlets, and breaded and trayed products. Air Products: (800) 654-4567 or visit www.airproducts.com/food

Tougher Food Safety Regulations Are Coming – Is It Time To Upgrade Your Inspection Capabilities? Talk to the company that sells more metal detection and x-ray systems than anyone else in the world.

METTLER TOLEDO Safeline

PowerPhasePRO Metal Detector

SmartChek X-ray Inspection System

%CNN r'OCKNRKOCTMGVKPI"OVEQOr8KUKVYYYOVEQOUCHGNKPGWU

TechShowcase Industry News

Get the free mobile app at

http:/ / gettag.mobi

GEA Group Aktiengesellschaft announced it has expanded the share of food process technology in its portfolio through the acquisition of Convenience Food Systems (CFS) from funds managed by AEA Investors LP. GEA called CFS one of the most multifaceted suppliers of secondary food processing and packaging machinery (meat, fish, cheese). The company, headquartered in Bakel, Netherlands, has more than 2,000 employees and expects a turnover of about EUR 400 M in this financial year. The transaction remains subject to approval by the antitrust authorities and is expected to be consummated during the first half of 2011. “This acquisition follows our declared strategy to expand the food process technology activities of GEA Group horizontally. We are taking our portfolio another big step forward towards the less cyclical food industry. In doing so, we can leverage the brand value of GEA by offering our customers ever more solutions along their entire process chain from one single source,” declared Jürg Oleas, CEO of GEA Group. “In the medium term, GEA sees potential to considerably boost profits at CFS in cooperation with the existing management and to realize synergies with existing GEA businesses,” said Niels Graugaard, member of the executive board and COO of GEA. “The market segment of animal proteins is one of the fastest growing within the entire food industry. As part of the GEA Group we will have the chance to develop new customers and find access to new markets. GEA offers ideal growth conditions for an innovative and quality focused company such as CFS,” added Brian McCluskie, CEO of CFS. 68

Handtmann Inc. has introduced the Handtmann Preventive Maintenance Program with NoWorry Service. Developed with extensive processor input, the program is a straight forward, effective, and efficient way to assure OEM lifetime precision for Handtmann stuffer and linker operations. Handtmann No-Worry Service addresses key customer concerns for ease of use and reduced repair costs by efficiently managing all major recommended upkeep and scheduled maintenance topics, delivering greater operational dependability, and regularly optimizing equipment for performance, hygiene and safety. It offers 1,000and 2,000-hour service overhauls of all stuffing and linking lines in the processing facility and is designed to be customized to each plant’s specific needs. All No-Worry Service includes a 45 Function guaranteed preventive maintenance process that assures OEM service quality, includes maintenance-based training, and delivers detailed recommendations and reporting for continuous improvement and seamless record keeping. OYSTAR GmbH, a manufacturer of packaging equipment technology, announced a restructuring that creates OYSTAR North America, a $250 million company with 650 employees. The new North American company combines OYSTAR USA, a New Jersey-based sales operation representing packaging machinery brands manufactured in Europe, as well as packaging equipment manufacturers OYSTAR Packaging Technologies, Davenport, Iowa; and OYSTAR Jones, Covington, KY. The Shoulders U.S. merger is a further result of the successful restructuring of the OYSTAR Group. “We began restructuring one and a half years ago,” explains Tom Graf, CEO. “From the onset it was our goal to centrally manage individual product and customer groups, and no longer through several subsidiaries. The past financial year clearly shows that this was the right path.” Barry Shoulders, president of OYSTAR Packaging Technologies, has been chosen to lead OYSTAR North America, which becomes one of the largest suppliers of packaging machinery and services in the United States, Canada and Mexico. “All of us at OYSTAR North America are excited by this new customer-focused structure that will translate into more complete packaging solutions and stronger partnerships with both customers and vendors,” Shoulders said. Others assigned to senior management roles within the new company structure include: Tom Riggins, sales; Gordon Bonfield, transition officer; Jeff Wierenga, service; Susan Awadalla, finance.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

ACCEPT NO SUBSTITUTES

If it Impacts Meat, Poultry or Seafood Processing, it’s at AMI Expo. You know AMI will bring you an unparalleled collection of new business partners showcasing the latest in food safety, plant operations and packaging innovations. It’s as simple as stepping into the convenient one-stop shop packed with an array of interactive exhibits, demonstrations and experts to answer your questions. Now is the time to register!

EXHIBIT HALL HIGHLIGHTS: INNOVATIVE EQUIPMENT AND SUPPLIES — You’ll be

SUSTAINABILITY PAVILION — Solutions to minimize

one of the first to test-drive all the latest machinery and equipment.

packaging waste streams, increase efficiency and quantify your progress.

SEASONINGS, FLAVORS AND INGREDIENTS PAVILION —

MEAT TECH — Interactive presentations prepared by exhibitors on operational and technical issues, held in a classroom on the exhibit floor during show hours.

Address consumer demand for healthy choices, new tastes and evolving product development.

POWERFUL PARTNERSHIPS. PROVEN SOLUTIONS. TAKE NOTE OF NEW DATES! WEDNESDAY, APRIL 13 – SATURDAY, APRIL 16, 2011 McCORMICK PLACE, CHICAGO, IL, USA [email protected]

REGISTER TODAY AND SAVE AT WWW.AMIEXPO.COM FREE SATURDAY REGISTRATION FOR PROCESSORS AND PACKERS: Free entrance to the exhibit hall from 10:00 am – 2:00 pm on Saturday, April 16.

TechShowcase

Registration has opened for the 2011 PROCESS EXPO, taking place November 1-4, 2011 at McCormick Place in Chicago. “We are looking forward to the strongest PROCESS EXPO attendance ever,” said Scott Scriven, chairman of the Food Processing Suppliers Association and president of Weber Inc. “With a show floor over 75% larger than in 2010, including bellwether equipment manufacturers across all segments of the food and beverage industry, interest in PROCESS EXPO is at an all time high. Exhibitors have been promoting the show to customers and prospects for months now and now they will be able to sign up and learn even more about the show.” Advance registration for PROCESS EXPO is $25 and provides full access to exhibits and an extensive educational program providing processing and packaging solutions for the various segments of the industry. For more information about attending PROCESS EXPO 2011, visit www.myprocessepo. com or contact Andy Drennan at (703) 663-1201 or [email protected] . To book space or inquire about exhibiting in PROCESS EXPO, contact Grace Cular Yee at (703) 663-1220 or gyee@ fpsa.org. Foran Spice Co. has appointed Jon Falk to senior food technologist/meat specialist. Falk is a 15-year food industry professional experienced in Research & Development, Quality and Production in both USDA and FDA environments, with a strong record of new product innovation and HACCP compliance. He is a graduate of the University of Wisconsin – Madison in Meat and Animal Science. Falk was previously with Falk Palermo Villa and at Patrick Cudahy Inc, where he gained industry experience in sausages, bacon and ham. 70

Formax has launched a Team Poultry Initiative to further its efforts to educate and serve poultry processors internationally about the latest forming technologies. Team Poultry provides one-on-one consultations with insights and tips on how to innovate and create superior poultry products. “We created Team Poultry to reach out, inform and enable more processors to discover the superior versatility, productivity and lower cost of ownership that Formax has to offer, said Brian Sandberg, global product manager. Formax also has enhanced its poultry forming capabilities with three different fill systems, three different water spray systems and natural look of True-Sculpt. The VertiForm filling system produces chicken nuggets, patties, tenders and more. The Port-Fill filling system is ideal for natural muscle breast shapes, and Standard-Fill for traditional chicken patties. True-Sculpt tooling creates whole muscle products with natural top and bottom contours to produce 3-D chicken patties, boneless wings and selects that look “hand cut.” Samuel C. Collup has joined Bettcher Industries Inc. as regional manager. Collup will be responsible for sales and service activities for Bettcher’s Whizard Trimmer and AirShirz scissors product lines. He will support meat processing customers in the Rocky Mountain and Pacific regions of the United States, including California, Oregon, Washington, Montana, Idaho, Wyoming, Utah and Nevada. The company also announced the appointment of Collup McAfee Amber F. McAfee to the Bettcher Industries sales team. McAfee will be working in a strategic role and covering new business opportunities from a sales and marketing perspective. EAGLE Food Registrations Inc., specializing in third-party certification to international management system standards, announced has begun certifying companies to the Safe Quality Food (SQF) Ethical Sourcing Standard. SQF Ethical Sourcing is a voluntary standard that provides guidance to organizations on documenting their management systems and procedures relative to fair labor and socially responsible environmental practices. “EAGLE is embracing the Ethical Sourcing standard and the accountability it will drive across organizations. We believe it is the right thing for businesses to do, even if it is not yet mandated by their customers. Many companies are already ‘doing the right thing.’ Certification provides documented proof from a third-party that companies have effective processes in place to manage and sustain their system,” said Albert “Skip” Greenaway, President/CEO, EAGLE Registrations.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

We have a seat at the Exchange Ches Jackson President Monogram Foods Jeff Johnson Vice President Operations Monogram Foods

SM

SEPTEMBER 11-14, 2011 THE LODGES AT DEER VALLEY PARK CITY, UTAH

“The productivity during MPX has saved us months of time and the partnerships created have contributed to our bottom line.” Contact Becky Simon-Burton to reserve your seat [email protected] - 952-736-9361

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

CAREER OPPORTUNITY

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

Please send resume to:

QA Mgr. (Bf. Sl/Fab) ....................................$90K QA Mgr. (Bf. Sl/Fab) ....................................$80K QA Mgr. (Sausage) .......................................$90K Asst. QA Mgr. (Bf. Sl/Fab) ...........................$52K Night Mgr. (PC Steaks) .................................$75K GF (Pork Sl.) .................................................$52K GF (Pork Cut & Conv.) .................................$62K PSM Mgr. (Ref., Degree) ............................$125K Sales (Foodservice/FP) .................................$75K

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

Place an ad in The National Provisioner Classified Network NP0211BillBraggs.indd 1 1/24/11

EQUIPMENT FOR SALE

*Handling both Contingency and Retained Searches* National Openings available including but not limited to: sPlant Management sOperations Supervisors and Managers sMaintenance and Engineering sQuality Control Supervisors and Managers sSanitation Supervisor and Managers sWarehouse Supervisor and Managers sEngineering Project/Process/Management sPositions available at various levels! To submit resumes or engage searches please contact: Kelly Meaney, Associate VP

Judge Inc. Tel: 888-819-3916 x 1302 s Fax: 904-998-0966 [email protected] www.judgeinc.com

MEAT & POULTRY CAREER OPPORTUNITIES Contact: Arnie Holder 727-461-4868 The Spectrum Group/USA Food Jobs Visit: www.usafoodjobs.com [email protected]

72

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

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

Are you making the money you want? Do you have an “in” at a ground-floor opportunity? When you look up do you see nothing but chances to advance in your organization? Chicago Meat Authority, a financially solid and growing player in the beef and pork processing industry with a world-class reputation is seeking high performers to join its team. We are a mid-sized, privately-held company with an engaging culture providing unprecedented access to the owner and senior leadership. Our candid management style 12:02 PM lets the highest performers shine but does not allow those that might hold you back to hide. Performance based high earning compensation packages are standard and, with this company, career potential is truly unlimited.

Stop being a small fish in a big pond – join the CMA team and become a big fish! John Skeffington • Recruiter Chicago Meat Authority, Inc. (773)446-5662 • jskeffi[email protected] www.chicagomeat.com 1120 W 47th Place • Chicago, Il 60609

EQUIPMENT FOR SALE

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

EQUIPMENT FOR SALE

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

AMERICA’S LARGEST INVENTORY OF QUALITY BUGGIES & LIFTERS

IN STOCK… READY FOR IMMEDIATE DELIVERY; 400LB. BUGGIES WITH DRIP LIP…HANDLE… RE-ENFORCED BOTTOM PLATE…88LB. CAPACITY…EU MADE

Mo Fikry • 626-375-6291 mofi[email protected] Jay • 323-972-5373 jay.mofi[email protected]

www.MoFikry.com

CALL OR EMAIL FOR PRICE QUOTE & QUANTITY DISCOUNT.

We are an equal opportunity employer

PACKAGING

Ross Mdl. S90X M.A.P Tray Sealer, 3 lane, 8”x 10” tray size, complete w/tray elevator, support conveyors, color touch screen controls/monitor, spare sealing dies and more, mfg. 12/2005, in excellent condition - Less than six months use. $65,000.00 www.barliant.com email: [email protected] Ph (630) 553-6992 Fax (630) 553-6908

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

73

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

METALQUIMIA 6000# VACUUM TUMBLER SYSTEM--STOCK

WOLFKING 600 LITE VACUUM PADDLE MIXER W/ C02--STOCK

MTC 5000# VACUUM RIBBON BLENDER--STOCK

REITZ 8000# RIBBON BLENDER--STOCK

ROSS 950-3 SLICER W/ EXTRA PRODUCT CHUTES--STOCK

RYOWA RH-100 HIGH SPEED SLICER--STOCK

EQUIPMENT IN STOCK OR AVAILABLE

POLAR 4000# GLYCOL VACUUM MASSAGER & ALKAR 2 TRUCK GAS FIRED SMOKEHOUSE--STOCK

75 HOGS PER HOUR KILL FLOOR--LISTING

* VMAG HP15S W/PORTIONER & LINKER DRIVE......................................... STOCK * GROEN INA 250 STEAM JACKETED KETTLE ....................................... STOCK * 2- JC PARDO 150 GALLON JACKETED KETTLES ..................................... STOCK * THURN MD. # JR SLICER W/ CHECKWEIGHER & TAKEAWAY ................................ STOCK * MULTIVAC M86OEPC ROLSTOCK W/ LOTS OF DIE INSERTS................................. STOCK * CSE 2000# VACUUM RIBBON BLENDER W/C02 ........................................ STOCK * REISER 803 AUTOMATIC CHAMBER MACHINE (2003) ALL SS ............................... STOCK

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

EQUIPMENT FOR SALE • 40’ trailer FULL of Hollymatic 500/580 machines 4 or 5 complete machines - the rest are good parts. • We have 1/ 850 Hollymatic with a broken shaft (for parts) • Buy the whole lot or just parts • We also have a warehouse FULL of used meat processing equipment.

Call for details. Contact Gilbert @ (570) 752-4526

74

Denman Equipment Partnership Denman Equipment Equipment LiquidatorPartnership & Locator EQUIPMENT FOR&SALE Equipment Liquidator Locator

• Alkar 4 Truck Gas Smokehouse EQUIPMENT FOR SALE • Foldenauer Mdl 75 Browner • Weber CCS7000 Slicer 4OLEDO7ORKHORSE7RAPPING3YSs&ORMAX • Vemag Type 203 Link Proc. 'ROTE3LICERs3MITH-IXERs#60!6ACUUM • Mettler Toledo Exact Workhorse Wrapper • Safeline Pipeline 3” Metal Det.

901-755-7135 Fax: 901-754-0105 901-755-7135 Fax: 901-754-0105 e-mail: [email protected] .denmanequipment.com e-mail: [email protected] ss www www.denmanequipment.com

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

EPDM INFLATABLE DOOR SEALS,

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

FOOD SAFETY

EQUIPMENT FOR SALE

Geor ge Lapsley Enterprises Food Safety Specialist www.getfoodhelp.net T: 267-221-2426 HACCP / SSOP / 3rd Party Audits E. coli, Lm, BSE Compliance Recall Technical Assistance USDA Assistance

SERVICES

ost out m e h t Get f you o

r mon ey

Advertise in The National Provisioner

FEBRUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

75

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

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

Slaughter Equipment Cutting & Boning Equipment Rendering Equipment Processing & Packing Equipment Packaging Materials / Containers Miscellaneous & Safety Supplies

www.SCOTTSMOKEHOUSES.com

(888) 343-5421 “Where There’s Smoke, There’s SCOTT!” Check out these and more ads at Provisioneronline.com SLAUGHTER

Water Saving Washers

Split Carcass Washers

Hide-on Carcass Washers

Head and Tongue Washers

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

76

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

Consultation Repair Services Plant Design Mesh Aprons, Processing Gloves & Sleeves Equipment Equipment Appraisal Specializing in QUALITY NEW-USED-RECONDITIONED-REBUILT equipment for the food industry

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

Tenderizers New and Refurbished Machines - Trades accepted Surgical steel blade needles, replacement parts for most popular models at low prices. * New stainless/corrosion resistant Mag Head Won’t break in half if dropped! w prices. Tender King by Staples Research Corp (703) 335-1301 [email protected]

WANTED TO BUY

LOOKING TO BUY Meat Purveyor Plant with business in the Dallas / Ft. Worth, Texas area email [email protected] or call (239) 768-9891

SPECIAL SERVICES Place an ad in The National Provisioner Classified Network

AdIndex Company

Page

American Meat Institute / AMI Ashworth Bros., Inc. Beacon Inc. The Biro Manufacturing Company CFS NorthAmerica Danisco USA Inc. Dewied International Douglas Machines Corp. Eriez Food Automation & Manufacturing Conference & Expo Food Processing Suppliers Association / FPSA framarx/Waxstar Handtmann, Inc. Hawkins, Inc. Henry & Sons Inc. Hixson Hollymatic Innophos James V. Hurson Associates, Inc. Jarvis Products Corp. JBT FoodTech Meat Processing Xchange / MPX Mettler-Toledo Safeline, Inc. Multisorb Technologies, Inc. NDC Infrared Engineering, Inc. Pfizer Animal Health Poly-Clip System Corp. PolyConversions, Inc. Purac America, Inc. Purdue University Quickdraft Rehrig Pacific Company Reiser Risco USA Corp. Rollstock Inc. Tippmann Group Water Management Resources Weber Manufacturing West Liberty Foods Wire Belt Company of America World Technology Ingredients (WTI), Inc.

Web site 69 17 39 IBC 29 15 27 46 48 65 57 37 IFC 9 20 41 6 19 62 47 7 71 67 59 36 45 3 55 11 49 38 64 23, 35, 51 25 61 44 13 43 12 31 21, BC

www.amiexpo.com www.ashworth.com www.beaconmetals.com www.birosaw.com www.cfs.com www.danisco.com www.dewied.com www.dougmac.com www.eriez.com www.foodautomationconference.com www.myprocessexpo.com www.framarx.com www.handtmann.com www.hawkinsinc.com www.dhenryandsons.com www.hixson-inc.com www.hollymatic.com/np www.innphos.com www.hurson.com www.jarvisproducts.com www.jbtfoodtech.com [email protected] www.mt.com/safelineus www.multisorb.com www.ndcinfrared.com/meat www.polyclip.com www.polyconversions.com www.purac.com www.agecon.purdue.edu/agribusiness www.quickdraft.com www.rehrigpacific.com www.reiser.com www.riscousa.com www.rollstock.com www.tippmanngroup.com www.watermr.com www.weberslicer.com www.wlfoods.com www.wirebelt.com www.wtiinc.com

SM

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] • (440) 227-8377

Ann Kalb

REPRINTS

Jill L. DeVries

[email protected] • (248) 244-1726

Wayne Wiggins

Gary Campbell

CLASSIFIEDS

Diana Rotman

[email protected] • (847) 405-4116

Reaching an average qualified circulation of 23,000 copies. Source: December 2009 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

R E L I A B L E F O O D P R O C E S S I N G M AC H I N E S W W W . B I R O S AW . C O M

Md. 44 18” Power Cutter Md. B350M Moisture Resistant Manual Feed Slicer 350mm Dia. Blade 1/2 HP (.35kw motor)

Md. VTS-500 Vacuum Tumbler 500 lb. (227 kg.) Approx. Capacity

MD. 109PC - Electronic Horizontal Slicer w/conveyor Boneless Whole Muscle

Md. 1056/1556 Heavy Horsepower Grinder

Md. AFMG-56-4 Auto Feed Mixer Grinder 400 lb. (181 kg.) Hopper Capacity

MD. VTS-100 Vacuum Tumbler 100 lb. (45 kg.) Approx. Capacity

Md. 548 - 7548 552 - 7552 Heavy Horsepower Grinder

Md. FBC-4800 Tempered Meat Block Chipper

Md. Pro-9 HD 3/4 HP Heavy Duty Tenderizer Strip Cutters Available

Md. AFMG-52-4 Auto-feed Mixer Grinder 400 lb. (181 kg.) Hopper Capacity

Md. AFMG-56 MK III Auto-feed Mixer Grinder 800 lb. (362 kg.) Hopper Capacity

Md. AFMG-48 Auto-feed Mixer Grinder 200 lb. (91 kg.) Hopper Capacity

Md. 55 22” Power Cutter

Md. AFMG-24 Auto-feed Mixer Grinder 140 lb. (64 kg.) Hopper Capacity

Md. 109PC-M Mechanical Horizontal Slicer Boneless Whole Meat Md. EMG-32 Ergonomic Auto Mixer Grinder 150 lb. (68 kg.) Hopper Capacity

Md. 3334-4003 FH 16” Power Cutter (Fixed Head)

Md. BCC-100 Table Top Poultry Cutter

Md. 4436-DII 31” Throat Power Cutter Double Heavy Duty Rolling Tables

Md. 4436-D5E3 31” Throat Power Cutter Stationary Tops w/Roller Inserts

Phone: 419-798-4451 Fax: 419-798-9106 Email: [email protected] & [email protected]

147RB-4C-7-09


, Ê9"1Ê  

*,"
/6 ÊÊÊÊÊÊUÊœœ`Ê->viÌÞ UÊ9ˆi`Ê“«ÀœÛi“i˜Ì ÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊUÊ-œ`ˆÕ“Ê,i`ÕV̈œ˜ ÊÊÊÊUÊ
Ê >ÌÕÀ>Ê>Liˆ˜} UÊ-…iv‡ˆviÊ ÝÌi˜Ãˆœ˜

WITHOUT IMPACTING FLAVOR? Call us today at 877-221-8558 Or visit www.wtiinc.com

IF YOUR FIRST SEAL DOESN’T DO THE JOB,

then try a machine

Heat and pressure from above and below create two superior seals.

WITH TWO. What do bad seals really cost? Rework. Returns. Food safety problems. Lost customers. Supervac automatic belt vacuum chamber packaging machines feature a Double Biactive high-pressure sealing system that provides two superior seals to every bag, virtually eliminating leakers and the problems they cause. Superior seals are just the start. Supervac machines reduce labor costs while increasing productivity. Their ergonomic design allows a single operator to load, style and run the packages. Supervac’s exclusive Expansion Cushion reduces evacuation times by up to 30%, pushing the operator to keep up with the machine and resulting in more packages at the end of the day. Their small footprint allows the Supervac to fit into tight areas where other machines cannot. Its low cost of ownership and stainless steel construction make Supervac the smart choice.

Supervac GK501B

Supervac GK169B

725 Dedham St., Canton, MA 02021 • (781) 821-1290 • www.reiser.com

Leading the food industry in processing and packaging solutions.

JARVIS

Provides Free Service and Training

Buster Series Carcass Splitting Bandsaws

Reciprocating Breaking Saws

Skinning Tools

Circular Breaking Saws

Electric Beef Brisket Saws

Wellsaw® Reciprocating Breaking Saws

Dehorners

We have the tools you need for all your kill and cutting floor applications Distributor Inquiries Invited.

New and Used Bandsaws Available.

Jarvis Products Corporation

View these tools at our website

33 Anderson Road, Middletown, CT 06457 Tel: (860) 347-7271 Fax: (860) 347-9905 E-mail: [email protected] http:// www.jarvisproducts.com

PROCESSOR INDEPENDENT

Volume 003

F EB R UARY

C

O

N

T

No. 06

2 0 1 1

E

N

T

S

F E A T U R E S

10

»

16 18 20 24

Problem solver Rick Leiding has found his calling in the meat industry with research & development services.

Patience is a virtue Producing award-winning hams at Sailer’s Food Market requires a little time.

Waiting for the USDA Proposed changes to government policy could have a significant impact on both large and small meat processors.

A humane priority Proper handling of animals is a necessity for any company involved in slaughtering.

Top 75 Entry Form Submit your company’s information for Independent Processor’s annual report.

D E P A R T M E N T S Sam Speaks . . . . . . . . . . 6

SEMA Report . . . . . . . . 26

Cordray’s Corner . . . . . . . 8

SMA Report . . . . . . . . . 26

Processor Perspective . . . . . 9

AMI Report . . . . . . . . . 27

AAMP Report . . . . . . . . 25

NAMP Report . . . . . . . . 27

NMA Report . . . . . . . . . 25

Ad Index . . . . . . . . . . 30

INDEPENDENT PROCESSOR is a supplement to THE NATIONAL PROVISIONER and other BNP Media Publications. INDEPENDENT PROCESSOR is published by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to THE NATIONAL PROVISIONER, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected]

4

INDEPENDENT PROCESSOR | FEBRUARY 2011

R E L I A B L E F O O D P R O C E S S I N G M AC H I N E S W W W . B I R O S AW . C O M

Md. 44 18” Power Cutter Md. B350M Moisture Resistant Manual Feed Slicer 350mm Dia. Blade 1/2 HP (.35kw motor)

Md. VTS-500 Vacuum Tumbler 500 lb. (227 kg.) Approx. Capacity

MD. 109PC - Electronic Horizontal Slicer w/conveyor Boneless Whole Muscle

Md. 1056/1556 Heavy Horsepower Grinder

Md. AFMG-56-4 Auto Feed Mixer Grinder 400 lb. (181 kg.) Hopper Capacity

MD. VTS-100 Vacuum Tumbler 100 lb. (45 kg.) Approx. Capacity

Md. 548 - 7548 552 - 7552 Heavy Horsepower Grinder

Md. FBC-4800 Tempered Meat Block Chipper

Md. Pro-9 HD 3/4 HP Heavy Duty Tenderizer Strip Cutters Available

Md. AFMG-52-4 Auto-feed Mixer Grinder 400 lb. (181 kg.) Hopper Capacity

Md. AFMG-56 MK III Auto-feed Mixer Grinder 800 lb. (362 kg.) Hopper Capacity

Md. AFMG-48 Auto-feed Mixer Grinder 200 lb. (91 kg.) Hopper Capacity

Md. 55 22” Power Cutter

Md. AFMG-24 Auto-feed Mixer Grinder 140 lb. (64 kg.) Hopper Capacity

Md. 109PC-M Mechanical Horizontal Slicer Boneless Whole Meat Md. EMG-32 Ergonomic Auto Mixer Grinder 150 lb. (68 kg.) Hopper Capacity

Md. 3334-4003 FH 16” Power Cutter (Fixed Head)

Md. BCC-100 Table Top Poultry Cutter

Md. 4436-DII 31” Throat Power Cutter Double Heavy Duty Rolling Tables

Md. 4436-D5E3 31” Throat Power Cutter Stationary Tops w/Roller Inserts

Phone: 419-798-4451 Fax: 419-798-9106 Email: [email protected] & [email protected]

147RB-4C-7-09

» SAM SPEAKS BY SAM GAZDZIAK

PROCESSOR INDEPENDENT

A SUPPLEMENT TO BNP MEDIA PUBLICATIONS Group Publisher . . . . . . . . . . . . . . . . . . . . Peter Havens (847) 405-4055; [email protected] Publisher/Midwest Sales . . . . . . . . . . . . . Dave M. Lurie (248) 593-0337; [email protected]

Telling our own story

W

hile writing about humane animal handling in this month’s issue, I was trying to think of another industry where the actions of one company reflected badly on the whole industry. For example, Toyota has had some major recalls within the last year, yet I don’t know of anyone who gave up driving their Ford in protest. I do know people, though, who gave up meat completely because of the Westland-Hallmark case, or a similar animal abuse story. Perhaps those events remind people that the meat industry is built on the death of animals, and if you want to enjoy a steak tonight, some cow had to die for it. It’s an uncomfortable truth for some, and that could be why the industry has kept that particular part of the process under wraps. Unfortunately, it’s been kept under wraps for so long that it looks like the industry has something to hide, and now the only time that people think about slaughterhouses is when they see a video from PETA or HSUS documenting animal abuse. We, as an industry, have let the enemy tell our story the way they want it told. There’s a reason why the animal rights groups don’t release undercover videos of slaughterhouses where everything is well-regulated and the animals are treated humanely. Having been on the defensive for so long, is it possible for the meat industry to go on the offense? The overwhelming majority of companies in the industry treat their live animals humanely; there has to be some way

6

to get that fact out, so consumers hear more than the PETA horror stories. It’s too bad that it took an HBO movie with a star like Claire Danes to get Temple Grandin some recognition in the public eye. She should have been a household name years ago, and the meat industry should have showcased her work as an example of how the industry cares. Packers with holding areas build to her specifications should promote that fact and talk about all the little things the handlers do to ensure no animals suffer needlessly. There is a whole other side of the story that must be told.

Orders of business There are two upcoming events of interest to our IP readers. Coming in April is the Food Safety Summit in Washington D.C. If you want to learn about the latest and greatest ways to keep your food safe and your company out of harm’s way, this is the place to be. The event is scheduled from April 19-21; go to www.foodsafetysummit. com for more information. The next is IP’s annual Top 75 Report, coming this spring. If you’ve given us information in the past, or if you want to get your company added to our list of top small and midsized meat processors, we need to hear from you. You can find the entry form on page 24 or online at www. provisioneronline.com. Or, e-mail me at [email protected], and I can fax or e-mail you a form. IP Sam Gazdziak, Editor in Chief

INDEPENDENT PROCESSOR | FEBRUARY 2011

EDITORIAL Editor-In-Chief . . . . . . . . . . . . . . . . . . . . .Sam Gazdziak (770) 594-0050; [email protected] Art Director . . . . . . . . . . . . . . . . . . . . . . . . . .Patty Catini ADVERTISING Great Plains/West Coast Sales . . . . . Wayne Wiggins Jr. (415) 387-7784; [email protected] Southeast/East Coast Sales. . . . . . . . . . . . Rick Parsons (407) 302-7952; [email protected] Sales/Business Development Mgr. . . . . . Gary Campbell (440) 227-8377; [email protected] Production Manager . . . . . . . . . . . . . . . . . . . Gail Porter (847) 405-4104; [email protected] Classified Sales . . . . . . . . . . . . . . . . . . . .Diana Rotman (847) 405-4116; [email protected] Corporate Reprint Manager . . . . . . . . . . . . . . Jill DeVries [email protected] AUDIENCE DEVELOPMENT Audience Development Coordinator . . . Teresa Owens Corporate Fulfillment Manager . . . . . . . . . . Alison Illes Audience Audit Coordinator . . . . . Carolyn M. Alexander

Independent Processor is published with the support of the National Meat Association, American Association of Meat Processors, Southwest Meat Association, North American Meat Processors, Southeastern Meat Association and American Meat Institute. These trade organizations do not endorse this magazine nor do they review the editorial prior to printing.

provisioneronline.com BNP Corporate Directors

Publishing Timothy A. Fausch Publishing John R. Schrei Corporate Strategy Rita M. Foumia Marketing Ariane Claire Production Vincent M. Miconi Finance Lisa L. Paulus Creative Michael T. Powell Directories Nikki Smith Human Resources Marlene J. Witthoft Director, Tradeshows & Conferences Emily Patten Clear Seas Research Beth A. Surowiec BNP Media Helps People Succeed in Business with Superior Information

www.riscousa.com

I am Raring toGrow RS 105: Primary Technology Available for Small Scale Processors The RS105 continuous vacuum filler is an extremely complete versatile machine; ideally suited for small to medium producers. This model includes all the technology of the larger models utilized by larger producers and the result is a compact, reliable, and user friendly machine.

Main Features: • Higher Versatility for all Meat Production • Patented Risco Long Life Vane Product Pump for Superior Quality Products • Precision Portioner • Easy to use Microprocessor Control • Possibility to Connect the Filler to a Wide Range of Risco Accessories and Systems to Meet any Present and Future Production Requirements.

The flexibility of the filler permits easy changeover to different kinds of products and programs during the production time.

Risco USA Corporation 60 Bristol Drive | South Easton, MA 02375

|

Tel: 508 230 3336

Risco: Solutions for Moving you Forward

|

Fax: 508 230 5345

|

[email protected]

»CORDRAY’S CORNER BY DR. JOE CORDRAY

Mixing time is critical in the manufacture of sausage products

W

hen manufacturing sausage products we essentially do four things; comminute meat (comminute is a fancy word for reduction in particle size i.e. grinding, flaking, dicing or chopping), season the product, manipulate proteins and shape the product. How we perform these four activities produces the wide variety of sausage products available. Mixing plays a very important role in two of these steps — seasoning the product and manipulation of proteins. When we season a sausage we want the product to have a uniform flavor profile throughout. Improper mixing can result in one part of the batch being too salty or having too intense a flavor while another part of the batch is bland. Non-meat ingredients should be evenly sprinkled over the top of the meat while the mixer is operating. Do not add the seasoning all at one time or on top of the meat when the mixer is not operating. Mixing also achieves even distribution of the fat and lean in the product. Mixing plays a key role in how the protein is manipulated and the final texture of the product. Protein extracted during manufacture is coagulated during heating and ultimately determines the texture of the product. For example, in fresh sausage a loose texture after cooking is desirable. You want to be able to push down with a fork on a cooked fresh pork sausage patty and have it break apart. If a knife is needed to cut the patty, the texture is too tight. Consequently, you should minimize protein extraction during the manufacture of fresh sausage. Mix it just long enough to achieve good distribution of the nonmeat ingredients and the fat and lean. A paddle mixer which has the tendency to be a little gentler on the meat works nicely for fresh sausage. Ribbon or auger mixers often work the meat more and increase protein extraction. If you are manufacturing a cooked sausage such as a link smoked sausage you want to maximize the extraction

8

INDEPENDENT PROCESSOR | FEBRUARY 2011

Consistency is a key factor in generating repeat sales and uniformity of mixing time can be a key factor in achieving consistency. of protein during manufacture. You are going to rely on extracted protein to help bind fat and moisture during cooking. The fat and moisture bound during cooking contribute to both yield and quality. Adequately bound moisture and fat is required for the product to have optimum flavor and juiciness when consumed. During mixing we extract protein through the addition of salt, which solubilizes protein, and the imparting of mechanical energy. The longer you mix a batch of sausage, the more protein you extract. Fresh sausage is typically mixed 1 or 2 minutes, while smoked sausage is often mixed 5 to 7 minutes. The texture of meat for smoked sausage should be very sticky (extracted protein) at the end of the mixing cycle. If you put some of the meat batter into your hand and then turn your hand upside down it will stick to your hand. If you take two identical batches of fresh sausage and mix one batch one minute and the other ten minutes, the texture of the two products will be entirely different. Consistency is a key factor in generating repeat sales and uniformity of mixing time can be a key factor in achieving consistency. Once you determine the optimum time to mix a batch of sausage, each batch should be mixed the same. Remember: Decide on what you think is right and stick to it. IP Dr. Joe Cordray is the Extension Meat Specialist at Iowa State University.

PROCESSOR PERSPECTIVE « BY JOHN VATRI

A Christmas Truce

O

ver Christmas I’m forever reminded of a story my father would tell me about my grandfather, who was in the First World War. He would tell me that although his father would rarely if ever talk about the war, he did tell him an incredible tale that during one Christmas Eve soldiers on both sides, in their respective trenches, began to sing “Silent Night.” That prompted the soldiers to leave the protection of their trenches and walk across ‘no mans land’ to meet to exchange food, drink and Christmas wishes. After which, their commanders had them return to their respective sides in order to begin fighting again the next day. It was many years later that I found out to my astonishment that this amazing event did in fact take place. It is during the Christmas season that I’m once again reminded that pathogenic bacteria, unlike enemies in other great battles, even WWI, do not know the meaning of the word truce regardless of the time of year. One only needs to go to the respective government websites over Christmas to see more food borne illnesses leading to recalls due to E coli, Listeria and Salmonella. Even as Dr. James Marsden tells us that as an industry we can certainly celebrate some of the recent battles won against pathogenic bacteria, the war goes on and, incredibly, we are now opening our eyes to a more prolific enemy as FSIS considers expanding the definition of adulteration to include other possible disease causing strains of E coli. So we must continue to work together to keep the alliance between the farmers, harvesters and processers strong. It is through cooperation and the sharing of information that we will continue to discover new and unobtrusive ways to augment our processes to eliminate these pathogens, with the ultimate goal of a producing a truly pasteurized carcass married with processors that will handle the product in a way to ensure recontamination does not occur. I know that together as an industry if we continue

So we must continue to work together to keep the alliance between the farmers, harvesters and processers strong. It is through cooperation and the sharing of information that we will continue to discover new and unobtrusive ways to augment our processes to eliminate these pathogens, ith the ultimate goal of a producing a truly pasteurized carcass married with processors that will handle the product in a way to ensure recontamination does not occur. to marry our unique processes with investment in new techniques and technologies to eliminate pathogenic bacteria, we will indeed one day achieve our own truce; who knows, maybe our grandchildren will have a few stories to tell about us. “The world is a dangerous place, not because of those who do evil, but because of those who look on and do nothing.” Albert Einstien IP

John Vatri is the director of food safety at Cardinal Meat Specialists Ltd., one of Canada’s leading burger and cooked protein processors.

FEBRUARY 2011 | INDEPENDENT PROCESSOR

9

COVER STORY

Problem Solver Rick Leiding has found his calling in the meat industry with research & development services. BY SAM GAZDZIAK, EDITOR

Along with assisting multi-national companies with R&D projects, Leiding supplies a wide range of sausages, hams and other meat products to consumers in the Danville, Ill., area.

W

ith a knack for details and precision, a natural sense of creativity and a love of meat processing, Rick Leiding has given invaluable assistance to companies around the world. However, most

10

of them don’t know who he is. As the owner of Leiding’s Meats and Catering, Leidig provides his Danville, Ill., community and surrounding area with a wide range of award-winning meat products, including bacon, sausages and burger patties. However,

INDEPENDENT PROCESSOR | FEBRUARY 2011

much of his work is done in relative anonymity, as Leiding also provides first-class research & development work to a number of large, international companies. If a meat processor or an supplier company needs help developing a product or solving a

Fact Box Leiding’s Meats & Catering

production problem, Leiding may get called on to help. “We do a lot of flavor and color development, various physical meat processes, both liquid and wood smoke processes, and product development with plastics, barrier development and collagen casings,” he explains. “We work with various flavor and ingredient manufacturers to help them bring a new product to fruition for prospective customers.” Since getting involved in R&D work more than 10 years ago, Leiding has worked on a number of products, including ham, deli beef, bacon, whole-muscle and ground turkey products, snack sticks, pepperoni and dried and semi-dried sausages. Due to proprietary contracts, Leiding cannot and does not discuss many of his other projects, nor can he disclose the companies that use his services. “We’ve had to refuse work from other companies, because it would be a conflict of interest with a prior proprietary contract,” he explains. “I can’t do work for everybody, and I will not cross that line. We hang our hat on a high standard of integrity, and it’s a reputation that we’ve worked hard to maintain.” Companies may turn to an outside R&D processor for several reasons. The company in question may not have a test kitchen or may not want to tax its resources on a project. A processor may have changed its procedure or ingredients, which would necessitate further changes to the processes or materials downstream. Other times, a flavor or ingredient manufacturer has a new product, and Leiding will help to choose a particular protein and flavor profile that would be most appealing to consumers. If the project involves another processor, Leiding often does not know the identity of that company, and they do not know him. Doing R&D work and being successful at it requires strict attention to detail. Developing an item like jalapeño bacon requires producing multiple batches of varying flavor

Danville, Ill. Founded: 1996 Employees: 4 Specialties: The most popular sellers in his retail store include bratwursts, bacon and Andouille sausage. Leiding’s research & development work has led him to work on projects for companies from around the world. 217-442-4398

concentrations, and there is no room for guesses or estimations. “It’s time consuming, and you’ve got to be accurate with your data,” he says. “I’m a data nut, so that’s what makes me good for this type of project.” Leiding may not be a household name to the end users that have benefited from his work, but his talents have not gone unnoticed by those suppliers and other third-party companies that have worked with him. While his tests are usually done in the presence of the client, his work is trusted enough that he often works unsupervised. “One customer told me that there are guys who want to be in R&D and there are guys who are in R&D, and he said that I wasn’t a wannabe,” he notes.

Continuous learning processes Leiding developed his passion for meat processing after working as an apprentice in a processing plant during the

FEBRUARY 2011 | INDEPENDENT PROCESSOR

11

More Yield. Less Waste. More Profit. Count on greater savings when you choose TREIF.

TREIF USA, Inc. 1.888.77.TREIF

www.treif.com [email protected]

COVER STORY

TREIF offers value-packed options. TWISTER mat Fully automatic loading for dicing, shredding and strip cutting

mid-1970s. He ran a meat company for three years before selling it in 1978, and he re-started Leiding’s Meats in 1996, thanks to the encouragement of his wife, Carolyn. Originally, Leiding’s processed deer during hunting season, and one of the fliers he produced advertising his venison sausages ended up in the hands of a corporate R&D team. “They said, ‘If this Leiding guy can make the sausages to a high-quality standard, maybe we should contact him about doing our sausage kitchen test work,’” he recalls. After interviews with several officials from overseas, Leiding began doing R&D work out of his facility in Danville. He says that in addition to an attention to detail, he’s always been up front with his clients if they ask him to do something he’s never done before. He adds that he’s never had a job where he hasn’t learned something, which makes the R&D work especially rewarding. Some projects have been particularly challenging, such as the one where he was asked to make a product with 51 pounds of meat and 49 pounds of water. “The first time we did it, it looked like soup and dumplings, but after three runs, I was able to dial in on the time when you incorporate spices and binders in the water with the meat,” he says.

Some of the projects do end in failure, but Leiding says that’s the nature of R&D work. However, he has experienced many successes as well, and his clients have come away from the tests with revenue-generating products. One of his favorite projects involved creating jalapeño bacon. Leiding sells it at his retail store, where it is extremely popular. “Jalapeño bacon has been something that a lot of companies are struggling with, to get a good flavor profile and appearance of product, and we’ve got it nailed,” he says. Where some attempts he’s seen look almost green, Leiding’s jalapeño bacon has an orange tint, which is both eye-catching and appealing. He also solved the problem that processors often have – what to do with the trim – by creating a jalapeño bacon cheddar cheese chuck burger. “We’ve just got to come up with a name that isn’t so long!” he says, laughing. “You can eat it faster than you can say it.” In order to provide a comprehensive list of services, Leiding has added several pieces of equipment to the shop specifically for R&D work. Early on, he bought a smokehouse with a microprocessor in order to get more exact data, as well as a macerator for working with whole-muscle products. His most recent acquisition is a double-end clipper, which will allow

PUMA EB Accurate portion cutting, even for bone-in products

DIVIDER 660 Modular slicing system with check weigher and loading belt options

FALCON conti Weight-controlled precision cutting and continuous loading

For more information about the above models and other dicing, slicing, shredding and strip cutting equipment, call or visit our website.

1.888.77.TREIF

www.treif.com

COVER STORY

him to test casings in higher-speed applications. The beauty of purchasing the equipment for R&D work is that he’s also able to use the equipment for his retail and catering operations as well. With the smokehouse, he points out, he can produce all his cured meats as well as some delicious chocolate-chip cookies as a dessert for catered parties. Along with the equipment, Leiding has also used his R&D experience to benefit his business. “A lot of the flavor profiles, spice and meat blocks that we’ve been exposed to have widened my education and understanding of various meat processes – thermal processing, mixing, blending, emulsifying, bowl chopping,” he says. He’s also learned about the types of ingredients and binders that should be used with those protein types. That knowledge has led to the development of many unique products. Leiding has won numerous awards from national and state-wide cured meat competitions. At last year’s American Association of Meat Processors convention in Kansas City, Mo., he was the grand champion for Andouille sausage at the American

14

Cured Meat Championships. Unlike other sausage processors who buy an Andouille spice blend, Leiding made his sausage completely from scratch. As it was his first time making Andouille sausage, he asked for some divine guidance beforehand. “I went through different flavor profiles until I zeroed in on what I wanted to run with,” he says. “I opened the oven door when it was done, and the color was just awesome. It had a wonderful golden-orange color to it. When I cut into it and ate it, I was overwhelmed. I said, ‘Lord,

INDEPENDENT PROCESSOR | FEBRUARY 2011

thank you,we got it.’” In addition to the Grand Champion award in Andouille sausage, Leiding’s Meats was one of four champions in six other categories. Leiding says that his R&D experiences have led to other successful products for his business, including the jalapeño bacon and bacon-cheddar chuck burgers, a chorizo sausage and a chorizo snack stick. His sense of creativity also has led him to take some product development risks that have paid off more often than not – such as his turkey sausage with cheddar cheese and peanut butter. “We were doing some ground turkey products for a customer for the AMI show in Chicago many years back,” he recalls. “I thought it would be cool if we put some cheddar cheese in it. Then, our senior minister at my church loves peanut butter, so I thought we could make some peanut butter and cheddar cheese cured and smoked turkey sausage, stuffed in a pepperoni-style casing, and see what happens. And it was a hit!” He adds that several international customers who sampled that sausage still tell him that he needs to get it on the market. On another occasion, he created a boneless ham that tasted alternately like honey and orange marmalade or

COVER STORY

honey and red raspberry, depending on which end of the ham is being sliced. “All we did was change the recipe up for the cure that we injected into the muscle,” he explains. The downside to R&D projects, Leiding notes, is that while they are his priority, they only come on an as-needed basis. Fortunately, the other areas of Leiding’s meats have continued to grow as well. Winter months bring a steady demand for deer processing, and the summer months bring catering. As the Danville community has struggled in the recent economy, the catering business has expanded to include the nearby Champaign–Urbana metropolitan area. Doing so has helped keep the

catering business dollar intake steady, and he’s taking on more and more larger jobs, feeding anywhere from 500 to 700 guests. The recent addition of the facility’s retail area has brought enough success that he’s considered moving into a larger building, preferably located on a main road. “[The retail success] proves to me that people want good quality,” he says, “and it also proves to me that if we were to move onto the main road, the retail would really go through the roof.” The drawback to that growth would be that it might take interfere with his R&D work. If he gets hammered with many R&D projects in a short time span, it might interfere with his ability to keep a larger retail space stocked.

The retail success he’s enjoyed and the number of awards he’s won for his products stand as a testament to his abilities. However, much of his R&D work will have to remain a secret, as it would violate the confidentiality agreements he has signed. He points out that integrity means everything in that business, and revealing any confidential information even once would bring his R&D business to an abrupt end. “There’s a new product right now that’s going out in the marketplace, and it’s cool,” he says. “Can’t say a word about it, and I don’t make any money off the future sale of the product. But the beauty of it is, I was allowed to be involved in it, and no one can take that away from me.” IP

MODEL KDCMA AUTOMATIC DOUBLE CLIPPER

Its versatility is matched only by its productivity. The high-performance KDCMA clips, loops and strings all types of sausage chubs, chains and rings.


The mobile KDCMA automatic double

clipper is the industry’s most versatile sausage clipping machine.
System can produce chubs, chains and rings using natural or artificial casings.
System can use spool clips, stick clips, loops and string.
The KDCMA can grow with you – its modular design allows easy add-on of components, including automatic looper, thread dispenser, spool clip and label printer.
Adjustable casing brake prevents casing overload and ensures exact-weight portioning.
Hygienic, stainless steel design.

(800) 331-2905 • www.tipper tie.com marketing@tipper tie.com

» PRODUCT FOCUS: HAM

Patience is a virtue Producing award-winning hams at Sailer’s Food Market requires a little time.

S

ince 1923, five generations of the Sailer family have owned and operated Sailer’s Food

Market & Meat Processing Inc., and as many generations of Elmwood, Wis., residents have enjoyed the

Select from 100 Models and Variations

Reliable Power Saws

Model 55 22" Saw

Model 4436 Series Design 5E3, 31" Saw

Model 44LP 18" Saw Low Profile, High Speed

Model 3334-4003 16" Saw

Model 44 STD 18" Saw

Model 22 12" Saw

Model 1433 14" Saw

The Biro Manufacturing Company Marblehead, OH 43440-2099 USA 419-798-4451 Fax 419-798-9106 www.birosaw.com email: [email protected]

16

INDEPENDENT PROCESSOR | FEBRUARY 2011

131RB-2C-1003

company’s hams, bacon and sausages. The fifth generation, Jake Sailer, has been involved with the management of the business since 1995, and he’s overseen new equipment purchases, the transition from a grocery store to a meat market and the relocation to a larger building. The quality, however, remains unchainged, as evidenced by the number of awards the company has won for its meat products, particularly its hams. Sailer says that 90 percent of the hams the company produces are semiboneless hams, along with 7 percent boneless hams and 3 percent a new commercial ham he began producing last year. He started producing a smaller, less expensive formed ham that could also be sliced and sold as deli meat. “The only bone-in hams we sell are from the custom hogs that we do,” he says. “We process probably a little over 1,500 custom hogs a year.” Sailer adds that the majority of hams Sailer’s Food Market produces come from hogs slaughtered by the company. He stresses the importance of quality pork in producing quality hams, and slaughtering the animals eliminates the risk of getting poorquality PSE (pale, soft, exudative), pork from other producers. For Christmas and Easter holidays, Sailer says that he will buy shank hams and make them semi-boneless himself, to keep up with the demand. The hams are sold out of the company’s retail space, and several area grocery stores added them during the Christmas season. Sailer says that the hams have to be visually appealing in order to sell well, so he takes extra care with the presentation. “I’m so particular, that I clean up and hand-tie each one of those semi-boneless hams for Christmas and Easter, and then I double-net them, so they hang really nicely and have that nice shape,” he explains. Sailer’s Food Market has also bene-

PRODUCT FOCUS: HAM

«

Jake Sailer displays some of the award-winning hams found at Sailer’s Food Market in Elmwood, Wis.

fited from technology to improve the quality of its hams. Sailer says that his father used to artery-pump all the hams, which were more of a country ham style. Tired of hearing complaints that the bacon and hams were too salty, Sailer convinced his father to buy a tumbler and injector. “Once we got that, we didn’t have to worry about missing any spots and having uncured spots in the middle of the ham,” he says. “Everything was consistent, everything got pumped evenly. We probably even upped our yield a little bit.” Just because the production room has high-productivity equipment, it doesn’t mean that the hams are rushed through and sent straight to the smokehouse. After the hams come out of the tumbler, they set for at least two days before entering the smokehouse. “That’s where you get your good cured meat color, and that good cured meat flavor development,” Sailer says. “I think it takes a little time for everything to set and the chemicals to work. If you look in my meat case and see all the nice, pink hams that I’ve got, that’s what it’s all about.” IP

SWISTICK DOUBLE CLIPPER FOR AUTOMATED SAUSAGE HANGING

Increase your smoked sausage production. The Tipper Tie Alpina SwiStick automatically portions, clips, string loops and hangs sausage directly onto smoke sticks.

 The SwiStick automatically string loops

sausages and accurately deposits them directly onto smoke sticks.  The SwiStick’s motorized smoke stick magazine

allows continuous hanging and ensures the highest levels of sausage production.  The SwiStick safely and precisely hangs

sausages in plastic, fibrous and collagen casings with diameters from 20–120 mm and lengths of up to 1,000 mm. It hangs up to 100 loops/minute onto the smoke stick, depending on the product.  Up to 22 smoke sticks can be inserted into

the motorized magazine. A monitoring system alerts the operator with a visual signal when only a few smoke sticks are left. If the magazine is emptied, the complete line stops automatically.

(800) 331-2905 • www.tipper tie.com marketing@tipper tie.com

2011 OUTLOOK Waiting for the USDA Proposed changes to government policy could have a significant impact on both large and small meat processors. There are plenty of outside pressures that can threaten a processor’s profits. A drastic increase in corn prices can send raw material costs soaring, or an increase in gas prices can make refueling the delivery trucks an expensive proposition. Then, there are the government regulations. A new ruling can increase the amount of paperwork or raise the costs of doing business to the point that an owner may decide to shut down the business. Last March, FSIS published a Draft Guidance on HACCP System Validation and asked the industry for comments. While there was plenty of confusion as to how

Proposed changes to GIPSA could forever alter the relationships between packers and producers.

the draft guidance could be interpreted, it seemed clear to most in the industry that FSIS was asking establishments to conduct substantially more testing than they ever had in the past, as they would not be able to rely on previously accepted scientific documentation to validate their HACCP plans. The American Association of Meat Processors was one of the associations that led the charge against this revision and

18

INDEPENDENT PROCESSOR | FEBRUARY 2011

reinterpretation of HACCP plans. “There are several well-recognized, long-standing processes and supporting documents which, when followed, result in the production of safe meat products,” AAMP wrote in the April, 2010, issue of the Independent Processor. “Depending on the FSIS interpretation of this guidance information, the potential microbiological testing that may be required by this validation initiative would be extremely costly to all meat processors and be a specific huge financial burden for the very small and small independent processors that make a wide variety of meat products.” AAMP President Daniel Glier, owner of Glier’s Meats Inc. in Covington, Ky., said, “If they [FSIS] do press forward, each company or small plant would have to choose a product or two that they’re going to continue to manufacture, and the rest will have to go, or a lot of them will drop out [of federal inspection] and go to retail exempt. I don’t see any other way around it.” The second draft was supposed to be released in August, 2010, but it may now be released in the spring of this year. Another proposal with possible widespread ramifications concerns the USDA’s Grain Inspection and Packers and Stockyards Administration (GIPSA). Among its proposed changes, a producer need not show harm to competition as part of a Packers and Stockyards lawsuit, and packers who own livestock will not be permitted to sell their livestock to another packer. While the rule is being championed by some producer groups, trade groups like the National Cattlemen’s Beef Association and the American Meat Institute have spoken out against it repeatedly. The AMI has said that the rule would limit or eliminate any marketing agreements between packer and producer, leading to increased vertical integration and more com-

modity meats. Three studies commissioned by meat industry associations have pegged the loss of revenue to the industry in the hundreds of millions and the loss of jobs in the tens of thousands. More than 60,000 comments were submitted to the USDA in regards to

the proposed GIPSA changes. Colin Woodall, NCBA vice president of government affairs, said in a December, 2010, video update that the USDA will analyze those comments and do a costbenefit analysis. The economic and legal analyses will then be sent to the White House for further review. IP

FEBRUARY 2011 | INDEPENDENT PROCESSOR

19

» PRODUCTION: HUMANE HANDLING

A humane priority Proper handling of animals is a necessity for any company involved in slaughtering.

T

he images have an immediate visceral impact: A prone cow being beaten and dragged with chains. Turkeys and veal calves being kicked or prodded. Animal-rights groups have targeted slaughterhouses repeatedly, and undercover videos that document animal abuse have continuously put the industry as a whole in a bad light. One company cannot help it if a slaughterhouse operator in another part of the country has employees who willfully disregard animalhandling rules. The best thing any management team can do is to have their employees well-versed in what is and is not acceptable behavior so that it’s not their company in the headlines. Not only is there a moral obligation to treat the animals with respect as they are led to slaughter, there is the financial risk that the entire company may be lost because of the action of one or two workers. Industry veteran Jerry Karczewski, who recently started Karczewski Consulting, emphasizes that proper animal handling must be emphasized from the top of the plant or company management chain down. “Most employees want to do what the company wants them to do, so if the company sends a clear message that animal handling isn’t important, then that’s a huge obstacle to overcome,” he says. Karczewski says that animal safety is one of the four safeties where a company must be effective (the other three are worker, food and earth or environmental safety), and he adds that the company and plant leadership must have an awareness of the company’s animal-handling procedures.

20

INDEPENDENT PROCESSOR | FEBRUARY 2011

PRODUCTION: HUMANE HANDLINE

“A good test of this is, how willing are you to show your livestock handling and stunning areas to visitors,” he notes. “Would you take a college group or a group of customers through your handling area, or do you avoid that part of the plant when you’ve giving a tour?” Karczewski notes the importance of engaging the animal handlers and giving them a voice in how a company can achieve animal-welfare goals, so that they can take ownership of the process and understand the responsibility of their roles. Employees who work with live animals must have a sound knowledge of animal behavior, for both employee safety and animal safety. Those lessons should be reinforced at least once a year. “It’s giving them points about understanding the flight zone, the point of balance and how that affects cattle behavior,” he says. “Also, reinforcing the aspects of patience and gentleness when handling cattle is very important.” Karczewski recalls one animal handler who worked with him at a plant in Pennsylvania. She would sing to the animals as they were being driven into the restrainer, believing that music helped cattle along. Whether she was right or not, she had the right mindset for an animal handler and did her job well. He also says that handlers must be aware of the differences in the types of cattle, as that will play a large role in how the animals will be handled. “A feed lot steer moves virtually like water through a livestockhandling area,” says Karczewski, “as opposed to dairy cows, which really require a lot of patience. Most of their animal lives they’ve never been rushed, so they certainly don’t get rushed at the slaughterhouse.”

handling and slaughter practices. One relatively recent advancement is the use of remote video technology to monitor the animal-handling areas. “That’s been a huge benefit, because companies and plants have done a good job of training their employees and laying out the expectations for

what’s right,” Karczewski says. “The key is, is it done consistently?” Some companies have had cameras in the live animal area for several years, Karczewski says. However, using a third-party auditor has brought an all-new dimension to that step. He knows of several companies that

Technology aides Along with proper education, there have been some technological advances that have impacted the animalFEBRUARY 2011 | INDEPENDENT PROCESSOR

21

«

Shout It Out Loud! Count on advanced technology, the highest safety standards, increased yield and exceptional quality when you choose TREIF!

TREIF USA, Inc. 1.888.77.TREIF

www.treif.com [email protected]

PRODUCTION: HUMANE HANDLINE

«

TREIF has « solutions worth shouting about! TWISTER mat Fully automatic loading for dicing, shredding and strip cutting

PUMA EB Accurate portion cutting, even for bone-in products

DIVIDER 660 Modular slicing system with check weigher and loading belt options

FALCON conti Weight-controlled precision cutting and continuous loading

received excellent scores on their internal audits, but third-party auditing showed that they were getting a biased look at their internal numbers. The methods of stunning animals have changed over the years. Karczewski says that electrical and even CO2 stunning has been researched for larger animals like cattle. Electrical stunning has been used extensively in Australia and New Zealand for those countries’ grass-fed cattle, but the

practice has not gained widespread acceptance in the U.S. “On the technology side for captive bolt stunners, I think most stunner manufacturers are using stuntesting equipment that really validates whether the equipment is operating effectively or as it should,” he adds. “It’s a small thing, but important when you want to get a good stun the first time.” IP

For more information about the above models and other dicing, slicing, shredding and strip cutting equipment, call or visit our website.

1.888.77.TREIF

www.treif.com

Independent Processor Fourth Annual Top 75 Questionnaire Due Friday, April 8, 2011 The INDEPENDENT PROCESSOR is conducting its annual survey of meat, poultry and prepared foods companies. WE WANT TO INCLUDE YOUR COMPANY IN THIS PRESTIGIOUS LIST, which will be published this spring. To ensure the accuracy of the information we print, please take a few moments to fill out the questionnaire. Return this completed form to Sam Gazdziak at [email protected] or fax to (248) 502-9036 by Friday, April 8, 2011. You can call Sam at (770) 594-0050 if you have any questions. You may also submit your information at www.provisioneronline.com/independent_processor

CONTACT INFORMATION

YOUR NAME and TITLE: ________________________________________________ ______________ __ ___ PHONE/FAX/E-MAIL: ___________________________________________________ _______________ __ ____ ______ __ __ ____ ___ _ COMPANY INFORMATION

C R P

FULL CORPORATE NAME: ____________________________________________ _____ _________ ___ _______ __ ______ ____________ ____ _____ ______ ___ __________ ________ __ ADDRESS: __________________________________________________________ _____ _______________ _________ __ _____ ______________________ ____ _____ ________ ______ ____ _________ _____ ___ __ PHONE/FAX/WEB B SITE: ITE: _______ __________ ______________________________________________ ___ ___ _ ____ ___ ______________________ _ ____ ________ _____ ______ ___ ____ _____ ______ ___ __ CER’S S NAME, TITL TITLE: TLE: E: _____ ___ __ _ __ _________________________ _ ___ _______ ____ _______ ____ ______ ___ ___________ __ CHIEF OFFICER’S _________________________________________ ECENT ANNUAL ANNUA UAL SALES S LES SAL SA ES S (ME ((MEAT MEAT M AT T AND/OR AN ND/OR PO POULTR RY) Y): $ $__ _________ * MOST RECENT POULTRY): $__________ Please breakk down dow wn your wn yo ou ur sales sal ales es by by percentages pe percentag ercenta age ess into e i to the in h following he ffo o categories: catego ories: ____% Beef ____% ____ _% Chicken Chiccke ken en ____% __ __ __% % Pork P ____% Turkey __ ____% ___% % Lamb/Veal La Lamb/V amb mb//V /Veal Vea Veal al ____% Prepared Foods ____% Other (Please Pleasse se Sp Specify: S eci ciffy: ___________________ cify: ci ______________________________) How much of yourr sales are product? _____% a for exported p How much of your product products are certified natural or organic? _____% cts sold a (* Approximations are acceptable eptable and an nd may include recent acquisitions. Please note any conditions to the figure you are reporting and they will be included. d The ranking of the top companies is based on sales of meat and poultry, therefore this information must be provided to include your company on this list.)

FISCAL YEAR ENDS: ______________________________ NUMBER OF EMPLOYEES: __________________________ NUMBER OF MEAT AND/OR POULTRY PLANTS: __________________ OPERATIONS/PRODUCTS PROCESSED (Please check all that applies to your business) Beef Slaughter Fresh Pork Poultry Slaughter Rendering Export

Boxed Beef Fresh Sausage Natural/Organic Case-Ready Game

Beef Further Processing Cured Sausage Veal Frozen Prepared Foods Poultry Further Processing

Ground Beef Ham Lamb Portion Control

Pork Slaughter Bacon Seafood Prepared Meals

HIGHLIGHTS OF YOUR COMPANY’S YEAR (This could include acquisitions, new products, record sales, a new facility, or any other highlights you wish to mention. Please e-mail a photo and/or a press release if applicable):

ASSOCIATION NEWS - AAMP «

Nutrition Labeling of Single-Ingredient Products Soon To Be Required The U.S. Department of Agriculture (USDA) Food Safety and Inspection Service (FSIS), has published the final rule, “Nutrition Labeling of Single-Ingredient Products and Ground or Chopped Meat and Poultry Products.” Beginning in 2012, nutrition labels must be provided for the 40 major cuts of singleingredient, raw meat and poultry products identified by FSIS. Nutritional information can be provided on the product label, or through point-of-purchase materials. All ground and chopped meat and poultry products must provide nutritional information on the label. The nutrition materials must include the number of calories and the grams of total fat and saturated fat a product contains. Additionally, any product that lists a lean percentage statement on its label must also list its fat percentage. Failure to provide nutrition information renders a product misbranded, according to the rule. The new rule does not apply meat and poultry products that are intended for further processing, not for sale to consumers, custom slaughtered or prepared, intended for export, or individually wrapped, small packages of less than

0.5 ounce net weight. The rule does not apply to products that are ground or chopped at a customer’s request and ground or chopped products in packages that have a total surface area for labeling of less than 12 square inches, that includes no nutrition claims or nutrition information and provided that an address or telephone number that a consumer can use to obtain the required information is included on the label. Small businesses that use statements of percent fat and percent lean on the label of ground products, provided they include no other nutrition claims on the product label, are exempted from providing further nutrition information. USDA is currently developing point-of-purchase materials and make them available over the Internet free of charge. If retailers cannot obtain point-of-purchase materials over the Internet, FSIS personnel will have copies of the information to provide to retailers. Nutrition panels are available through AAMP’s Nutrition Labeling service. For more information, visit www.aamp/nutrition or call (717) 367-1168.

ASSOCIATION NEWS - NMA «

Meat Industry CareerLink The Meat Industry CareerLink—a partnership between National Meat Association, Southwest Meat Association and the American Meat Science Association—is the first and only multi-association online job board dedicated to serving the meat processing industry exclusively. With its focus on meat processing industry companies and professionals, the CareerLink offers a premier, easy-to-use and highly targeted workforce development resource for online employment connections. It’s important for meat companies to have an option that allows them to concentrate job postings on a site dedicated to attracting the qualified professionals who specialize in serving the needs of the meat industry. Employers interested in taking advantage of this outstanding tool simply post jobs or can actively search for qualified candidates from a database of stored resumes. It’s even possible to create an online resume agent to email

qualified candidates daily. Users of the site also benefit from online reporting that provides job activity statistics. And both members and non-members of the cooperating associations can use the CareerLink to reach qualified candidates, although members do so at discounted rates.

FEBRUARY 2011 | INDEPENDENT PROCESSOR

25

» ASSOCIATION NEWS - SEMA

The Southeastern Meat Association (SEMA) is made up of processors from across the Southeastern United States that are industry leaders in beef, pork, and poultry processing. We share a common commitment to food safety, education and building a stronger industry. SEMA keeps its members informed of industry regulations, trends and the latest news with a monthly newsletter. The SEMA convention is a great time to network with your industry peers, hear presentations from industry leaders and check out the associate member’s exhibits. SEMA partners with other Regional and National Association on workshops and industry issues, such as the ethanol issue, FSIS validation of HACCP, Food Defense Plan, U.S. Immigration and Customs Enforcement, and Trade Reporting. SEMA awards scholarships and works closely with some of the Southeastern Universities. 2011 Annual Convention June 10th & 11th The Shores Resort & Spa Daytona Beach Shores, FL Membership starts as low as $200.00 Fiscal year: January 1- December 31 For more information on SEMA and membership go to www.southeasternmeat.com e-mail: [email protected] or call the SEMA office 407.365.5661.

» ASSOCIATION NEWS - SMA

ASSOCIATION NEWS - AMI «

AMI Expo 2011 Gives Independent Processors the Extra Edge AMI’s Meat and Poultry & Seafood Convention and Exposition, April 13-16, 2011 at Chicago’s McCormick Place, is the ONLY show for independent processors seeking a competitive edge in the marketplace. More than 10,000 meat industry professionals are expected to attend the event. You spoke, and AMI listened: The show is now in the spring so that more people can attend with fewer conflicts on your busy calendar. The demands on small and independent processors are greater than ever, from new regulations to customer interest in

sustainability. The AMI show is designed to help you succeed with practical ideas from the supplier community and experts in the field. Don’t wait until the fall to see the latest technological innovations. The show floor features everything you need for your meat business: sanitation, food safety and packaging, as well as pavilions dedicated to Sustainability and Ingredients, Flavorings and Seasonings. Provocative speakers will detail consumer trends, new business technology, sustainability, food safety, management and human resources, operations, regulatory developments and other critical and timely issues. Peer-to-peer instruction is a key part of the show’s practical education program. Can’t stay the entire time? Local companies will benefit from the FREE SATURDAY program. Enjoy the show and all the education sessions absolutely FREE on Saturday. Don’t get lost in the shuffle at broad food shows, or packaging shows… Plan today to join your peers at the ONLY technology show for the meat, poultry and seafood industry. There is so much to see, hear and learn — you’ll need to bring an entire team from your plant to make sure you don’t miss a single moment. Visit www.AMIExpo.com for more information.

ASSOCIATION NEWS - NAMP « Want your personal network to include the real decision-makers with the most successful meat and poultry processors in North America?

NORTH AMERICAN MEAT PROCESSORS ASSOCIATION ASSOCIATION AMÉRIQUE DU NORD DES TRANSFORMATEURS DE VIANDE A SOCIACIÓN N ORTEAMERICANA DE P ROCESADORES DE C ARNE

Regular NAMP programs that will put you in contact with our members include:

Join NAMP today and enjoy direct access to an international group of businesses that process and distribute meat, poultry, seafood or game to the foodservice industry. Learn more and apply at www.NAMP.com or call +1 703.758.1900 ext. 102.

• Spring Meat Industry Management Conference • Fall Outlook Conference • Center of the Plate Training® • E. coli Conference

Enjoy immediate marketing benefits with an ad in the 2010 Member Resource Directory published in January or a sponsorship program at the Annual Meat Industry Management Conference presented by NAMP, March 19-21. Contact Chuck Jolley at 1 913.205.3791 or Chuck@JolleyAssociates today.

FEBRUARY 2011 | INDEPENDENT PROCESSOR

27

To place your classified ad in Independent Processor call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] CONTINUING EDUCATION

EQUIPMENT FOR SALE

SPIRAL HAM SLICERS & SUPPLIES

Phone: 1-800-888-0327 Fax: 1-800-301-0092

PLASTIC FREEZERS SPACERS

3005 Bledsoe • Ft. Worth, TX 76107 •

800-343-8133

www.spirocut.com

www.sfbplastics.com

New, Used, & Reconditioned. Contact Tom Misfeldt-Spirocutter

Dry & Semi-Dry Sausage April 5-7, 2011

Sausage & Processed Meat July 18-22, 2011

HACCP Workshop October 27-29, 2011

Basic Sausage November 8-10, 2011

WWW.SCOTTSMOKEHOUSES.COM

Cured Meat January 17-19, 2012

(888) 343-5421 www.ans.iastate.edu/meatcourses

FOOD SAFETY

Geor ge Lapsley Enterprises

“Where There’s Smoke, There’s SCOTT!”

Food Safety Specialist www.getfoodhelp.net T: 267-221-2426 HACCP / SSOP / 3rd Party Audits E. coli, Lm, BSE Compliance Recall Technical Assistance USDA Assistance

Want to advertise your classified ad in Independent Processor? Diana Rotman 847-405-4116 Fax: 248-502-9083 E-mail: [email protected]

28

INDEPENDENT PROCESSOR | FEBRUARY 2011

USED FOOD PROCESSING EQUIPMENT BUY sSELL s AUCTION sLIQUIDATE Check our new, updated website at

www.kohlerequip.com for the most recent information on our equipment and upcoming auctions. 4925 N 56TH ST., LINCOLN, NE 68504 PH: 402.465.8845‡ FAX: 402.465.8847 EMAIL: [email protected]

To place your classified ad in Independent Processor call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] SPECIAL SERVICES

EQUIPMENT FOR SALE

FOR SMOKEHOUSES

X-RAY INSPECT ION

WET BULB SOCKS FOR HUMIDITY CONTROL

HACCP compatible solution for detecting foreign particles in your product.

SAVE YOUR PRODUCT AND YOUR GOOD NAME

• Metal • Stone • Bone • Rubber • Glass • Plastic

EPDM INFLATABLE DOOR SEALS, SILICONE GASKET RECORDING CHARTS & PENS

FAST RESPONSE • FREE TESTING Call CX R COMPANY

ALSO SMOKEHOUSE PARTS

Warsaw, IN

GREGG IND., INC.

800-817-5763 fax 574-269-7140 www.cxrcompany.com

“THE WET BULB SOCK PEOPLE”

EQUIPMENT FOR SALE

PHONE & FAX:

608-846-5143 email: [email protected]

www.smokehouseparts.com

NEW/USED WALK-IN-COOLER-FREEZER BOXES REFRIGERATION SYSTEMS – EQUIPMENT HUGE INVENTORY, ALL SIZES

Want to advertise your classified ad in Independent Processor?

Buy Sell - Nationwide - Wholesale Prices

Tel. 216-426-8882 www.awrco.com [email protected]

contact Diana Rotman at E-mail: [email protected] Phone: 847-405-4116 Fax: 248-502-9083

PROCESSOR INDEPENDENT

*HW\RXUÀ[ on the go! Get everything you love about The National Provisioner anywhere you have internet access with our digital edition available at ProvisionerOnline.com. All of the topical columns, useful features and technology updates you look forward to can be viewed in an environmentally friendly format from your laptop, iPad or Smartphone.

www.ProvisionerOnline.com

» AD INDEX COMPANY

PAGE NUMBER

Web site

Biro Manufacturing

5, 16

www.birosaw.com

Foss

19, 21

www.foss.us

Jarvis Products Corp.

3, IBC

www.jarvisproducts.com

Reiser

IFC

Risco

7, BC

www.riscousa.com

Spartan Chemical

18, 20

www.spartanchemical.com

Tipper Tie

15, 17

www.tippertie.com

Treif

www.reiser.com

12, 13, 22, 23

PROCESSOR INDEPENDENT

SERVING SMALL AND MIDSIZE MEAT, POULTRY, AND GAME PROCESSORS

www.treif.com

Reader Services LETTERS Sam Gazdziak Independent Processor 155 Pfingsten Road, Ste. 205 Deerfield, IL 60015 [email protected]

BNP Media

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

SINGLE COPY SALES/ BACK ISSUES Ann Kalb [email protected] (248) 244-6499

REPRINTS Jill DeVries [email protected]

Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Confection & Snack Retailing, Dairy Foods, Flexible Packaging, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, Meat & Deli Retailer, The National Provisioner, Nutrasolution, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods, Refrigerated & Frozen Foods Retailer and Snack Food & Wholesale Bakery

30

INDEPENDENT PROCESSOR | FEBRUARY 2011

(248) 786-1596

PRINT & INTERNET ADVERTISING Dave Lurie Publisher/Midwest Sales [email protected] (248) 593-0337

Wayne Wiggins Jr. Great Plains/West Coast Sales [email protected] (415) 387-7784 Rick Parsons Southeast/East Coast Sales [email protected] (407) 302-7952 Gary Campbell Sales/Business Development [email protected] (440) 227-8377

LIST RENTAL For postal information please contact Rob Liska at: 800-223-2194 x726 or e-mail him at robert.liska @edithroman.com For e-mail information please contact Shawn Kingston at: 800-409-4443 x828 or e-mail her at shawn.kingston @epostdirect.com

NEW FROM JARVIS

Model SER-03 RECIPROCATING BREAKING SAW

• Suitable for production breaking and general purpose use on beef, hogs, sheep and veal.

• Lightweight - 18.6 lbs (8.4 kg) for ultimate flexibility.

• High speed for good cutting performance.

• Common applications include cutting forequarters, shank bones, primal cuts, aitch bones, brisket opening and splitting.

We Provide Free Service and Training Distributor Inquiries Invited

Jarvis Products Corporation

View these tools at our website

33 Anderson Road, Middletown, CT 06457 Tel: (860) 347-7271 Fax: (860) 347-9905 E-mail: [email protected] http:// www.jarvisproducts.com