FOOD SAFETY AND REGULATORY ISSUES FOR 2021
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eHANDBOOK FOOD SAFETY AND REGULATORY ISSUES FOR 2021
www.FoodProcessing.com
TABLE OF CONTENTS
Food Safety and Regulatory Issues for 2021 3
New regimes at FDA and USDA, the pandemic’s after-effects and the evolving
‘New Era of Smarter Food Safety.’
How To Select the Right X-ray Machine 9
Is Excess Capacity Dragging Down the Performance of Your Compressed Air System? 12
Hygienic Design Enclosures Offer Superior Cleanability 15
Protecting Your Customer with Traditional and Magnetic Strainers 18
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Sani-Matic • www.sanimatic.com 17
eHANDBOOK: Food Safety and Regulatory Issues for 2021 2
www.FoodProcessing.com
Food Safety and Regulatory
Issues for 2021
New regimes at FDA and USDA, the pandemic’s after-effects and the
evolving ‘New Era of Smarter Food Safety.’
By Food Processing
N
ew year, new president, new heads there. Although one tiny change from FDA:
of USDA and FDA and the old pan- It looks very likely that the agency this year
demic winding down. One-third of will add sesame to its list of allergens that
the way into the new year, the 2021 food must be declared on a label.
safety and regulatory landscape is starting
to take shape. Here are some of the issues For the most part, the to-do lists for both
you and the regulatory agencies will have to agencies are already set.
deal with in the coming months.
In the midst of the pandemic, the FDA
AGENCY CHANGES? NOT SO MUCH announced in mid-2020 “The New Era of
Both USDA and FDA will get new leadership Smarter Food Safety Blueprint.” It’s kind of a
from the Biden administration in the coming successor to the 2011 Food Safety Moderniza-
months, which could change the agencies’ tion Act, FSMA. At this point, the New Era is
policies and actions somewhat. As of this just a blueprint, an outline, but in the coming
writing, a secretary of agriculture has months the agency will flesh it out into a new
already been confirmed for USDA, none food safety act. It’s clear where the agency
other than Tom Vilsack, who held that is headed: They want the country’s food sys-
same job in the Obama administration. tems to be more digital and more traceable.
Despite the Trump administration being The New Era blueprint has four main points:
perceived as pro-business and anti-reg- 1. Tech-enabled traceability
ulation, USDA and FDA did very little 2. Smarter tools and approaches for pre-
backsliding in the realm of food safety in vention and outbreak response
the past four years – except for the reduced 3. New business models and
inspections due to the pandemic. So there retail modernization
probably will be little perceptible change 4. Food safety culture
eHANDBOOK: Food Safety and Regulatory Issues for 2021 3
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The July 2020 announcement said: “When EFFECTS FROM THE PANDEMIC
we look at how industries track, through Consider for a moment coronavirus’
digital means, the real-time movement of impact on the manufacturing side of
planes, ride sharing and packaged goods the food & beverage industry: meat
or how firms are harnessing big data to & poultry plant workers catching the
identify trends, it is clear FDA and our virus, some dying, plants closing; USDA
stakeholders should be looking at how to and FDA inspectors making fewer
tap into new technologies that include, but inspections; processors caught with
are not limited to, artificial intelligence, the too much commitment to foodservice
Internet of Things, sensor technologies, and or the wrong products, having to pivot
blockchain.” to make pantry items for retail.
FDA also revealed in September of last All those conditions and more would be
year a proposed rule to establish additional perfect breeding grounds for a major food
traceability recordkeeping requirements safety incident. Corners could have been cut,
for certain foods, primarily leafy greens improperly trained employees could be in
and fresh cut fruits and vegetables. The place, familiar lines might switch to making
rule follows a number of recent foodborne unfamiliar products, no oversight from the
illness outbreaks that involved produce authorities. Successful companies – and most
and sprouts, and they proved to be some food & beverage companies were successful
of the most difficult to trace back to last year – had to quickly adapt and even alter
the source. the way they were operating. But there were
no serious food safety breeches last year.
The Food Traceability Proposed Rule will
be a key component of that New Era of It may seem counter-intuitive, but since the
Smarter Food Safety Blueprint and would beginning of the pandemic, the food industry
implement Section 204(d) of FSMA. Its has seen lower than normal rates of recalls.
specifications for electronic record keep- According to Sedgwick Brand Protection
ing, especially during what it calls Critical Solutions, which collects data on recalls,
Tracking Events, indicates what the agency there were 28 USDA recalls in the fourth
will be looking for from all food & beverage quarter of 2019, a typical number. There
processors to quickly identify lots of con- were fewer recalls in the next three quarters
taminated products and their source. The combined – six, nine and 10, respectively.
FDA right now is digesting comments on its
proposal and will come out with the formal FDA figures were similar: The agency
rule before the end of this year. reported 156 recalls in Q4 of 2019 and 141,
eHANDBOOK: Food Safety and Regulatory Issues for 2021 5
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79, 106 and 92 in the four quarters of 2020. THORNY ISSUES TO DECIDE
To the extent inspections did occur, they The government regulatory agencies also
were often announced, due to COVID-19 face a handful of issues, mostly labeling
safety protocols at the plants. The rea- and terminology ones, with products that
sons why there were fewer recalls in an weren’t around a few years ago. While
otherwise challenging year vary – from they’re not entirely food safety concerns,
less regulatory agency oversight to sim- they do have food safety implications.
pler products and less variety to increased
sanitation in the facilities. Even more Plant-based analogues made great inroads
hand-washing probably helped. in the past year, and the FDA is being
pressured to weigh in on labeling of these
While government inspections in 2020 products. For instance, whether a plant-
were scant and sometimes paused, they based patty can be called a burger or in any
undoubtedly will increase as the pandemic way compare itself with meat. Or whether a
subsides, but they may never reach past soy beverage can be called milk.
numbers. Not only did USDA and FDA
conduct fewer inspections because of the Likewise, cultured meats, which just a year
pandemic, so did programs of the Global ago seemed far off in the future, suddenly
Food Safety Initiative (GFSI), including are approaching near-price parity with tra-
the U.S.-based Safe Quality Food Insti- ditional animal meats. An early indication
tute (SQFI). Some of the 2020 inspections from the agencies last year indicated FDA
were replaced with automatic extensions and USDA together will assess their safety.
of food safety certifications, video visits or
more-detailed paperwork. Cannabis ingredients THC and CBD made
strides in the past year. 15 states have legal-
Both government and non-governmen- ized marijuana, and many of those states
tal organizations have found ways to also allow the use of its two key compo-
make sure companies are doing an ade- nents in foods and beverages. Someday
quate job of food safety without as many soon the FDA will have to face this issue,
in-person inspections. A spokesperson not just the for regulatory and labeling
for SQFI insisted site audits will remain issues, but whether these ingredients are
the heart of that agency’s certification truly safe to put in foods.
process. But even GFSI said it’s gearing
up for a new world of auditing with the
inclusion of information and communica- Read the complete story on
FoodProcessing.com.
tions technologies.
eHANDBOOK: Food Safety and Regulatory Issues for 2021 7
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How To Select the
Right X-ray Machine
By Heat and Control
A
s a food manufacturer, you make detect foreign objects or see large gaps in
an enormous commitment to bring packaging; metal detectors can only detect
a product to market, so protecting the presence of metals. One advantage of
your brand in the marketplace is critical for using X-ray inspection is the ability to find
success. The benefits are customer loyalty, more than just metal; also, the performance
improved market position, reduced liabil- is not affected by product signal, typical
ity risk, and overall positive branding of with metal detectors.
the product. However, because consumers
expect a consistent, quality product, a single The ability of X-ray inspection systems to
food safety recall could destroy your invest- provide unsurpassed detection of a wide
ment and reputation for product quality. range of physical contaminants – includ-
ing metal (e.g., iron, steel, stainless steel,
Because of this, food manufacturers are more aluminum), glass, stone, calcified bone,
vigilant to ensure uncontaminated product. and high-density plastics – means they
Fortunately, the technology in inspection and can be used to keep contaminants out of
detection equipment continues to advance the production process, as well as catch
so food manufacturers readily can improve contaminants before products leave
their quality control programs and utilize the factory.
more sophisticated inspection equipment
that detects smaller foreign objects, reduces X-RAY DETECTION
false rejects, and handles a wider range of X-rays are generated by an X-ray tube,
products to assure maximum food safety with and this energy is emitted from the
higher productivity. tube in a focused beam which passes
through the product being inspected.
X-ray inspection and metal detection are On the other side is a sensor, called a
often used in inspection, and because they photodiode array, which converts the
find different non-conformances, they are received energy to light and then to a
best used in tandem. X-ray machines can voltage. The voltage is transformed to
eHANDBOOK: Food Safety and Regulatory Issues for 2021 9
www.FoodProcessing.com
the greyscale image that can be viewed
on the screen or saved as an image.
If inclusions are present which are denser
than the product, these are displayed as
darker patches where less X-ray energy was
received. Voids and fissures are displayed
as lighter patches because higher levels of
X-ray energy were able to pass through to
the sensor.
X-ray machine showing an empty tomato tray
The system can be set to automatically
reject items that have either type of defect. what is the maximum width, height, and
length? The answers will narrow down
As product passes through the X-ray the list of potential machines. Another
system, the machine can detect foreign consideration is the location of the machine
bodies. The minimum detectable size of within the manufacturing process.
particle varies from one material to another,
the product being inspected, and the sensi- Because X-ray inspection machines can
tivity of the system. be used at various critical control points
(CCP) on a production line, their install-
Foreign bodies are not the only inconsisten- ment can strengthen both quality control
cies an X-ray system can spot. Voids and and quality assurance for a food manufac-
broken or missing product pieces become turer. X-ray systems that are commonly
visible, expanding areas for quality control. found at the end of the production line are
In addition, X-ray inspection can also be used to identify defects before products
used for other functions, including to esti- are dispatched and sent to the retailer
mate weight. or distributor.
APPLICATION Inspection of incoming ingredients may
When selecting an X-ray machine, offer important benefits, such as protecting
determine what product is being inspected, machinery and/or eliminating contaminants
as well as the type of packaging, and before they can be fragmented ...
sizes of the products. Is the product
unpackaged, or in glass, cans, metallized Download the complete
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film, foil packaging, or cartons; and
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Is Excess Capacity Dragging
Down the Performance of
Your Compressed Air System?
By Kaeser Compressors
I
t is rare for compressed air consumption alarms, nor do they want to re-revisit com-
to be consistent, so it makes sense for pressed air system design every few years as
air systems to be sized so that the total they grow. So, they purchase as big as their
capacity meets peak demand. The problem budget allows at the outset.
is that most systems have far more capacity
than needed. Overly conservative consulting engineers
may add to the problem by assuming that
Kaeser Compressors has performed more all pneumatic equipment will operate fully
than 10,000 air system audits in the United loaded all the time. They may even add a
States, and we have found that, on average, safety factor on top of that. In nearly all
users operate at only 44% of total capacity. cases, there’s fudge factor on top of fudge
Despite a concerted effort by compressed factor, with all stakeholders believing that
air professionals to educate users about the they are acting in the interest of ensuring
negative impacts of oversizing on operations compressed air availability, without under-
and the bottom line, gross oversizing remains standing the negative impacts on energy
common practice. consumption, maintenance costs and long-
term reliability.
How does this happen? In many cases, users
select compressors based on the compres- IMPACT OF OVERSIZING ON
sor(s) that they already have, adjusted with ENERGY USE
some prognostication about expected busi- Compressed air efficiency is best measured
ness growth. Generally, little measurement in terms of specific power, which is most
and analysis goes into it. often expressed in kW/100cfm. Specific
power increases as compressors operate
Also, most operators are inclined to up-size further away from their full output capacity.
for peace of mind. They don’t want to hear To be clear, higher specific power means
complaints of equipment with low pressure higher power consumption and lower
eHANDBOOK: Food Safety and Regulatory Issues for 2021 12www.FoodProcessing.com
Compressor Control Impact Across Full Operating Range
efficiency. In fact, a specific 70
Customer B 65.54 kW/100 cfm
power measurement of 65
60 Customer A 66.28 kW/100 cfm
25 kW/100cfm is a good Modulation
55
Variable Capacity
target; 20 kW/100cfm is
Specific Power (kW/100 cfm)
50 Dual Control (1 gal/cfm)
Dual Control (5 gal/cfm)
considered excellent. 45 Variable Speed
Customer A
40 Customer B
35 Customer C
The Compressed Air and
30
Gas Institute (CAGI) has 25 Customer C 17.65 kW/100 cfm
an excellent program that 20
encourages compres- 15
0 10 20 30 40 50 60 70 80 90 100
% of System Capacity
sor makers to publish the
Figure 1. Efficiency curves for common compressor control types.
specific power for each
compressor. This tool is a
great way to compare two are grossly oversized. 50 hp screw compressor,
compressors side by side, Let’s look at some actual a 285 cfm refrigerated
but it cannot be used to pre- examples of oversized sys- dryer, and a 400 gallon
dict what the user’s actual tems and the inefficiencies receiver tank. The peak
system performance will be. that resulted. demand measured was 65
As the car makers say: “your • Example A. For this green- cfm and the average flow
mileage may vary.” field plant, the company was 22 cfm, so the 236
specified dual 125 hp cfm compressor was far
So much depends on how compressors, two 230 over-sized for the current
the compressors are run. cfm refrigerated dryers, demand. The calculated
The CAGI data sheets 1,000 gallons of storage, system specific power
for fixed speed machines an air main charging valve, was also sky high, at just
assume 100% load, which and a master system con- under 66 kW/100 cfm. The
rarely happens in practice. troller. The system was company would be much
Whether a single machine grossly oversized and their better off with a pair of 10
or multi-compressor system, specific power was over hp compressors.
under-utilized compres- 66kW/100cfm (more than • Example C. This facility
sors do not operate at three times as large as the currently operates with
their datasheet perfor- 20 kW/100cfm target). three 200 hp compressors,
mance specification. Their needs could be met three 1,000 cfm ...
with a pair of 15 hp units.
From our many system stud- • Example B. The facility Read the complete
story here.
ies, we know that systems currently operates with a
eHANDBOOK: Food Safety and Regulatory Issues for 2021 13HYGIENIC DESIGN FOR
YOUR WHOLE LINE
Rittal hygienic design enclosures are engineered to keep you running at peak efficiency while
reducing cleaning time and chemical use.
V Sloped tops that stand up to frequent washdowns
V A smooth surface grain with no pores
V No gaps between the enclosure and the door
V Hinges mounted inside the sealed zone
V An integrated, non-detachable rear panel
V Rittal’s signature, easily distinguishable blue gasket
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Hygienic Design Enclosures
Offer Superior Cleanability
By Rittal
L
ike many industries, the North design principles to provide maximum flex-
American food and beverage indus- ibility, modularity, scalability and reliability.
try is changing rapidly. Whether Rittal enclosure, climate control, power
you brew beer, make wine, bake cakes, or distribution and IT solutions incorporate
process dairy or meat products, the chal- these principles, offering food and bever-
lenges are often similar: labor, energy and age producers the ability to adapt quickly to
raw material costs are rising; competition evolving market dynamics, capture growth
and regulations are tightening; compa- opportunities, meet safety regulations and
nies are merging or acquiring each other. maximize profitability.
Once stable markets are splitting into
innumerable sub-segments and cross-seg- BEER/WINE/BEVERAGE/BOTTLING
ments with increasingly shorter product Beer
life cycles. Updated nutrition guidelines The North American beer segment of the
are leading consumers to demand newer/ industry is booming. With 4,144 breweries
better/healthier/safer food and bever- in the United States, output has nearly
age alternatives. quintupled over the last 10 years.
To keep pace with these trends, food and Both large breweries and smaller craft
beverage processors must recognize them breweries must respond quickly to
quickly and respond appropriately. That consumer demand for more variety and
requires the right production technology distribution. Production assets, including
(e.g., machines, control systems, motors, enclosures and other production IT
drives, sensors) and the network infrastruc- components, must be able to adapt
ture (e.g., data centers, servers, switches, to accommodate these trends. Asset
enclosures) to connect them to each other. reconfiguration, such as for switching from
packaging in bottles to cans, often must
This technology and infrastructure must happen in a narrow timeframe with limited
integrate Industry 4.0 tools and efficient delays, disruptions or capital investment.
eHANDBOOK: Food Safety and Regulatory Issues for 2021 15www.FoodProcessing.com
Although the risk of contamination is greatly raw/pressed juices, ready-to-drink tea/coffee,
minimized as a result of the raw ingredi- and non-dairy probiotics.
ents, end-product and by-products of the
beer-making process, breweries in general Bottling
still maintain very high standards of clean- Differentiation in the beverage industry
liness in their production facilities. Stainless isn’t limited to the products themselves. It
steel is often used for production equipment, also has dramatically impacted bottling and
including electrical enclosures, to prevent packaging. From size variations and multi-
corrosion from frequent washdowns. packs to non-traditional form factors (wine
in a can, anyone?) and situational designs,
Electrical enclosures also have sloped tops bottling and packaging innovations have
and sealed access points to prevent water or become the norm for beverage companies
cleaning agent infiltration that could result in looking for new ways to meet consumers’
electrical failure, unscheduled downtime and changing demands and entice them to buy.
expensive repairs.
Dairy
Wine Consumers demanding more natural food and
Like the beer industry, the North American beverage options is good news for the dairy
wine industry is experiencing significant year- industry, which has seen inconsistent growth
over-year growth, a proliferation of limited/ across the globe. These trends provide an
medium output operations (which represent opportunity for dairy producers to expand
99% of U.S. wineries), consolidation/acqui- production and distribution of previously or
sition among and by larger wineries, and declining product lines with higher fat content.
changing consumer tastes and preferences.
Meat processing
Other beverages The meat industry has experienced signifi-
Other segments of the beverage industry cant challenges over the last decade in the
include soda, bottled water, sports drinks, forms of disease/contamination, consumer
energy drinks, distilled spirits, fruit juices, tea, health fears, and changing consumer habits.
coffee, and hard cider. Regardless of bever- Still, global consumption of meat rose 2%
age type, these producers face the same core by volume in 2015, driven primarily by
market dynamic as beer and wine: rapidly leaner/healthier options such as poultry and
changing consumer preferences. In general, pork...
the change is away from sugary sodas and
juices to healthier, niche options. This includes Download the complete
Buyer’s Guide here.
plant-based waters, craft/artisan beverages,
eHANDBOOK: Food Safety and Regulatory Issues for 2021 16www.FoodProcessing.com
Protecting Your Customer
with Traditional and
Magnetic Strainers
By Sani-Matic
F
ood and beverage processing facili- and is carried along with the process, a
ties face many challenges in keeping shaving of metal that dislodges from pre-
their product safe for consumers. vious piping modifications, or other similar
One such challenge is keeping product free events that go unnoticed.
of unwanted contaminants or particulates
as the product is prepared, processed, and Enter the sanitary process strainer – a
ultimately packaged and sent to either fur- component that has been successfully
ther processing or the end user. helping capture these unwanted con-
taminants for many years. Easy to use,
How do foreign and unwanted particulates the strainer element captures the for-
sneak into the process? They can arrive in eign material so it can be removed from
various ways – sometimes coming into the the process before ending up in the
product from the ingredients themselves, final product.
such as from field produce or from a
water supply that has issues with the feed The general idea of any strainer is that it
piping. Operators can also inadvertently is capturing particulates – however, there
contaminate the process by dropping are many different strainer types and
something into any open processing area strainer element sizes and types for differ-
such as when ingredients are being added ent applications.
or the process is being checked on.
TEE-LINE STRAINER, ANGLE-LINE
In many cases the unwanted contaminants STRAINER, BASKET STRAINER
are a result of the production process Tee-Line strainers are often used
itself – a gasket or seal that breaks off for equipment protection (like in
eHANDBOOK: Food Safety and Regulatory Issues for 2021 18www.FoodProcessing.com
front of a pump) to help keep larger not be possible. In that case, a magnetic
debris from causing issues for strainer (which utilizes magnets enclosed
important process equipment. within a protective stainless-steel barrier
for process compatibility) can help cap-
Larger strainers like angle-line or basket ture these particulates.
strainers can strain larger volumes of
particulates and can also utilize a vari- Many of the traditional particulate strain-
ety of element types, such as perforated ers and the magnetic trap strainers are
or Wedge Wire elements, to strain out different components, installed indi-
certain sizes of particulates while allow- vidually within a process line. However,
ing for product to flow through. Often Sani-Matic’s new Magnetic Trap Strainer
times perforated elements utilize mesh is a 2-in-1 solution that combines the
overlays or filter tubes that slide over the magnetic trap with the process particu-
perforated element to strain to finer (i.e., late straining capabilities of an angle line
smaller) levels. strainer. This solution allows for a single
component installation into the process,
MAGNETIC TRAP STRAINERS making initial installation and cleaning
The strainers discussed so far are and maintenance easier by reducing the
straining particulates out of the process process line breaks needed.
based on a physical characteristic of
the particle – the size. However, another PROTECT YOUR PROCESS
type of strainer is a magnetic trap While it is smart to identify the risk
or magnetic strainer which captures of where foreign and unwanted
unwanted particulates from a process particulates could be introduced and
based on their magnetic characteristics. try to mitigate these risks, no process
is immune to these issues. It is best
Iron, carbon steel and sometimes hard- to plan for equipment and product
ened types of certain stainless steel have protection through the strategic use
varying levels of magnetism that can be of strainers of varying types and sizes
captured by these types of strainers. – doing so will keep your process
equipment and product safe...
Often times these magnetic particulates
are very small pieces or shavings, so
catching them with a traditional strainer Download the complete
white paper here.
used for larger particulate straining may
eHANDBOOK: Food Safety and Regulatory Issues for 2021 19You can also read
