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eHANDBOOK
Manufacturing
Equipment’s Role
in Food Safety
2020
www.FoodProcessing.com
TABLE OF CONTENTS
Safety First 3
Respondents to our annual manufacturing survey rate food safety their top priority for 2020
To Convey Mechanically or To Convey Pneumatically— That is the Question 7
Plant Equipment Safety 11
Ideal Solution for Plant Sanitation Hot Water 14
How X-Ray Inspection Helps Food Manufacturers Improve Safety,
Mitigate Risk, and Stay Compliant 16
AD INDEX
Vac-U-Max • www.vac-u-max.com 6
Alfa Laval • www.alfalaval.us 9
Mettler Toledo • www.mt.com 10
Pick Heaters • www.pickheaters.com 13
Anritsu • www.anritsu.com 15
eHANDBOOK: Food Safety: Plant Equipment 2
www.FoodProcessing.com
Safety First
Respondents to our annual manufacturing survey rate food safety their top
priority for 2020.
By Food Processing
W
HOW DOES YOUR COMPANY ACHIEVE BETTER
hen it comes to overall man- SANITATION AND FOOD SAFETY?
ufacturing priorities for 2020, Employee training 76%
food safety came out on top in Third-party certification 37%
HACCP plan 36%
Food Processing’s 19th annual Manufactur-
More/improved sanitary equipment 36%
ing Outlook Survey. Presented with a list of Improved sanitary design of equipment 30%
issues, food safety was ranked first by 22% Improved pest control 29%
Outside consulting services 22%
of respondents.
Rapid microbial detection system 21%
MOST FREQUENTLY OUTSOURCED
In a weighted method of scoring (respon- PLANT SERVICES
dents were asked to rank the issues from
2020 2019
first to 10th) food safety had a top score of Pest control 71% 68%
964, followed by “cost control” (876) and Microbial testing 44% 50%
Engineering services 38% 38%
“worker safety” (853).
Logistics management 22% 14%
Sanitation 20% 15%
Food safety may be getting this high pro- Maintenance 19% 21%
Training 15% 14%
file because of a surge in recalls and alerts.
Year-long statistics for 2019 were not avail- in the food supply. “If companies think that
able at press time, but recalls have been on the FDA and the USDA are looking over their
a long-term uptick. Overall recalls rose 10% shoulder, they’re going to do a better job,”
from 2013 to 2018, and Class I recalls, the Jaydee Hanson, policy director at the Center
most serious, for meat and poultry rose 83% for Food Safety, told Time magazine.
in that period, according to the Public Interest
Research Group. Asked what they’re doing to improve sani-
tation and food safety, the overwhelmingly
That could, however, reflect increased vig- most popular answer in our survey, at 76%,
ilance, by both the government and food was “employee training.” The next choices
processors, rather than any increased danger (multiple responses were permitted) were:
eHANDBOOK: Food Safety: Plant Equipment 3
www.FoodProcessing.com
“third-party certification,” at 37%; “HACCP down as 30% saying they expect an increase
plan,” 36%; and “more/improved sanitary in production of 10-19%; almost as many, 28%,
equipment,” 36%. saying they expect to see a modest increase
of 2-9%; and another 19% saying they expect
Those respondents who offered further com- production to go up more than 20%.
ments mostly indicated that when it comes to
product safety, they were already doing what Much of that production increase presum-
they need to do. As one put it: “Already there, ably will come from increased efficiencies or
just [need] increased QC and vigilance and get longer hours on existing lines. Only a bare
our suppliers more involved in all areas to help majority of 54% said they anticipate open-
us [see] what we are missing to be perfect.” ing new plants or adding new lines; 29% said
facilities will stay the same, and another 8%
Food manufacturing professionals are opti- anticipate closing plants or lines in 2020.
mistic heading into 2020, and a strong
majority of them say their companies plan NEVERTHELESS, MORE CAPEX?
FACILITY STAFFING PLANS
to increase production. Asked how they feel Generally
going int
going into this year, 44% described them- Predictions of capital expenditures follow
selves as “somewhat optimistic,” and another roughly the same pattern, with a plurality of
29% as “very optimistic.” Only 10% described 44% saying that at their companies, capex
themselves as even “a little pessimistic,” with will go up. The largest segment, 19%, say
no one going any further. they’ll go up more than 10%, with another 13%
saying spending will grow 5-10%, and 12%
As for production plans, a whopping 77% said saying it’ll be less than 5%. By contrast, only
they foresee some degree of increase. It broke 3% said they expect capital expenditures to
FACILITY STAFFING PLANS In terms of production
Generally, how do you feel Generally, how do for
you2020
feel
IN TERMS OF PRODUCTION FOR
going into 2020? is your whole
going company
into 2020? planning
2020, IS YOUR WHOLE COMPANY
to: MA
GENERALLY, HOW DO YOU FEEL IN TERMS OF STAFFING, DOES
GOING INTO 2020? YOUR FACILITY PLAN TO: PLANNING TO:
4% 8%
10% 7% 9%
18% 2%
44% 51% 54%
35%
29%
29%
Somewhat optimistic 44% Add to the workforce 51% Expand production by opening or
adding lines or plants 54%
Very optimistic 29% Maintain staffing level 35%
20 In terms ofreduce
Passively production for 2020
workforce through attrition 7%
Stay the same 29%
Neutral/I’m not sure 18%
ning to: is your whole company planning to:2% Consolidate production by merging
MANUFACTURING PRIORITIES CAPIT
A littleMANUFACTURING PRIORITIES CAPITAL SPENDING BUDGET
Actively reduce workforce or closing lines or plants 8%
pessimistic 10%
Don’t know 4%
Don’t know 9%
eHANDBOOK: Food Safety: Plant Equipment 4
www.FoodProcessing.com
HOW COMPANIES ARE ADOPTING DIGITAL
TECHNOLOGY difficult. But automation came in at fifth
Replacing paper records with electronic 54%
place in our survey’s list of priorities.
Replacing analog devices with digital 43%
Providing more remote access to
machine controls
31% Phil Kafarakis, president of the Specialty Food
Shifting from local servers to cloud 30% Assn. (www.specialtyfood.com), suggests that
No action/wait and see 26%
part of the explanation may be that automa-
WHAT ARE THE PRIORITIES OF YOUR tion often is not compatible with the flexibility
TRADE CUSTOMERS?
in production that many processors require.
More stringent quality assurances 53%
Better product tracing 43%
Tighter delivery windows 39%
“There will continue to be a need to invest
Lower prices 38% in automation of manufacturing processes,”
Customized case/pallet loads 29%
Kafarakis says. “However, faster is not going
Share our records/allow access to our facilities 23%
to be better, nor will it be more efficient as
be down by any degree. “About the same” as it relates to margin management and higher
last year’s budget came in at 23%. volumes/output. Flexibility to produce zero
defect products that are unique and maybe
Process equipment will be the most fre- modified within the manufacturing process
quent spending target. In a weighted vote will be the focus of food manufacturers.”
among a list of alternatives, process equip-
ment edged out packaging equipment, with That sentiment was echoed by one of our
control systems coming in third. respondents, who works for a seafood
company: “Automation to replace labor [is
Automation is an area that might logically a priority], but [we] have not found many
be of interest to food processors, solution opportunities in our specific fish
especially during a sustained period of processing.”
low unemployment in an industry where
worker recruitment has been notoriously With increased automation comes increased
complexity, especially for floor workers. As
Kafarakis says: “More critically important will
WHO ANSWERED THE SURVEY be the talent required to operate sophisti-
Our 19th annual Manufacturing Outlook Survey, cated machinery.”
conducted online in late 2019, garnered 144 responses
from food and beverage industry professionals. In
terms of what is manufactured, the most common
categories were meat/poultry/seafood, at 15%;
further-processed foods, at 11% percent; and fruits and
vegetables, at 7%. In number of employees, the most
frequent range was 101 to 500, at 32%, followed by 51 Read the complete story on
to 100 at 18%.
FoodProcessing.com.
eHANDBOOK: Food Safety: Plant Equipment 5
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www.FoodProcessing.com
To Convey Mechanically or
To Convey Pneumatically—
That is the Question.
When mechanical conveying outshines transferring bulk dry materials;
and, when it falls flat.
By Vac -U-Max
W
hile pneumatic conveying manufacturers typically combine off the
is by far the most hygienic shelf components to design custom or
conveying method for bulk semi-custom systems that integrate seam-
dry powders, there are instances where lessly into a customer’s process.
mechanical conveying may be a better
choice: facilities with nominal head room The advantage of a mechanical conveyor
above equipment; a need for high speed over pneumatic is the ability to move large
transfer with minimal energy consumption; amounts of material with minimal energy
and transferring friable materials. consumption. In mechanical systems, there
is only a motor driving the system. Oppos-
The main differentiator between mechan- ingly, a pneumatic system requires a motor
ical and pneumatic is that mechanical and air to move the material. Due to the
conveying — including conveyor belts, additional power components needed in a
slip stick, aero mechanical, flexible screw, pneumatic conveying system, and the lack
and bucket elevators — use a mechanical of a dust filtration system, the dollar-to-dol-
device that is in direct contact with trans- lar comparison makes the mechanical
ferred material. Pneumatic conveying uses system less expensive to operate.
gas (usually air) to transfer suspended
material through tubes. Additionally, control panels on a mechani-
cal conveyor are about as simple as it gets,
Because every materials transfer system requiring minimal integration. Unless a com-
has unique characteristics and each orga- pany is working with a level controller or
nization aims to accomplish distinctive load cell, most of the time the control panel
objectives, no standard equipment is suit- is just a fancy motor starter, reducing ini-
able for all applications. Expert conveyor tial cost.
eHANDBOOK: Food Safety: Plant Equipment 7
www.FoodProcessing.com
In a pneumatic conveyor system, the control
panel includes a programmable logic con-
troller (PLC) or programmable relay, which
dictates the sequence of events that are to
occur, can handle complex information, and
provides customers the ability to download
data for evaluation.
Aero-mechanical conveyors are regularly
used as an alternative to pneumatic convey-
ing using two parallel tubes with a sprocket
on each end, and a drive motor on one end.
Inside the tube is a cable with discs on it,
often called a cable assembly. As the cable
assembly moves, it displaces air and mate-
rial, thus fluidizing the material, and carries it
in suspension along the conveyor. Flexible screw conveyors move less mate-
rial than aero-mechanical conveyors, but
Aero-mechanical conveyors move material they operate continuously, unlike the
at approximately 20 ft (0.6 m ) per minute
3 3
aero mechanical. A common use for aero
with a 3HP (2.25kW) motor, contingent mechanical systems is batch processing;
on material bulk density. depending on and, a flexible screw is ideal for continuous,
the design of the conveyor, the cost of a batch, or intermittent processing. Both can
mechanical conveyor vs. a pneumatic con- convey 2000 lbs of material into a mixer in
veyor for the same output can be one third 10 minutes, however, the flexible screw con-
the cost. veyor can operate continuously.
Flexible screws, also known as shaftless Aeromechanical conveyors require a
augers, helixes or spiral conveyors, are used metered infeed and they must start-up and
similarly to aero-mechanical conveyors. Flex- finish without material in the tubes. Flexible
ible screw conveyors, however, utilize only screws can be started and stopped with a
one tube and instead of a cable assembly, headload of material at the feed end.
they contain a metal spiral that rotates. The
spirals look like a stretched slinky or spring, Download the complete
white paper here.
having the same diameter from end to end.
eHANDBOOK: Food Safety: Plant Equipment 8
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Plant Equipment Safety
By Mettler Toledo
X
-ray inspection is used worldwide are right to be wary of radiation, it does
to ensure food safety and provide not mean they should be worried about
quality assurance. Despite this, using X-rays for food inspection.
some food manufacturers still have reserva-
tions about adopting X-ray inspection. This The paper begins by explaining why food
white paper refutes some of the common manufacturers use X-rays to inspect food,
myths about this increasingly popular before exploring what radiation is and
method of food inspection and delivers looking at the health and safety aspects
some astonishing facts. of radiation. To help readers understand
radiation levels, the white paper compares
INTRODUCTION dose rates from some natural and artificial
X-ray inspection has become increasingly sources of radiation that we are exposed
popular as food manufacturers worldwide to in day-to-day life. Finally, it discusses
strive to protect consumers’ welfare, how modern X-ray systems are designed
safeguard their brand reputations and to protect users from the effects of
comply with national and international radiation, and concludes that a factory
regulations and legislation, as well as containing correctly-maintained and
standards set by retailers. However, some well-managed X-ray equipment is just
manufacturers still have reservations about as safe as any other properly-controlled
adopting X-ray inspection as a method of and monitored working environment.
product inspection. They are concerned
their staff will object to bringing X-rays WHY USE X-RAYS TO INSPECT FOOD?
into the workplace and that consumers Food manufacturers use X-ray inspection
could switch to a brand that has not technology to ensure product safety
been subjected to X-ray inspection. This and quality. X-ray inspection gives them
white paper shows that although people exceptional levels of metal detection
eHANDBOOK: Food Safety: Plant Equipment 11www.FoodProcessing.com
for ferrous metal, non-ferrous metal, The spectrum runs from long-wave radio
and stainless-steel. The technology is at one end to gamma rays at the other.
also extremely good at detecting other Most parts of the electromagnetic spectrum
physical contaminants such as glass, are used in science for spectroscopic and
mineral stone, calcified bone and high- other probing procedures, in which matter
density plastics and rubber compounds. can be studied and characterized through
the use of radiation. X-rays are used for
In addition, X-ray systems can many purposes, from medical examinations
simultaneously perform a wide range of to the identification of contaminants
in-line quality checks such as measuring in foodstuffs and other materials.
mass, counting components, identifying
missing or broken products, monitoring The wavelength of X-rays enables them to
fill levels, measuring head space, pass through materials that block out visible
inspecting seal integrity, and checking light to a greater or lesser degree. The trans-
for damaged product and packaging. parency of a material to X-rays is broadly
related to its density, which is why X-ray
WHAT IS RADIATION? inspection is so useful in the food industry:
Energy from a given source is generally the denser the material, the fewer X-rays can
referred to as ‘radiation,’ and different pass through. Hidden contaminants, such
forms of radiation have been harnessed as glass and metal, show up under X-ray
by science for use in many different inspection because they reflect more X-rays
types of equipment that we often than the surrounding food.
take for granted in everyday life.
X-rays used in food inspection systems
Two main sources of radiation exist: natural should not be associated with radioactive
and man-made. Examples of natural materials such as uranium. Radioactive mate-
radiation include natural heat or light from rials are physical sources of radiation, and
the sun, radiation from the ground and they emit radiation in the form of alpha parti-
gamma rays from radioactive elements. cles, beta particles and gamma rays. They do
Examples of man-made radiation include so continuously, which is why they cannot be
microwaves from an oven and X-rays from switched off. The only way to contain radia-
an X-ray tube. X-rays are invisible as they are tion from a radioactive material is to encase it
a form of electromagnetic radiation, like light in a substance that absorbs radiation.
or radio waves. All types of electromagnetic
radiation are part of a single continuum Download the complete
white paper here.
known as the electromagnetic spectrum.
eHANDBOOK: Food Safety: Plant Equipment 12How Effective Is Your
Hot Water Temperature?
The Pick Variable Flow Direct Steam Injection
Heater is the answer for critical plant sanitation.
Its unique design provides hot water at a precisely controlled
temperature over a wide operating range. Only Pick can
accommodate wide variations in water flows and frequent
start-stop applications such as hose stations and still deliver
accurately controlled hot water on demand. Where medium to Perceived
high steam pressure is available, it is ideal for a central
heatingg system
y y
for all your p
plant sanitation and clean-up hot Clean
water needs.
vs.
Clean
®
www.pickheaters.com • 262-338-1191 • info1@pickheaters.comwww.FoodProcessing.com
Ideal Solution for Plant
Sanitation Hot Water
By Pick Heaters
W
here medium- to high-pres- Flow Heater is widely used for multiple hose
sure steam is available, the stations, plant sanitation, filter washing, CIP,
Pick Variable Flow Heater COP, and many other applications.
serves as a central water heating system
for multiple use points, supplying instanta-
neous hot water during both peak and low
demand. Ideal for multiple hose stations, it
is the only Steam Injection Heater capable
of keeping pace with rapid and wide vari-
ations in water flow to maintain a steady
outlet temperature.
The Pick Heater transfers all available
steam energy into the liquid, significantly Pick Variable Flow Heater
reducing water-heating costs up to 28%
when compared to Indirect Shell & Tube
or Plate Heat Exchangers. Additionally, the ABOUT PICK HEATERS INC.
unit is safe and compact, no operator use- In 1945, Pick Heaters developed and
point adjustments are required. patented a unique concept of Direct
Steam Injection Heating. Pick has
All this combined with an unlimited supply made a continuous flow of refinements
of hot water, low sound level (typically and innovation for over 70 years in
below 85dBA), and low water pressure drop various processing industries.
(less than 2 PSI), and no minimum straight
piping before or after the heater required For information: www.pickheaters.com or
makes Pick Heaters the right choice for your contact: info1@pickheaters.com; phone:
plant hot water needs. The Pick Variable 262-338-1191
eHANDBOOK: Food Safety: Plant Equipment 14WE INSPECT TO
HIGHER STANDARDS...
YOUR CUSTOMERS’.
Your customers have more on the line
XR75 than dinner...that’s why we built the XR75
X-RAY
INSPECTION
X-Ray. It protects consumers by detecting
SYSTEM the smallest contaminants in the industry, while
advancing product quality and overall food safety.
Learn more about the industry’s most precise and
reliable inspection detection equipment with unmatched
performance and low cost of ownership at anritsu.com/infivis.www.FoodProcessing.com
How X-Ray Inspection
Helps Food Manufacturers
Improve Safety, Mitigate
Risk and Stay Compliant
By Anritsu Infivis, Inc.
I
n early 2019, the United States Food challenging and very expensive, capable of
and Drug Administration (FDA) updated significantly hindering a food company’s
several components of its food safety resources and growth strategy.
guidelines via the Food Safety Modern-
ization Act (FSMA). A critical aspect of Given these circumstances, ANRITSU is
FSMA — one that is garnering significant currently advising its food manufacturing
attention from food manufacturers — is clients to enhance and possibly replace
its stringent inspection and recall thresh- their traditional metal detection-based
old. Manufacturers that receive more than inspection devices with devices based on
two customer complaints are instructed to newer X-ray technology. By widening the
conduct robust, self-administered inves- proverbial “lens” on detectable contami-
tigations and issue wide-scale recalls, nants — including both contaminant types
as necessary. and particle sizes — X-ray inspection helps
manufacturers proactively address com-
In the past, investigations like these were pliance and safety concerns in the face of
“triggered” by the detection of large and/or these new government policies.
problematic contaminants discovered during
analysis, setting a clear and predictable UPDATED GUIDELINES CREATE
standard for manufacturers. By describing UNCERTAINTY AND RISK
applicable customer complaints and recom- The 2019 FSIS Guideline for Industry
mended remedial steps in a general fashion, Response to Customer Complaints notes
however, the new policy creates substan- that “…when an establishment [i.e., food
tial uncertainty and risk for manufacturers. manufacturer] determines that a customer
Unexpected inspections and recalls are very complaint represents adulterated or
eHANDBOOK: Food Safety: Plant Equipment 16www.FoodProcessing.com
misbranded product that has entered The phrasing of key provisions in this section
commerce [,] the establishment should establish that this updated policy is decid-
respond by performing an investigation, edly structured as a guideline instead of a
notifying FSIS, and taking corrective mandate, incorporating terms like “should”
actions.” [1] These corrective actions, as and “may.” While guidelines offer manufac-
detailed in the subsequent Establishment turers more operational flexibility, they also
Response Plan and Investigation create potential legal liability. Food manufac-
section, are described accordingly: turers are faced with uncertainty regarding
inspection and documentation best prac-
“The establishment should quickly iden- tices, as well as the concern that if they take
tify any affected product (e.g., lot, date, “incorrect” measures to address customer
line, etc.) and identify distribution of the complaints, the government may hold them
affected product. Drafting and maintaining liable after the fact.
a written response plan is the recom-
mended best practice. The response plan Given the uncertainty and risk posed by
should include an investigation of the these recent guideline updates, it is crucial
production that incorporates a review of to proactively mitigate risk by upgrading
relevant records generated during the your detection capability to find the small-
production of the affected product and est size foreign contaminants as possible.
may include performing a visual inspec- This is where X-ray inspection offers man-
tion of any questionable product or labels ufacturers major technical advantages,
available, observing ongoing operations/ making it a worthwhile investment — espe-
production of like product, and talking cially for large manufacturers producing at
to employees who may have information a national or global scale.
pertinent to the investigation. Affected
product that has not been shipped should THE TECHNICAL ADVANTAGES OF
be held and inspected prior to shipping to X-RAY FOOD INSPECTION
determine if there are additional instances Although X-ray technology is more
of adulteration or misbranding. The estab- expensive than traditional metal detector-
lishment should use additional information based solutions, it is more reliable, robust,
to evaluate the design and implementation and capable in detecting contaminants
of the HACCP system including laboratory compared to traditional metal detectors.
sampling results, the intended use of the
product, supporting documentation, and Download the complete
white paper here.
expert analyses.” [1]
eHANDBOOK: Food Safety: Plant Equipment 17You can also read
