The National Provisioner December 2011

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22 COVER STORY

Healthy foundation JTM Food Group plans to grow across foodservice, chain-restaurant and retail channels.

10 | Regulations & Legislation: Role of processors in consumer education 12 | Fight for Food Safety: Turning the ‘phage’ to a new chapter

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Food safety episode

Read Us Online

NSF International’s Tom Chestnut discusses the Food Safety Modernization Act during Process Expo 2011.

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Departments New Products.................. 14 Ingredients ...................... 16 IPE Booth Profiles........... 52 Tech Showcase................ 56 Classifieds ....................... 62 Ad Index.......................... 70

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Leading the food industry in processing and packaging solutions.

December 2011

Tech

Volume 225 Issue 12

Editorial Board

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

CONTRIBUTING THIS MONTH H. Russell Cross Texas A&M University Dan Emery Meaningful Solutions

FOOD SAFETY | 34

John E. Johnson

Focus on antimicrobial agents

JBS

Processors are using antimicrobials to keep pathogens at bay, and several experts chime in on the effectiveness of these interventions.

Leigh Ann Johnston Tyson Foods

PACKAGING TECH 50 | Chip Bolton takes a look at the ol’ reliable chub package. PROCESSING TECH

PROCESSING TECH

42 | Video auditing has become a powerful tool for

46 | Smarter cutting

slaughter operations across the industry.

and deboning.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Kurt Vogel University of Wisconsin - River Falls

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editorial

Editor-In-Chief > Andy Hanacek [email protected] Editor > Sam Gazdziak This month’s contributors > Donna Berry, Chip Bolton, Elizabeth Fuhrman, Jessica Evans, Barbara J. Masters, Megan Pellegrini, Shawn Stevens Art Director > Mary Ann Lawrence

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Food Safety Summit

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Regulations&Legislation

Role of processors in consumer education By Barbara J. Masters

n a recent study by Phang and Bruhn (Journal of Food Protection, 2011) only 4% of volunteers used a meat thermometer for checking burger doneness; only 13% knew the recommended internal temperature for ground beef; and the average hand-washing time for the volunteers was 8 seconds. Likewise, according to the 2011 International Food Information Council (IFIC) Foundation Food and Health Survey, “although 8 in 10 Americans report following general and basic safe food handling practices, the numbers continue to decline, for example with washing hands with soap and water before handling food (79% in 2011; 89% in 2010; 92% in 2008).”

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Such studies suggest that consumer education needs to be incorporated into a processor’s food-safety efforts. Food processors need to augment the work that government agencies, meat and poultry trade associations, consumer advocate organizations, and university extension agencies are doing to educate consumers regarding the safe handling of products, especially raw products. Simple steps, such as hand-washing, preventing crosscontamination during preparation, proper cooking using a meat thermometer and prompt chilling of leftovers, are additional steps for consumers to utilize that can maintain food safety that was delivered at the processing establishment. Larger meat and poultry companies may have information on their Web site or a company spokesperson to assist with food-safety education. However, it is unclear how many companies contribute information on this aspect of food safety. Simple steps can be taken by establishments of all sizes to incorporate food-safety education as a component of their food-safety system. For example, establishments can take advantage of the recent efforts of the Food Safety and Inspection Service (FSIS) in presenting a new Ad Council Campaign on Food Safety Education. The materials are available at: http://foodsafety.adcouncil.org/. The Ad Council Campaign materials include a toolkit that provides information on how to share the public service announcements included in the campaign with local public service directors. There are also suggestions regarding how to get the materials included on the local radio station or in the local newspaper. The Ad Council Campaign materials also include downloads for outreach e-mails, banners for your Web site, and even ideas for food-safety programs that can be conducted at local schools.

10

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Consumer education does not replace the responsibility of producing safe food at the establishment. Further, there are clearly many entities with a primary responsibility for educating consumers. However, data suggests there is more work to do, and in fact the challenge is getting greater in reaching the consumers. Producing food safety is priority one; consumer education can and should be a complementary role for food processors.

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FightforFood Safety

Turning the ‘phage’ to a new chapter in food safety By Shawn K. Stevens

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n matters of food safety, it is most often what you cannot see that poses the greatest threat to the safety of food. Indeed, invisible pathogenic organisms are the greatest threat to the food industry’s collective well-being. These organisms, though virtually ubiquitous in nature, can be devastating to consumers and businesses alike if even small amounts find their way into our foods.

In light of the risks, the industry devotes enormous resources to ensuring that our food is as safe as it can be. For decades, science and industry have successfully developed new technologies to further mitigate the chances of pathogens contaminating the foods that we eat. In the 1960s, Pillsbury began working with NASA to develop the Hazard Analysis and Critical Control Point (“HACCP”) methodology. HACCP was critically important for NASA to ensure that the meals its astronauts were taking into space would be as safe as possible. HAACP soon became a staple of the American meat industry and, with the recent enactment of the Food Safety Modernization Act, will soon be implemented by nearly all companies in the food industry. One of the most promising emerging food-safety technologies is a post-packaging pasteurization technique known as high-pressure pasteurization (HPP). HPP can be used for a wide variety of perishable foods, and it works by uniformly applying nearly 90,000 pounds-per-squareinch of hydrostatic pressure to prepackaged foods for up to three minutes. The application of high pressure to the product inactivates both spoilage microorganisms and harmful pathogens without affecting the quality of treated food. There are many additional areas in which technology, bioscience and innovation are blending to improve foodsafety capabilities. Bacteriophages (phages) have been

12

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

studied for more than a century. The potential applications of these organisms have, until recently, been poorly understood. They are, in essence, viruses that attack different types of bacteria. Phages may be designed to attack a particular type of foodborne pathogen, rendering the food safe. Whether we’re talking about improved processing equipment, better antimicrobial interventions or more robust pathogen testing, advances in food-safety science and technology have reduced and will continue to reduce the annual number of foodborne Illnesses in the United States. Challenges will continue to emerge, and there will continue to be outbreaks. That is the simple, unfortunate nature of the world we live in. I have absolutely no doubt, however, that the tireless work of so many will overcome whatever challenges we may face, and that the safety of our food supply will continue to improve as we move on through the chapters. 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.

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NewProducts Jack Link’s, Cholula Hot Sauce team up on beef jerky variety

Sadler’s introduces ‘Texas Barbeque’ product line

Jack Link’s® Beef Jerky has brought hot news to the meat snacks category with Jack Link’s Cholula Hot Sauce Beef Jerky. The combination of Jack Link’s Beef Jerky with Cholula® Hot Sauce promises to deliver the perfect blend of savory beef, with Áavor and heat, all in a convenient, graband-go package. Jack Link’s new jerky combines tender slices of 100 percent beef, signature seasonings and Cholula’s special blend of peppers for a Áavorful, satisfying, betterfor-you snacking experience. Conveniently packaged in 3.25-ounce resealable packages, Jack Link’s Cholula Hot Sauce Beef Jerky is available in a variety of display options including open stock cases, clip strips and Áoor shippers.

Sadler’s Smokehouse announces its new Texas Barbeque line, featuring Àve authentic, readyto-eat beef, chicken and pork dishes with gluten-free barbecue sauces, available in select grocery stores nationwide. Created deep in the heart of Texas, the new line features Chopped Beef Brisket and Sliced Beef Brisket, both pitsmoked over hickory and other natural hardwoods and served with Sadler’s own Smoky Sweet Barbeque Sauce. Tender Pulled Chicken is slow cooked and complemented with a Spicy Chipotle Barbeque Sauce. Sadler’s Original Bold Barbeque Sauce provides classic Texas taste to Boneless Country Style Pork Ribs and pitsmoked Pulled Pork.

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14

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Creta Farms offers line of ‘better for you’ sausages Already well-established in European grocers and delicatessens, Creta Farms is introducing a product line that delivers “better-for-you” sausage without the off Áavors associated with some “better-for-you” products. Available in three delicious varieties, including Beef Smoked, Smoked and Cheese Smoked, Creta Farms Sausages are made with only the Ànest ingredients, including selected cuts of pork and beef and cheddar. By removing a portion of the animal fat and replacing it with Extra Virgin Olive Oil (EVOO), Creta Farms Sausages have up to 24 percent fewer calories and up to 53 percent less saturated fat than similar products. www.cretafarms.com

GNP Co. launches all-natural frozen chicken line GNP Co. has announced the launch of a new frozen chicken product line. With the Áavor of fresh chicken and the versatility of frozen, Gold’n Plump® new premium frozen chicken is packaged in a box, giving retail customers an attractive freezer display and added convenience for consumers. The new line offers All Natural™, hand-trimmed Boneless Skinless Chicken Thighs (4-pack), All Natural™ Chicken Breast Fillets (4- and 8-packs), and Premium 90/10 Ground Chicken chubs (2-pack). Cartons contain individually vacuum-packed servings, so consumers can use just what they need as well as minimize freezer burn. The pouch packaging reduces the need to touch chicken while opening, and gets rid of soaker pads, foam trays and sticky overwrap. www.goldnplump.com

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DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

15

Ingredients&Formulations

BATTLE

LINES DRAWN By Donna Berry

any of us wish it would go away, but salt and sodium continue to be hot buttons among most food industry authorities. This past month, food processors took a sigh of relief upon learning that a new congressional spending bill would modify the requirements for school lunches that the U.S. Department of Agriculture set earlier this year. The bill also requires further study on USDA’s long-term sodium-reduction guidelines for school lunches. Both the House and the Senate are expected to vote on the bill soon. If passed, this means that center-of-plate protein processors can slow down their efforts to (drastically) lower the sodium content of products intended for the National School Lunch Program, as sodium reductions are not going to be as extreme as many feared they would be for the very near future.

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This bill was welcome news to the Salt Institute, Alexandria, Va., a trade association that promotes responsible uses of salt, particularly for roadway safety, nutrition and water quality. For years, the Salt Institute has taken the position that low-sodium diets trigger a negative chain reaction in the body that increases the risk of diabetes, stroke, heart attack and heart disease. This opinion was most recently supported by a meta-

16

analysis published in the American Journal of Hypertension (published online Nov. 9, 2011). And mid-year, Scientific American (July 8, 2011) published an in-depth article entitled “It’s Time to End the War on Salt,” which further confirmed that there’s not enough science to support government regulations forcing reductions in sodium. The article explained there is plenty of science to show that the body can fail when it does

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

17

Ingredients&Formulations For years, the Salt Institute has taken the position that low-sodium diets trigger a negative chain reaction in the body that increases the risk of diabetes, stroke, heart attack and heart disease.

New SuperBind ™ HB-CT Superior Binding For Lower Sodium Meat & Poultry Products

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

not have enough sodium, an essential mineral that is a component of sodium chloride, the chemical name for salt. Salt Institute president Lori Roman says the problem goes beyond school cafeterias to the U.S. Dietary Guidelines on sodium, which aim to put virtually all Americans, not just schoolchildren, on a diet so low in salt it has never been seen in any country. “We should not subject our schoolchildren or any of our citizens to what amounts to a giant lab experiment,” says Roman. “There are negative health consequences of a low-salt diet. For many children, a school lunch is their main meal of the day. They simply need salt, an essential nutrient recent medical studies associate with longer life, less heart disease and lower cholesterol, among other health benefits.” But again, as I started out, the trend towards lowering sodium contents of foods is not going away, so this should remain a priority in your innovations lab. Here’s something to remember: Reducing sodium in center-of-plate of proteins requires more than replacing the taste of salt, as salt also impacts other flavors, texture and function, as well as influences moisture retention, preservation, shelf life and safety. In order to reduce sodium contents, it is critical to identify the right ingredient combination that delivers taste without any product sacrifice. Seldom is a simple reduction or replacement possible. Other ingredients must almost always be considered. Many animal-based proteins naturally contain 50 to 70 milligrams of sodium per 100 grams. So, in order to manage sodium levels in the final product, it is important to consider sources of added sodium. This includes, of course, salt, but also functional ingredients such as phosphates and lactates, which are necessary additives for ensuring the quality of many proteins. One concept to consider is including more umami-providing ingredients. What is umami? Umami is best described as a pleasant savory taste imparted by the amino acid glutamate, and a number of ribonucleotides, including inosinate and guanylate. These com-

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19

Ingredients&Formulations pounds occur naturally in an array of foods including meat, fish, select vegetables and certain cheeses. Umami is also recognized as a flavor enhancer. Its mode of action is different than sodium, but it can help trick the taste buds to thinking “salty.” To better understand how umami enhances flavor, try this little experiment suggested by Tokyo-based Umami Information Center. Rinse your mouth with water, then chew a cherry tomato 30 times and swallow. The subtle, pleasant taste that lingers in the mouth is umami, as tomatoes are a naturally rich source of glutamate. This lingering taste is often described as “deliciousness” and compensates for a reduction in sodium. One way to add umami to proteins is to formulate with yeast extracts, which not only provide the umami taste sensation, but also enhance the protein’s mouthfeel and body.Yeast extract can enhance the product’s taste, providing for faster, stronger and longer-lasting taste impressions, which allows for a reduction in sodium. Appropriate applications include formed meat products such as burgers and patties, where the yeast extract builds on the protein’s natural fla-

vors, as well as all types of ham. Here the yeast extract strengthens the smoky and salty notes, prolonging the aftertaste. When it comes to reducing sodium in brines and marinades, an option is to substitute some or all of the sodium phosphates with potassium phosphates, as the latter work synergistically with added salt. There are now a number of highly soluble potassium phosphate ingredients in the market that deliver the combined synergies while at the same time reduce the sodium quantity. Because there is a slight bitterness associated with potassium, flavorings and seasonings often must be added to mask such off notes. Another option is to introduce the mineral magnesium along with potassium. Magnesium has been shown to decrease bitterness and at the

same time enhance flavor and provide similar functionalities as sodium. Cured and processed meats, which are those proteins that are often served in schools, typically contain relatively high levels of sodium. Blends of potassium and sodium pyrophosphates allow for a significant reduction in sodium, as compared to using only standard sodium phosphates. These phosphate blends also bind moisture in deli meats, allowing processors to achieve improved yield, texture and sliceability. And because they help prevent lipid oxidation, they can help extend shelf life. It’s important to remember that just as our body needs sodium to function; edible proteins require sodium to be palatable. There are many options for reducing sodium contents in center-ofplate proteins. Finding the right combination of ingredients takes time. Donna Berry has a bachelor’s degree in food science from the University of Illinois at Urbana-Champaign and has been writing on food formulating for more than 15 years.

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CoverStory

JTM Food Group is led today by four brothers of the Maas family (from left to right): Jack Jr., Tony, Joe Sr. and Jerry.

22

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Healthy

FOUNDATION JTM Food Group plans to use its position as a recognized supplier of nutritional protein options as a launching pad into growth across foodservice, chain-restaurant and retail channels.

I

By Andy Hanacek, editor-in-chief • Photos by Ross Van Pelt

n a media-driven, instant-news-now society, it can be difficult, even in the business world, to keep one’s finger on the pulse of what truly drives dayto-day operations while simultaneously blocking out the noise and distractions. Life is no different in the protein-processing industry — processors are bombarded by a continuous stream of information, guidance and demand — some of it on-point, some of it misguided. Successful processors are those that can filter out the noise, identify the truly meaningful opportunities and take advantage of them quickly and with minimal upheaval. JTM Food Group, a Harrison, Ohio-based supplier of fully-cooked foodservice and industrial protein and food products, is one such processor, unafraid to use its unique capabilities and strengths to capitalize on trends, helping its customers and consumers in general.

Launching the “Assault” Over the course of 51 years, JTM had built for itself a reputation as a high-quality supplier of protein-based products to schools across the nation. However, in recent times, customers and the industry in general have begun to view JTM in a different light, explains Brian Hofmeier,

senior director of School Sales. “Many people used to say that JTM makes taco meat,” he says. “But now, when we talk to foodservice directors, national groups and even USDA, we’re viewed as one of the national leaders in reduced-fat/reduced-sodium technology, not only for schools but also for military healthcare and other markets.” Becoming a leader certainly doesn’t happen overnight, and Joe Maas Sr., vice president of manufacturing and production, acknowledges that the company can thank its ability to adapt quickly for its success recently. “Reducing fat was a huge trend a number of years ago, and we started our reduced-fat program,” he says. “We started cooking, draining and rinsing our protein products, and recently, as we did with fat 10 years ago, we saw that we really needed to start reducing the sodium in the products that we manufacture.” Hofmeier adds that JTM didn’t blink an eye when it came to reducing fat or reducing sodium in its product line, a credit to the leadership of the four Maas brothers who own the company and promote the family-business culture through the workforce. “They get it that sometimes, it’s the right thing to do and you need to just do it,” Hofmeier says. “We rolled

DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

23

CoverStory

Formed hoagie patties are measured for quality control prior to being cooked, frozen and packaged at JTM Food Group’s Harrison, Ohio, plant.

[reduced-sodium products] out at the same prices we sold the original products, and we’ve pretty much held true to form with that. … As a company, we made those investments because it’s the right thing to do.” JTM started what became branded as its “Assault on Sodium” program with a measured approach, rolling out one reduced-sodium beef taco filling and three reduced-sodium beef meatball items. The products ran for one year without any overt announcement to the change in the sodium content. “We wanted to look at customer acceptance of the product, because if you’re going to all of a sudden take your entire K-12 schoollunch product line and reduce the sodium across the board by 25 percent, you really want to make sure you’re going to have customer satisfaction and customer acceptability,” Hofmeier adds. “We didn’t make a big splash, it was stealth health.” After having no issues with the four reduced-sodium formulations, and subsequently announcing to its customer base the results of its “stealth health” trials, JTM set its goal of reducing sodium 25 percent on average across the board — including its substantial line of cheese-based products, and fast-growing macaroni & cheese product line. With the cheese products posing the greatest challenge to the 24

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Assault on Sodium, “Level One” reductions Meatballs Taco Fillings Spaghetti Sauces Ribs, Meatloaf & Salisbury Steak Breakfast Sausages Beef Patties Macaroni & Cheese Cheese Sauces Total average sodium reduction (all products)

-57.2% -42.9% -42.7% -38.5% -51.6% -40.7% -27.1% -25.7% -39.8%

DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

25

CoverStory goal, JTM happily announced a year ago that it had achieved a 39.8 percent average sodium reduction across all its products — including a 57.2 percent reduction in meatballs, a 51.6 percent drop in breakfast sausages and a 27.1 percent reduction in macaroni & cheese (see table on page 24), among other reductions. Certainly, Hofmeier says, these results surpassed JTM’s expectations, but the Assault on Sodium wasn’t simply about reaching particular percent reductions of the ingredient. “Our other goal was what we called ‘equilibrium of palatability,’ which is basically that it had to taste the same,” he adds. “We found from the customer base that everybody wants to do better, wants to offer a better product, but nobody ever wants to give anything up.” The simple logic behind that demand, he explains, is that students

don’t want to notice that their foods taste different, or worse for that matter. “Kids don’t eat ‘lower-sodium, reduced-fat taco meat on a whole-grain tortilla served with reduced-fat cheese and no-fat sour cream’ — they eat ‘tacos,’” Hofmeier says. “Adults want to serve the former, but kids just want to eat tacos or burritos. Kids mostly care about taste.” Fortunately, JTM was able to meet many of these requirements around sodium based on its work a decade or so prior with reducing the fat in its protein items, Maas adds. “We had to figure out as a company how to make food taste just as good as the full-fat, full-sodium product, yet sell it, produce it inline and be profitable without charging more,” he says. “We built an entire process in the plant to cook, drain and rinse product in line and run it at the same speed, and that makes

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a huge difference [in cost].” Today, Hofmeier says, JTM is advancing its Assault on Sodium — at a national school show this year, the company announced its Level Two program, which aims to bring sodium levels down 45 percent on average across the board. “Some items like taco meat, we might be able to pull 80 to 90, maybe 100 mg of sodium out of it,” Hofmeier says. “Other items like mac & cheese, we’re going to have to come out with a completely different SKU, because although we can reduce the sodium, … you are going to give up a little flavor when you pull out an additional 300 mg of sodium from Level One macaroni & cheese to Level Two.” At presstime, in fact, JTM was preparing to begin testing on its “Level Two” macaroni & cheese, which has 428 mg of sodium, down from the 728

Weigh Better Food Safety.

mg in the “Level One” version. JTM will test the item in schools, knowing that students’ taste buds have the final say. “Kids have a much more sensitive palate, and things that we think don’t taste salty at all, or are on the edge of tasting very good, a student might find it to be too salty,” Hofmeier explains. “We’ve seen that for years and have learned not to trust ourselves and to trust the ultimate customer, the students.” Reinforcements in other segments Using its unique process and ability to turn on a dime, as well as the company’s foresight in building out its facility in Harrison to accommodate future growth, JTM’s prospects look bright moving forward. Although JTM has done well to serve

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CoverStory schools across the country, Hofmeier sees plenty of opportunity in this channel. He says that JTM sells onto the menus of approximately half the schools in the nation, leaving a wide group of potential new customers in its sights. Furthermore, Hofmeier aims to place more of JTM’s wide variety of items on the menus of current customers. “Our goal is to be on the menu every single day in some way — cheese, beef, pork, Asian sauce, cheese sauce on the side; we even started making reduced-fat, reduced-sodium alfredo sauce for customers,” he says, highlighting JTM’s successful sauce business. “We’re not selling them the meat that day, but maybe we’re selling them the sauce.” JTM has parlayed its success in reduced fat and reduced sodium into the additional foodservice channels and customers it serves, explains Scott Bonta, general manager of Sales & Marketing. “We’ve essentially doubled down on or extended the strategic initiative of the reduced fat, reduced sodium in the school line across our entire product line,” he says. “We have a health-care strategic initiative that is very consistent with the Assault on Sodium. We’re taking probably 40 of our commercial items and reducing the fat and sodium in those items, in part because of our health-care business.” Hofmeier says the health-care and military segments are a bit more challenging than schools because of a lack of standardized requirements in those segments. “Schools have a very set roadmap on nutrition,” he adds. “When you get to the military, they know they want to lower the fat and lower the sodium, but they’ve yet to come out with that list of goals, and in the health-care world, it’s kind of the same way.” Nonetheless, Bonta agrees, there is opportunity in those channels for JTM. “The military has a ‘Go for Green’ health-care initiative, and we’re very much a part of that, so it’s really across all our lines of business,” he says. “With the

ABOVE: A JTM Food Group employee places product in cartons at the Harrison facility. TOP RIGHT: Michael Pickett (right), R&D chef for JTM Food Group, talks with Hanacek about the product-development process at the company in the on-site R&D lab and kitchen in Harrison, Ohio. BOTTOM RIGHT: One of JTM’s Asian sauce products travels along a conveyor to be packaged at the Harrison facility.

28

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

ABOVE: Joe Maas Sr. (right), vice president of manufacturing and production of JTM Food Group, discusses the company’s cooking processes with Andy Hanacek, editor-in-chief of The National Provisioner, in one of the Harrison facility’s kettlecook rooms.

leadership of the school division, we’ve just extended that strategy across all our lines of business.” As the demand for lower-sodium products trickles through the different levels of foodservice, eventually reaching the end consumer and becoming a retail demand, Hofmeier believes JTM has set itself up well over the long term. “Even your food giants are really starting to adjust sodium levels, because you can see where it’s going,” he says. “You’re better off to have already done it or be part of the solution now than be dragged along and be the person that has to catch up on all these specifications.” JTM, in fact, has already prepared to be a leader, rather than a follower. Winning the battle and the war A new product and a new processing room at the Harrison plant highlight JTM’s readiness to extend

the Assault on Sodium to entirely new areas of the food battlefield. When the Maas family approved the addition of a new cook/drain/rinse processing room to the tune of $5 million to $6 million, they showed a commitment to tap into the potential for their unique CrumbleCreations product. CrumbleCreations were created about five years ago, when a few JTM customers requested that the company sell them cooked meat only, without the added ingredients and sauces. Jack Maas Jr., vice president of Sales and Research & Development, explains that JTM agreed and began cooking, draining and rinsing ground beef and selling it to customers in five-pound boil-in-the-bag/ steam-in-the-bag pouches. Currently, the company sells fully-cooked plain ground beef, ground beef with an extender, and plain ground turkey, all individually quick-frozen. Production capacity on the product had maxed out in the large kettle

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CoverStory room that the Harrison plant houses, and JTM renovated a portion of the facility to devote to the process. Furthermore, at presstime, JTM was in development on an extended turkey crumble, an all-meat pork crumble and an extended pork crumble; and pepperoni, Italian and Mexican flavors for beef, pork and turkey crumbles. The pepperoni flavor, Maas says, is targeted toward foodservice customers looking to offer pizzas featuring the beloved pepperoni flavoring without the high salt content found in traditional pepperoni pizza. “Due to the Healthy Hunger-free Kids Act for schools, they’re being pressed to lower the fat,” he explains. “Well, the one thing you can’t do on pizza is take all the cheese off it, because then it’s not pizza. … Something like [a ground pepperoni crumble] might allow them to pull 9 or 10 fat grams off that pizza.” CrumbleCreations also allows JTM to capitalize on the growing demand for items that fit into a “speed-scratch” foodservice kitchen. “Everybody wants to say they make it themselves, but no one wants to actually make it,” he adds. “Also, you have to remember, in the fast-food and mid-scale or lower-end restaurant chains, with the high turnover rate, it’s really much easier to buy your meat already cooked, then add a spice pack, a No. 10 can of diced tomatoes and some beans,

Maas and Hanacek watch JTM’s automated warehouse sorter drop off a palette of product for shipment, and then pick up another to be held in the freezer storage at the Harrison facility.

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CoverStory mix it all together, and it’s chili — as opposed to starting the whole process from scratch.” If these trends continue to grow, JTM’s expansion has given it plenty of capacity to meet the needs of customers interested in offering CrumbleCreations to its employees. Maas says his current production slate filled only 8 percent of the capacity of the new CrumbleCreations addition at presstime — meaning there is plenty of opportunity for JTM and its customers to take advantage of this trend. Yet the future of the company does not hitch itself solely to the fate of the CrumbleCreations line. Maas admits that product line will be a key item toward building out the company’s reach, but its traditional kettle-cooked bagged entrée line is the bread and butter of the operation and still has room to grow. In non-meat items, JTM sees much promise in its bread operation, as well as its ability in the soups and sauces category. Going back to Joe Maas’ statement on the flexibility of the company to capitalize on the newest trends, JTM’s reputation as a leader in the production and development of nutritional foods ought to carry it to new opportunities across a variety of segments, from schools and foodservice to co-manufacturing and retail.

Scott Bonta (top photo), general manager of Sales & Marketing for JTM Food Group, and Brian Hofmeier (bottom photo), senior director of School Sales for JTM Food Group, discuss the sodium-reduction levels achieved with Hanacek during his visit to the Harrison, Ohio, processor’s headquarters.

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FoodSafety

ANTIMICROBIAL AGENTS

Keeping food-processing

By Jessica Evans, NSF International • Photos courtesy of NSF International According to the Centers for Disease Control and Prevention (CDC) 2011 Estimates of Foodborne Illness in the U.S., the top five pathogens that contribute to domestically acquired foodborne illness are Norovirus, Salmonella (nontyphoidal), Clostridium perfringens, Campylobacter spp. and Staphylococcus aureus. Exposure to these pathogens can be the result of food that was contaminated during the processing, packaging or transporting of food products. In 2010, the U.S. Food and Drug Administration (FDA) reported the recall of more than 500 million shell eggs due to 34

a multistate outbreak of Salmonella Enteritidis, in which over 1,000 people were sick. In September 2011, there was a multistate outbreak of foodborne illness due to Salmonella contamination of ground turkey. This outbreak resulted in the recall of 36 million pounds of turkey, according to the CDC. The risk of such contamination can be greatly reduced with the proper use of cleaners and antimicrobial agents by both the consumer and the food processor. Antimicrobial agents are essential in maintaining a clean environment in

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

g facilities clean

Multiple, effective hurdles provide our best defense Let’s take a look back. HACCP was developed in the 1950s to early 1960s primarily because we wanted to send safe food into space. The developers of HACCP knew then that you could not “test” safety into food. They acknowledged that food-safety hazards had to be prevented by using and ensuring that the critical control H. Russell Cross, points are Texas A&M University Editorial Board working as Member intended. For the next 30-plus years, HACCP was used effectively by the “ready to eat” food industry. It was not used significantly for the raw food segment. Then came the E. coli O157:H7 outbreak in early 1993. I recall the day when the Secretary of Agriculture asked me how many of USDA’s federally inspected plants had voluntarily implemented HACCP. I had to tell him I expected that fewer than 5% of the more than 7,000 plants had HACCP programs in place. I recommended to the secretary that we must mandate HACCP. Over the last 17 years, the U.S. meat and poultry industry has been going down two food-safety paths — two that actually contradict one another. One path includes implementation of HACCP for reasonably likely to occur food-safety hazards coupled with pre-requisite programs designed to provide process control.

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food-processing facilities as they help to mitigate and eliminate the growth of microorganisms such as bacteria, viruses or fungi. With the passing of the Food Safety Modernization Act, and the forecasted increase in FDA inspections, it is important for food processors to understand what products are acceptable for use in their facilities. Cleaning is the process by which food soils are removed from a surface. There are various types of cleaners that can be used for this purpose. Because of the multitude of soil types within a food facility, multiple types are needed to address the cleaning needs of the facility. General cleaners can be used on all surfaces within the food facility when followed by a potable water rinse. These

Continued on next page

DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

35

FoodSafety Continued from previous page

The other path has involved end or near-end product testing for E. coli O157:H7 in ground beef or raw materials intended for grinding. The industry should be applauded for the time and resources they have devoted to HACCP development and implementation and the science and technology associated with interventions. I give FSIS a low grade for forcing the industry down a non-science-based path trying to “test” safety into food. They have basically ignored the reason HACCP was developed. We have obviously spent excessive time and money over the past 17 years on the wrong kind of testing. The multiple millions spent on the “wrong” type of testing could have been spent on such micro testing to validate interventions and/or to develop more effective pre- and postharvest interventions. So where are we on interventions? As previously stated, the beef industry has made great strides in reducing E. coli O157:H7 over the past 17 years. I strongly believe in the hurdle concept for interventions, whether they are applied post- or pre-harvest. The industry’s focus has been on post-harvest because that is where it could have the greatest impact. The key focus area remains the management of safety hazards from the animal hide before, during and after removal. We have seen very little new and innovative technology post hide removal other than hot water and lactic acid. We are especially weak further down the processing chain (trim, primals, finished ground beef, etc.). We are seeing the industry increase its focus on the hide before removal from the carcass (washes, paddles, etc.). Back to the hide, momentarily. Over the past five years, we have seen much activity in the pre-harvest area with vaccines, phages, etc. Progress is promising, but we have a ways to go to get the efficacy where it needs to be and the cost down so that it works. Now, back to the hide and carcass. Most people agree that 90 percent

Continued on page 39

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

products are sold as concentrates or ready-to-use. Acid or alkaline cleaners can be used to remove mineral deposits or food soils respectively. Degreasers are used to remove tough greases. All antimicrobial agents used on surfaces in a food facility must be registered with the U.S. Environmental Protection Agency (EPA) as well as the state in which it will be used. The EPA reviews efficacy and safety data in addition to product labeling to ensure that the product is safe for the intended end use. States further review the products to ensure the labels meet the federal labeling regulations and any additional state requirements. These registrations must be in place before the product can be sold. Within the antimicrobial class of pesticides there are four primary uses: sanitizers, disinfectants, sterilizers and antiseptics/germicides. When used properly, they can significantly decrease the risk of product contamination within a food facility. To determine their proper use, the instructions on the product labeling should be followed. Sanitizers are used to decrease the presence of microbes. Sanitizers do not kill all microbes present; instead they reduce the microorganisms to a safe level. Sanitization is the last step in an acceptable food-processing cleaning procedure. Disinfectants are used to kill all microorganisms on a surface with the exception of bacterial spores. Sterilizers (or sporicides) are used to destroy all forms of microbial life including fungi, viruses and all forms of bacteria and their spores. Sterilization is the most powerful process for eliminating microorganisms and is very important for environments where the chance of cross-contamination is high, such as meat and dairy facilities. Antiseptics/ germicides are antimicrobial agents used on the skin. Because they are used on humans, these products are regulated by the FDA as over-thecounter drugs.

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FoodSafety Cleaning products in use Cleaning and sanitizing are important steps in food safety. Clean facilities reduce the possibility of contamination during production. Cleaners also fall under the definition of a nonfood compound and include a wide range of product types from hand soaps, to clean-in-place (CIP) cleaners to metal polishes. It is important that the appropriate product be used in any given application to ensure that cross-contamination does not occur. There are several types of products that should not be used within the production area. These products (e.g. glue removers and solvent cleaners) typically consist of hydrocarbons, chlorinated hydrocarbons or other water-immiscible solvents. There are also cleaners that can be used within a food-processing facility; however, they should not be used on food contact surfaces (e.g., metal polishes). Cleaners are not allowed to come into direct contact with food. By using cleaning products reviewed by a third party, and food-grade safe, a food facility can eliminate the need for trying to determine which type of cleaners are safe to use in their processing facility.

Product registration In the United States, food-grade lubricants, water-treatment products and other nonfood products were reviewed previously by the United States Department of Agriculture (USDA). In 1999, NSF International, an independent global public health and safety organization, assumed responsibility for these evaluations and continues to expand that program today. Working in collaboration with the USDA, NSF captured all previous review requirements. Today, NSF’s Registration and Listing Program is a resource recognized worldwide for nonfood compounds. The program is designed to complement the Hazard

Continued from page 36 or more of our problem comes from the surface of the hide and what is transferred to the carcass. It seems to me that we are not taking advantage of two good opportunities for interventions: Chemical dehairing — This process removes everything from the surface. Almost no bacteria survive. The process also increases the value of he hide. This process worked for Future Beef, and it has been improved. The industry should take a hard look. Carcass irradiation — FSIS took over five years to deny AMI’s petition. One of their main reasons was uneven application and thus uneven dosage. There is proven technology now available that provides for uniform application of e-beams and thus uniform dosage. I think the industry should push for another look. To conclude, I believe that: FSIS will continue to add pSTECS as adulterants. Our best protection is not more testing of raw materials or finished products, but development of more hurdles/interventions that work. We must debate the “science” around micro testing. Validation of interventions and their efficacy, not end product testing, is what will ultimately provide greater food safety. Let’s not forget why HACCP was created.

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FoodSafety

Analysis and Critical Control Points (HACCP) programs developed by food facilities. By providing an easy-to-use online list of products registered under the NSF Nonfood Compounds Registration Program, companies can quickly determine if a product is acceptable for use in their processing facility. The registration number assigned to each product allows for straightforward searching and traceability. The product list, also known as the NSF White Book™, is searchable by various factors such as trade name, company name, NSF Registration number and/or NSF category code. 40

The NSF White Book™ can be reached from the web site (www.nsfwhitebook.org). Once a product is found, a copy of the registration letter can be downloaded. The registration letter details what end use the product has been registered for and any limitations associated with its use.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

J Jessica Evans is the business unit manager for the NSF Nonfood Compounds Registration Program, leading N the Nonfood Compounds team in developing new service offerings, improving existing processes and acs commodating customer needs. For more information, contact her at (734) 913-5774 or [email protected].

AMIF studies show effectiveness of antimicrobials in use today against a wide range of pathogens By AMI Foundation Current antimicrobial compounds used by meat industry to destroy E. coli O157:H7 are effective against non-O157 STEC, according to an AMIF-funded study conducted by researchers at the Agricultural Research Service’s Meat Animal Research Center. Researchers evaluated the efficacy of six commonly used antimicrobials on Escherichia coli O157:H7 and non-O157 shiga toxin-producing E. coli (STEC) serogroups O26, O103, O111 and O145 on beef. The antimicrobial compounds used were acidified sodium hypochlorite, peroxyacetic acid, FreshFx, lactic acid, activated hydrobromic acid and hot water. The degree of effectiveness depended on the antimicrobial compounds used. Hot water was the most effective in reducing pathogens tested, followed by lactic acid. Acidified sodium chlorite and activated hydrobromic acid showed less immediate effect, but increased effectiveness after chilling for 48 hours at 4°C. Despite the reduced effect of these antimicrobial compounds, the recovery of these pathogens with low inoculation levels indicated that one of the following possibilities could occur: (a) the solutions might not be applied uniformly to all of the surfaces since carcasses have irregular shapes and surfaces, causing over-exposure to the treatment on one part and under-exposure on another; (b) even with a uniform spray, all antimicrobial compounds will not only inactivate the bacterial cells, but also inflict sub-lethal injury to the cells. At a suitable environment, sub-lethal injured cells repair their injury, gain their normal characteristics, and subsequently initiate multiplication. The report can be read at http://www.amif.org/ht/a/ GetDocumentAction/i/70695. A complementary AMIF study by the same research team evaluated the efficacy of those same six antimicrobials on nonO157 STEC O45, O121 and non- and multi-drug resistant (MDR) Salmonella strains. The final report provides a similar conclusion, noting that all antimicrobial compounds used by the beef industry were effective against non-O157 STEC and Salmonella. The reductions of these pathogens on inoculated fresh beef with tested compounds in general, were as effective against nonO157 STEC as E. coli O157:H7. The degree of effectiveness again depended on the antimicrobial compounds used. In this study, lactic acid, hot water, and acidified sodium chlorite were more effective in reducing pathogens. FreshFx had an intermediate effect, while peroxyacetic acid and BoviBrom had the least effect. The effectiveness of these compounds on nonMDR and MDR was inconclusive and possibly strain dependent, but Typhimurium were more resistant than Newport. Despite the reduced effect of these antimicrobial compounds, the recovery of these pathogens with low inoculation levels indicated that one of the following possibilities could occur: (a) the solutions might not be applied uniformly to all of the surfaces as carcasses have irregular shapes and surfaces causing overexposure to the treatment on one part and under-exposure on others; (b) even with a uniform spray, all antimicrobial compounds will not only inactivate the bacterial cells, but also inflict sub-lethal injury to the cells.

An enumeration with selective medium may overestimate effects of the antimicrobial interventions used. It should be noted that in a suitable environment, sub-lethally injured cells may repair their injury, gain their normal characteristics, and subsequently initiate multiplication. The final report is available at http://amif.org/ht/a/GetDocumentAction/i/72853. Additional AMIF-funded research was recently conducted by Colorado State University to determine whether interventions known for reducing E. coli O157:H7 contamination on beef trimmings are also effective in reducing non-O157 STEC, and MDR and susceptible Salmonella Newport and Salmonella Typhimurium. The interventions evaluated were lactic acid, acidified sodium chlorite, peroxyacetic acid, sodium metasilicate, Bromitize® Plus, SYNTRx 3300 and AFTEC 3000. Findings indicated that the antimicrobial effects of these decontamination treatments against the non-O157 STEC serotypes and S. Newport/Typhimurium antibiotic resistance phenotypes were generally the same as those against E. coli O157:H7. The final report is available at http://www.amif.org/ht/a/ GetDocumentAction/i/72071. For more information, research and education from AMI Foundation, visit www.amif.org on the Web.

Gleeson Constructors & Engineers, L.L.C. specializes in the design and construction of food processing facilities, cold storage facilities and distribution centers nationwide.

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DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

41

TechProcessing SLAUGHTER

Under watchful eyes

Remote video auditing is gaining widespread acceptance amongst meat processors as another tool in slaughter operations. By Megan Pellegrini • Photos courtesy of JBS SA IT’S ONLY HUMAN NATURE TO PERFORM BETTER when the boss is watching, particularly if it’s not known exactly when a supervisor was monitoring performance. With remote video auditing (RVA) systems, employee performance can be viewed randomly throughout the day, ensuring that proper food-safety and animal-welfare procedures are followed at meat- and poultry-processing plants. Only around commercially since 2008, RVA is gaining widespread acceptance now amongst processors as another tool in the battle against E. coli during slaughter processing operations. The numbers don’t lie. Since JBS SA, one of the world’s largest beef processors, initiated its RVA program in 2010, the amount of E. coli found by its inspectors decreased by 60 percent. Meat processors Cargill and OSI Group also have 42

launched RVA programs in the past couple years. In 2008, Cargill launched its first video auditing pilot at its Fresno, Calif., plant. “Cargill uses third-party remote video auditing (RVA) for animal-welfare auditing at all 10 North American beef harvest facilities, with pilot projects slated for our pork and turkey businesses,” says Michael Martin, director of communications, Cargill Inc., based in Minneapolis. “This provides unbiased audits and allows us to share information about our animalwelfare policy compliance and performance with customers seeking that information.” This August, the Food Safety & Inspection Service (FSIS) issued “Compliance Guidelines for Use of Video or Other Electronic Monitoring or Recording Equipment in Federally Inspected Establishments,” which established that using RVA systems is still voluntary, and FSIS agents will continue to inspect plants in person rather than via camera footage.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

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TechProcessing Auditing the auditors An RVA system works by sending video from the inside of a plant over a secure Web link to a third-party auditing center, which conducts animal-welfare audits at random times during the day, according to the American Meat Institute Animal Care and Handling Guidelines. After each audit, feedback is quickly offered to the plant managers so they can monitor and improve their employees’ performance. A second type of RVA that is used mainly in livestock production facilities relies on motion detection to flag events for review by third-party auditors. “These systems are useful for applications where limited animal handling takes place,” says Kurt D. Vogel, Ph.D., assistant professor of animal science livestock welfare and behavior, University of Wisconsin-River Falls. “Examples would include sow gestation operations and broiler houses.” In essence, RVA allows a plant to verify that animal handlers are following the animal-handling program in their facility. A major advantage of RVA is that the plant does not know when an audit is in progress during the day, but managers receive feedback on their performance on the audits that are conducted nearly in real-time. “This allows management to respond quickly to animal-handling issues in the plant, and it allows the plant to develop a culture that rewards good animal handling by collecting unbiased data and then using the data to reward excellent

livestock handlers,” says Vogel. In fact, plant managers are, in some cases, seeing employees respond to this system with some lively competition. “It was fascinating [at our Animal Care & Handling Conference] to hear the impact it has on human nature,” says Janet Riley, senior vice president of public affairs, American Meat Institute, based in Washington, D.C. “We heard about shift one and two in the same plant, for example, competing with one another to improve performance and ‘beat’ the other shift.” Improving interactive training According to Leonard Huskey, head of animal welfare for JBS, it was important for JBS to be able to use RVA as a tool to train and provide feedback to employees as a part of its ongoing inter-

active training strategies, while showing the importance of animal welfare or food safety tasks as detailed in its Slaughter Actions for Excellence (SAFE) program. “The camera system gives us the opportunity to perform an unbiased audit of key tasks,” notes Sherri Jenkins, food safety director for JBS, based in Greeley, Colo. “We want to be sure that we are carrying out these critical parts of our operations as effectively as possible.” In the spring of 2010, JBS’ Souderton, Pa., plant was the first to install cameras for a 100-day pilot. A total of 16 RVA cameras were set up in the animal-welfare and food-safety areas, from the receiving of the cattle to after stunning and all along the slaughter line to monitor that animal handling is done properly, avoiding stress to the livestock, and to help assure that cross-contamina-

U.S. industry and slaughter automation During a brief interview at Process Expo with Andy Hanacek, editor-in-chief of The National Provisioner, Vincent Volpe, president of Jarvis Products Corp., offered these key insights on the incorporation of automation and robotics into slaughter operations. Robotics technology has improved, setting up a perfect combination of factors that should drive the industry into automation at a quicker pace moving forward. “Americans always love high speeds — the more you put through the line, the better the overhead,” Volpe says. “And when the American meatpackers traveled to Europe, they discovered that running [a little slower] wasn’t so bad in that it was easier on the equipment.” Volpe believes the U.S. market should continue along this path as meatpackers move toward a more deliberate pace of operations, based on food-safety and inspection demands as well. “If you put two machines on the line processing 800 carcasses an hour, and if you have two lines, you can get to 1,600, versus the 1,100 that the USDA approved originally,” he adds. “Furthermore, USDA says if you get 800 on a line, they can inspect that more easily than we can 1,100 on a line.” 44

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

tion is avoided during the hide removal process, Huskey says. The images were then sent to a digital video recorder that was accessed by the vendor, as well as JBS plant managers and corporate office. After the cameras were first installed, “we realized that some of our employees were at 100 percent compliance, while a few employees were at considerably less than average compliance levels,” he says. “Once we gave feedback to our employees, the non-compliant employees quickly moved up to high levels of compliance. Importantly, we’ve been able to sustain these improvements and see further incremental improvements.” The RVA images are recorded on a continuous loop and saved for no more than a few days before being erased with new images. Any review with employees would normally take place within the same work shift. Pleased with its results, JBS then

moved to implement approximately 25 to 30 cameras in its seven other beef slaughter and processing plants in 2011 ahead of the E. coli “hot season” (April to September), Huskey says, which it achieved by mid-May. Dealing with the elements Adding RVA to plant facilities requires a substantial investment, which not all processors can afford. “A challenge I see is adapting RVA technology to fit the needs of smaller processors that may find the current systems difficult to afford,” notes Vogel. To add RVA to facilities, processors pay for high-tech cameras and their pressurized housings (which are filled with nitrogen to prevent moisture from entering the cameras), electrical contractors to add conduit for cable and fiber for the network in order to capture images and send them to the DVR. Also, processors pay for ongoing

maintenance of the system and fees associated with the vendor’s third-party auditing program, Huskey says. “Proper installation is key,” he says. “As we’ve gone through this process, we’ve learned that it’s important to fully protect the cable, fiber and connections from moisture getting into the housing. We also work with our sanitation contractor so they avoid contact of high-pressure water with the camera housings.” Indeed, one of the challenges that processors face with any video-recording technology in slaughter plants is the environment in which the cameras are located. “The environment in slaughter plants includes rapid and extreme changes in temperature, humidity and vibration — a deadly combination for many surveillance cameras,” says Vogel. “We will have to continue to work to improve the durability of the cameras that we install in these environments.”

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DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

45

TechProcessing

Smarter cutting and deboning As automated systems improve, processors continue to push harder to get even better yields off carcasses. By Elizabeth Fuhrman • Photos courtesy of GTRI Food Processing Technology Division CUTTING AND DEBONING IS A DIFFICULT PROCESS, but much is being done to improve the physical cut of meat to increase yield and to reduce risks associated with the procedure. One yield improvement is deboning before full aging is completed, says Douglas Smith, associate professor and director of the poultry processing laboratory at North Carolina State University in Raleigh, N.C. While the meat is tougher, it releases cleaner from the rib cage area. The downside of this, however, is the potential increase of bones as the fan bone tends to snap off with the fillet, he says. Physical cuts, sometimes yield and definitely reduced risks for deboners and portioners is aided by the use of equipment after the actual deboning process, Smith says. The most popular equipment for post-debone cutting and portioning are form cutters or water-jet cutters, both of which have replaced people with knives or scissors, he says. Historically, pulling the breast and skinning

the carcass was the most physically demanding portion of the line. Today, through job rotation and automation of the breast skinning process, this has shifted to other more finesse-related positions, says Brad Williams, operations manager for Wayne Farms’ Pendergrass, Ga.-based Fresh Processing Facility. “Ergonomically designed work stands and stations have brought the work closer to the employee and made the jobs more comfortable,” he says. Virtually all tools today are designed with comfort and ergonomics in mind. “Handles are contoured to fit the hand and made of lighter materials,” Williams says. “Blades are more consistent and designed to be sharpened by high-tech grinding equipment that requires much less expertise.” Sharpening equipment and personal sharpening devices also have evolved over many years. “Tool sharpening is no longer an art,” Williams says. “It is very much a science. Several systems exist today that, given an initial capital investment, require minimal training to produce consistently sharp tools in great numbers with few people.” Man vs. machine More thorough training and, in turn, higher levels of employee retention have become essential parts of any successful deboning operation. “No company can afford to routinely start over with new employees and continue to compete,” Williams says. “Step-by-step, and in some cases videotaped, methods are employed to ensure consistent comfortable techniques are used to help people be successful.” More imaging and better robotics also are aiding the cutting and deboning process. Machines that adapt to cut the bird are now on the market, rather than the old technology of automated deboners, which offered few adjustments

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

and no individualization, Smith says. In some areas of the country, automation is very prevalent for the large poultry companies. Automation is typically too expensive for smaller companies and is used where labor is short or too expensive, Smith says. The downside of automation is that the lines typically produce more bones than a well-trained cone line, he says. In terms of breast deboning, Williams agrees that automation remains a level below hand-deboning. “Many operations have made the switch to fully automated systems only to return to the tried-and-true cone line hand-deboning [setup],” he says. “Opportunity for equipment manufacturers continues to be great, but quality and yield loss issues have yet to be overcome. Thigh deboning and breast skinning are two areas that have become reasonably successful.” Gary McMurray, chief of Georgia Tech Research Institute’s (GTRI) Food Processing Technology Division, agrees that the predominant move processors are making is to return more to manual systems, while the industry continues to work on solutions for the front half of the bird. “Back when the economy was going well and it was a matter of pumping out as much product as you could, there was more of an issue of the

labor concern,” he explains. “But right now, yield seems to be more critical, so the company can still get a higher yield with the manual line than they can with the automated lines.” Automation is more frequently used in processing dark meat, such as the leg and thigh, because the processing is a little more constrained, McMurray says. Along with equipment suppliers, GTRI is working on its own boning system for the breast fillet to address the challenges the front half of the birds bring. Deboning outlook In the future, Smith would expect more robotics and imaging. More sophisticated automated yield-tracking systems, and further use and development of more economical X-ray systems are probably on the horizon for the deboning process, Williams adds. GTRI is working on one such bonemonitoring system that might allow for a real-time yield monitoring. The system uses infrared light shown up from inside the bird, through the cone, with cameras mounted on the outside looking at the carcass. “When you do the cutting, there is the issue of the yield, but there is also a food-safety issue,” McMurray says. “We are working on a system that, instead of looking for the proverbial needle in the

haystack, we look for the needle to see if it’s missing in the first place. We have been looking at carcasses at the end of the process line to see if the bones are still on the carcass. An additional benefit of being able to inspect the carcass is to see how much meat is left on the carcass.” “A real-time yield-measurement system is something that is always going to be important in all of these deboning systems,” he continues. “It’s closing the loop as to how do you really know how well you did and how do you really measure that in a significant manner.” Advancements will continue to occur in the cutting and deboning process because it’s an area that attacks a problem, McMurray adds. “In one sense, it’s very suitable to automation,” he explains. “It’s dull [work], it’s dangerous and it’s dirty, so it makes sense to try to automate. It’s just that right now, especially with the front half, it’s still such an unstructured problem. For the dark meat, I think there is a little more structure to it.” Yield will remain a critical factor in driving the systems forward, however, as opposed to labor replacement. “Once we get a system that can provide the right yield, the labor reduction is just going to be icing on the cake,” McMurray explains.

DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

47

TechProcessing

Controlling the process Technology is improving process controls at meat and poultry plants. MEAT AND POULTRY PROCESSORS ARE UTILIZING new technology in their process-control systems to improve food safety, reduce costs, decrease energy use and lessen environmental risks. At Cargill, plants have implemented camera-augmented beef grading and brand certification with the United States Department of Agriculture (USDA). “This is considered to be a ‘best practice’ and streamlines operations by reducing the number of re-graded carcasses, as well as reducing down time,” says Michael Martin, director of communications, Cargill Inc., based in Minneapolis. The processor also conducts tenderness audits for its beef. To increase its sustainability, Cargill is capturing methane gas generated from its water treatment ponds, which is then used as a fuel source for boilers that heat water for sanitation at the beef processing facilities, he says. “This technology allows us to offset approximately 25 percent to 30 percent of our energy use at these facilities,” says Martin. “We also re-use water up to three times before treating and discharging it, with treatment between each use.” At Cargill’s two pork-processing facilities (Beardstown, Ill., and Ottumwa, Iowa) as well, captured methane gas is used as a fuel source that offsets about 15 percent of those plants’ energy requirements. “Process controls imply measurement, which is essential for ongoing improvement,” notes Martin. “We cannot properly manage or improve processes unless we can measure their performance.” Improving older systems Kayem Foods proves it is possible to combine innovative process controls with, in some cases, 70-year-old smokehouses. “Some products still come out better in the older cooking system, so we look at what technologies improve efficiencies and throughput and maintain quality,” says Robert Campbell, Ph.D., quality assurance food safety manager, Kayem Foods, based in Chelsea, Mass. “Our new cooking system — cooking in a package so there is no post-cooking contamination — offers more control of data acquisition and temperature controls, and improves yields and energy efficiency by having more precise process controls.” Kayem Foods has also invested in new filtration systems to decrease its total water usage by recycling its water, Campbell says. 48

By Megan Pellegrini

I, Robot? Robots aren’t ready to replace all manual labor at processing plants, but many processors are already utilizing robots for broad data collection or simple inspection and lifting tasks. “If we look at key pressures on the poultry industry — labor, quality and food safety — these are areas that robotics can provide solutions for on multiple platforms,” says Doug Britton, senior research engineer and manager of the Agricultural Technology Research Program, Georgia Tech Research Institute, based in Atlanta. For now, robots are limited by their lack of sensors for detection activities that humans excel at and lack of “Ànesse” to change tasks once they are set up for a purpose, he says. To improve worker safety, he says Kayem Foods is working on a number of systems such as automatic lookouts and electric eye systems so machines stop if someone enters a potentially unsafe zone. “With new process-control systems, the biggest issue is getting our mechanics up to date and investing in their training,” says Campbell, “because you can’t plunk a system down and it works right away.” Cutting implementation costs According to Lee Johnson, Ph.D., vice president of technical services, West Liberty Foods, based in West Liberty, Iowa, robotics and automation in processing operations are the next big devices for improving process control. “We look at automation as a tool in the process: either as a standalone feature like a boot wash or equipment that can replace an employee or as part of a much larger process such as creating a new way to slice product that is better,” says Johnson. New technology enables West Liberty Foods, for example, to slice 10-foot logs of product, he notes. Although data-capture systems have been around for 15 to 20 years, Johnson points out that implementation of new technology is much more economical. “As industry challenges, such as regulatory and foodsafety issues, become tougher every day, if automation can make some things simpler then that’s a good thing,” he says.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Happy Holidays :HDSSUHFLDWH\RXUEXVLQHVVDQGZLVK\RX SHDFHDQGSURVSHULW\LQWKHQHZ\HDU From the staff of The National Provisioner

PackagingTech

CHUBS

What’s ‘old’ is … spot-on relevant By Chip Bolton, J.H. Bolton Communications LLC LONGEVITY SEEMS NOT TO CARRY THE CACHET IT ONCE DID. What’s new, what’s hot, and what-have-you-done-for-melately attitudes often carry undue influence over decision-making. But things that are time-proven and perform consistently day-in and day-out can still have their place. A case in point is chub packaging. Believe it or not, more and more chub packages are showing up in retail meat cases. Who knew? Chubs of ground beef have been around longer than laptops … a point of reference, by the way, appreciated by an alarmingly large segment of our population. But, it is an old package that still delivers, satisfying the needs of processors, retailers and consumers alike. And now, with most shoppers’ purses lighter than they used to be, chubs look even better because they are often the vehicle of choice for ground beef features at retail. Since 2007, the use of chub packages for ground beef increased from 28 percent of ground-beef packages to 35 percent in 2010. During that same period, the use of modified-atmosphere packages for ground beef fell from 35 percent to 25 percent, according to the 2010 National Meat Case Study, a retail meat case audit that provides information about meat merchandising trends and was funded by Sealed Air’s Cryovac Food Packaging, The Beef Checkoff Program, and the National Pork Board. A couple of points to consider about chubs’ “renewed” popularity are their production efficiency and retail appeal. Think of having your cake and eating it too. It is all about controlling costs in ground beef and ground poultry production, and you would be hard-

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

pressed to find a more cost-effective way to produce packages of ground product. Production line speeds commonly exceed 100 packages per minute for chubs that can carry striking eight- to 10-color printed graphics that not only stand out in any meat case, but also speak loudly to price-conscious shoppers looking to stretch their meal dollars. Think tacos, spaghetti sauce and chili, to name some favorites. Improvements to the package have been developed and are available, but they come with increased costs — one reason they have not found traction in North America. Three years of hard economic times have amplified chub packaging’s production efficiencies, and any discussion of added costs would seem to be a nonstarter with processors. However, according to packaging industry sources, in Asia there is some use of ultra-sonic sealing with monolayer Saran films for chub sausage products. The stated advantage is superior package seals even through contaminants, but the process slows production line speeds and adds to packaging costs, according to those same sources. So, is what’s old new again? No, even better, what’s old is still spot-on relevant to a marketplace demanding more cost-effectiveness, performance and value at every stage of distribution. Forget the age. Remember the result. Chip Bolton is a principal at J.H. Bolton Communications LLC, with more than 20 years experience in the food packaging industry. For more information, contact him at (864) 525-3494, or [email protected].

Innovative poultry processing and packaging solutions. At Reiser, we offer a variety of processing and packaging equipment designed for poultry products. Whether your application calls for injecting, forming, extruding, coextruding or depositing to vacuum or modified atmosphere packaging, Reiser has the solution. From chicken shapes to kievs, from injecting to tenderizing, from case ready ground turkey to vacuum packaged chicken sausages, Reiser is your one source for all your processing and packaging solutions. For more information, contact Reiser at (781) 821-1290.

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Leading the food industry in processing and packaging solutions. DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

51

IPE Pre-show

Ashworth Bros. Inc.

Poultry industry’s future on display The International Poultry Expo has long been the poultry industry’s source for solutions to current industry challenges, as well as a glimpse of the future technology. The 2012 edition of the show, scheduled for January 24-26 at Atlanta’s Georgia World Congress Center, will bring together poultry and egg industry leaders from around the world. This year’s event will not only provide a look at the latest in technology and services, it will examine the future of the American poultry and egg industries. The show is the world’s largest display of technology, equipment, supplies and services used in the production and processing of poultry and eggs and for those involved in feed manufacturing. All segments of the industry are represented: feed milling, hatchery, live production, processing, further processing, marketing and all support activities. The 2011 IPE brought had more than 20,000 attendees and more than 900 exhibitors. The event is organized by the U.S. Poultry & Egg Association. Funds earned at the International Poultry Expo are funneled directly back into the industry in the form of research grants, educational programs, communications and technical assistance.

Over 45 years ago, Ashworth invented the Àrst spiral conveyor and today remains the world’s largest manufacturer of conveyor belting for the food processing industry and the only manufacturer of both metal and plastic spiral belts, offering customers the best belting solutions for their speciÀc requirements. Ashworth has pioneered belting advancements that maximize throughput while minimizing life-cycle costs. We have been granted more patents than any other spiral belt manufacturer. Ashworth belts featured at IPE will include the super-strong Omni-Pro®, the only USDA Accepted plastic spiral Advantage, and our most recent introduction, ExactaStack®, the drop-in replacement for self-stacking spirals. Additionally, Ashworth’s Factory Service team will be present to discuss any of your freezer or cooker service needs from belt replacement to increasing capacity to relocation. Please visit us at Booth #4455.

The educational program has always been a key aspect of the IPE, and this year’s program will feature a conference titled, “Charting the Course: An Executive Conference on the Future of the American Poultry Industry.” The conference will be moderated by Mike Donohue, vice president of Agri Stats Inc., and will examine current economic conditions, global competitiveness, and provide a vision of the American poultry industry in the coming years. The conference is free of charge to all expo attendees. For more information about IPE 2012, please visit www.ipeweek12.org. The following pages contain previews of some of the machinery and technology that will be displayed by several IPE exhibitors.

IPE, January 24-26 Where: Atlanta’s Georgia World Congress Center Exhibit hours: Tues.: Noon – 5 p.m.; Wed.: 9 a.m.-5 p.m.; Thurs.: 9 a.m. – 3 p.m. Exhibitors: More than 900 Attendees: More than 20,000 expected

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Ashworth Bros. Inc. 450 Armour Dale Winchester, VA 22601 (800) 682-4594 Fax: (540) 662-3150 www.ashworth.com IPE Booth #4455

Birko Birko provides chemical, equipment and technology food safety solutions to poultry processors. Birko Chicxide® is a patented lactic and citric acid based antimicrobial intervention approved by the USDA for use on whole carcasses pre-chill that stops Salmonella up front and can prevent it from traveling deeper into poultry processing operations. Birko’s product range includes cleaners and sanitizers, EPA registered eggshell sanitizers and equipment such as the Chad Conveyorized Antimicrobial Spray System (shown). We also distribute Emech F3 and F5 control systems for accurate temperature control in poultry processing operations. Founded in 1953, Birko has been family owned for three generations. We pride ourselves on our reputation for unsurpassed service and commitment to our customers. Our food safety solutions help poultry processors meet HACCP and SSOP standards. We can also provide employee training in proper sanitation and chemical safety procedures.

Handtmann Inc.

The Handtmann whole muscle, dual vacuum HVF 670 Deli Series stuffer with the Handtmann Integrated Vacuum Management™ (IVM) system will be featured at the IPE. The HVF Deli Series delivers ultraprecise control and the industry’s most precise weights for the ultracompetitive poultry processing industry, and the HVF 670 controls whole muscle product through its adjustable vane cell system with 2 millisecond servo accuracy. The HVF 670 powerful vacuum system dramatically improves product consistency and naturally delivers more efÀcient cooking and slicing while improving product quality and lowering resource inputs. Finally, the HVF 670 Deli Series has been designed to reduce residual product waste by 50% and lower setup/cleanup time up to 75% - all while enabling the traditional old world quality with new economy precision and unmatched consistency that today’s poultry processing demands.

Birko 9152 Yosemite Street Henderson, CO 80640 (800) 525-0476 or (303) 289-1090 Fax: (303) 289-1190 www.birkocorp.com IPE Booth #4667

Handtmann Inc. 847.808.1100 Toll Free: 800.477.3585 www.handtmann.com IPE Booth #6539 (B Hall)

ISI ISI offers All-Natural Carrageenan systems to improve yield, modify texture and reduce cook loss in case-ready, rotisserie and other injected and/or tumbled marinated meat and poultry products. ISI’s Natural and OrganicAllowed carrageenans can replace phosphates and allow for reduced salt levels. Dedicated to providing complete technical support from our R&D Center in Waldo, Maine, with a staff of over 150 years combined experience, ISI recently added a Texture Technologies TA-TX Plus to our Applications Lab. The TA-XT Plus provides sophisticated texture analysis on hydrocolloid gels plus a wide range of Ànished food products including processed meats, dairy products and snack foods. Our product line also includes Xanthan Gums, Sodium Alginates and our own TextuRite Texture Systems. The entire ISI staff is dedicated to providing quality products and exceptional service.

ISI 631 Moosehead Trail Waldo, ME 04915 (800) 628-3166 www.ingredientssolutions.com [email protected] IPE Booth #4066

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IPE Pre-show

Jarvis Products Corp. Jarvis Products Corporation produces top-of-the-line poultry processing equipment. The company specializes in pneumatic tools for eviscerating and performing several offline processing procedures. A high-precision vent cutter that economically removes poultry vents, on any type or sized bird. Durable chicken and turkey hock and neck cutters for faster hock and neck removal. A lung gun that is ideally suited for chicken, turkey, duck and goose lungs and kidney removal. Jarvis’ picking Ànger installer is cost effective by eliminating rubber Ànger damage, and speeding the Ànger installation process. Three different sized, air power scissor models are available, with many different blade sizes and styles, to perform many operations currently done by ordinary scissors, knives or hand clippers. Jarvis tools are sold and serviced worldwide through 15 branch locations, and Jarvis’ Federation of Distributors. For more information about these tools, product CD’s and literature are available. Please visit us at the IPE in Atlanta, Booth # 4412, January 23-27, 2012. Jarvis Products Corp. 33 Anderson Road Middletown, CT 06457 (860) 347-7271 Fax: (860) 347-9905 www.jarvisproducts.com [email protected] IPE Booth #4412

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QMS Internationsl Inc. See us at our Booth #4345 to see the new MKiii Servo Drive Siebeck Jet 2000 Tying Machines. The MKIII is the all new 21st-century tying machine, featuring: QWear-free AC Servomotors QAutomatic reset of knotting unit and ring QSmart Motion Controller with LED displays QTies up to 63 strings/min QSelector switch for 1,2,3,4 cross and continuous tying See the Tying Machine for roasts and poultry, combine high performance with excellent reliability to offer maximum productivity. What it does: The Siebeck JET 2000 comes in a semi-automatic version and is a tying machine perfect for many poultry tying applications. Why it’s different: By eliminating the need for workers to tie poultry by hand, the machine can result in signiÀcant labor and cost savings. Why you should check it out: Cost savings, labor savings and health and safety reasons. QMS International Inc. 1833 Folkway Dr. Mississauga ON L5L 2X1 Canada (905) 820-7225 Fax: (905) 820-7021 [email protected] www.qmsintl.com IPE Booth #4345

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

Reiser 725 Dedham Street Canton MA 02021 (781) 821-1290 Fax: (781) 821-1316 www.reiser.com IPE Booth #4024

Wire Belt Co. of America Wire Belt, the leading developer of open mesh stainless steel conveyor belts, has been keeping your lines running for over 60 years. Our conveyor belts are extensively used for breading, battering, frying, blanching, cooking, coating, dusting, and cooling. Wire Belt’s entire line of belting products are accepted by the USDA NSF/ANSI/3-A hygiene standards. This is the only acceptance that can assure you that you have the cleanest, safest conveyor belt available. Wire Belt’s Flat-Flex XT® conveyor belt is perfect for poultry processors. It provides XTra strength and XTra support for longer belt life. XT’s unique spacing is designed to outperform competitive style belts especially in bread crumb and Áour applications, where typical belts are greatly stressed and damaged during this process. To learn more about Wire Belt’s complete line of products, including our CarrySmart conveyors, please stop by Booth #4872.

WTI Inc. WTI is a specialty ingredients company that provides the food processing industry with new technology and customized clean label solutions to enhance food safety and quality. Our highly skilled food-artisans and scientists have honed their craft through education, research and personal experience, and are ready to meet your challenges. We are experts in the development and use of functional specialty ingredients. Our product portfolio includes marinades, custom blends, water soluble ingredient mixtures and nutraceuticals. We are excited to exhibit our ingredients in a sundry of meat and poultry products offered at our “world famous” deli counter. Come see and taste the difference in quality and food safety that WTI could provide for your products at IPE.

Yamato Corp. Multihead Weigher Designed To Withstand Harsh Poultry Packaging Environments Mequon, WI Yamato Corporation will display its NEW Dataweigh Omega multihead weigher at the International Poultry Expo, Booth #4231, January 24-26, 2012 in Atlanta, GA. With an emphasis on sanitation and food safety, Omega’s improved design offers an IP67 rating, allowing it to withstand severe washdown procedures. Improved polygon-shaped feed pans and weigh buckets eliminate product build-up. Speeds up to 90 weighments per minute in single-shift mode for IQF proteins. Other features include a rugged load cell design that can withstand up to 150kg of force and a tapered body for optimum product Áow, speed and improved performance.

WTI Inc. 281 Martin Luther King Jr. Ave. Jefferson, GA 30549-1477 800-827-1727 Fax: (706-387-5159) www.wtiinc.com IPE Booth #4167

Yamato Corporation

Wire Belt Co. of America 154 Harvey Road Londonderry, NH 03053 (603) 644-2500 [email protected] www.wirebelt.com IPE Booth #4872

6306 W. Eastwood Court Mequon, WI 53092 262-512-3378 Fax: 262-236-0036 [email protected] www.YamatoAmericas.com IPE Booth #4231

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TechShowcase

Former Formax’s VerTex1000 forming system couples the industry’s largest capacity with state-of-the-art technology to offer superior versatility, natural texture and low cost of ownership. AccuPump technology, a servodriven dual lobe pump that protects the natural structure of the product, promotes consistency, reduces maintenance and prevents product overworking by keeping product movement under the operator’s control. The former ensures accurate Àlls at drum speeds up to 30 RPM and Àll rates up to 18,000 pounds per hour.

Sausage Linker The new Áexible Vemag FSL210 from Reiser is the perfect system for linking and cutting a wide variety of fresh sausage products. The FSL210 is a single machine that combines precise portioning by weight, linking by length and precise link cutting to consistently produce individual sausages with exact weights and lengths. The FSL210 automatically adjusts to produce links in natural or collagen casings and in all diameters, lengths and weights. Reiser: (781) 821-1290 or visit www.reiser.com

Provisur Technologies Inc: or visit www.formaxtransforming.com

Metal Detector CEIA SpA has developed a metal detector that simultaneously uses a broad spectrum of multiple frequencies. The THS-MS is the only metal detector capable of accurately seeing the difference between a metal particle and speciÀc product effect conditions which can simulate the presence of metal when none exists. Product effect false reject signals account for costly delays, product re-inspection, and waste if not accurately detected. CEIA multi-spectrum detectors automatically learn and track product effect conditions.

Oil Filter Adapter To take advantage of the beneÀts provided by full synthetic oils, Busch now offers a bolton oil Àlter adapter for all R5 series vacuum pumps. It repositions the spin-on oil Àlter to a vertical, self-draining position to allow changing of the oil Àlter without draining or changing the pump oil. Oil sampling and testing are used to monitor the condition of the oil and determine when the Àlter should be changed, increasing oil drain intervals. Busch USA: (800) USA-PUMP or visit www.buschusa.com

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Heat and Control Inc.: (800) 227-5980 or visit www.heatandcontrol.com

Separator Equipment Baader’s Separator line of machinery separates solid from soft components helping the processor to obtain more yield from their product. This gentle form of separation guarantees better texture, higher protein content and less bone material than high-pressure systems. There are Àve sizes of separators available, with a number of available options that allow customers to handle a variety of products. Baader North America Corp.: (800) 288-3434 or visit www.baader.com

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Antimicrobials The USDA has granted A&B Ingredients approval for its CytoGuard as a Salmonella intervention agent in ground poultry products. CytoGuard has been developed for use as a powerful antimicrobial agent to combat common foodborne pathogens. Based on Lauric Arginate, a derivate of Lauric Acid, L-Arginine and Ethanol — all naturally occurring substances — CytoGuard LA is speciÀcally designed for use in ready to eat (RTE) processed meat and poultry products. A&B Ingredients: (973) 227-1390 or visit www.abingredients.com

Pumps Bird Handling Module

MasoSine offers a line of Sine pumps. Their capacity of pumping large particulates while providing powerful suction and smooth consistent Áow rates provides the ultimate solution for pumping marinated boneless poultry products. Unlike typical poultry further processing plants which implement labor intensive methods to place marinated meat products on conveyors using up to ten workers across a 40 inch belt, the MasoSine pump eliminates unnecessary labor by mechanically spreading the product directly onto the conveyor.

Anglia AutoÁow N.A. is introducing Easyclean Modules for live bird handling to the Americas. The Easyclean Module’s framework is a galvanized steel, sealed structure without any open galvanizing holes. The key to this design is that the roof has a continuous Áat surface with open construction peaks which allow for unobstructed access for washer jets to easily remove debris. There is no place for the dirt and water to enter the frame. Anglia Autoflow N.A.: (404) 374-3966 or visit www.aaflow.com

MasoSine: (800) 282-8823 or visit www.masosine.com

Microwave Packaging Flexible microwave packaging by Nordenia International allows greasy, breaded or bread-like foods to be prepared in the microwave so that they are crisp and tasty. The innovative and Áexible NorAbsorbit microwave packaging absorbs both moisture and grease during cooking in the microwave. The food is cooked directly in the packaging until it is crispy. Preparation is noticeably more convenient, shorter and cleaner than conventional frying in a pan. Nordenia International AG: visit www.nordenia.com

Batch Controller Mettler Toledo offers the new IND780batch stand-alone batch controller which combines advanced batching control technology while adhering to the ISA SP-88 Batch Standard. IND780batch optimizes batch processes with consistent, accurate material transfers, to minimize material waste, improve batch quality, and yield increased proÀts. It is a powerful and Áexible stand-alone terminal for single or multi-scale batching applications. Multi-material automatic batching control handles up to 28 automatic materials with recipe-speciÀc control. Mettler Toledo: (800) 638-8537 or visit www.mt.com/IND780batch

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TechShowcase

Temperature Verification New Black Body Calibration sources from Wahl Instruments are used for calibration and veriÀcation of infrared temperature instruments. Twenty-two different models are available, to suit a variety instrument speciÀcations. Both cavity and hot plate types feature dull black surfaces, to achieve an emissivity of as close to 1 as possible. Models with built-in or standalone temperature controllers are available, to provide stable, repeatable temperatures for uniformity, while also displaying the temperature of the target area.

Soy Protein Solbar has launched two new advanced products to expand its line for meat and poultry applications. Solbar Q 932 is an isolated soy protein carefully designed by the Solbar R&D team to support protein-enhancement systems applied in wholemuscle meat products. Solcon S-210 is a new functional soy-protein concentrate for emulsiÀed and comminuted cured meats, poultry and Àsh targeted for premium products. It contributes excellent emulsiÀcation and gelling properties to comminuted meat products. Solbar: Visit www.solbar.com

Wahl Instruments Inc.: (800) 421-2853 or visit www.palmerwahl.com

Temperature Sensitive Labeling PakSense XpressPDFLabels monitor time and temperature of perishable items during distribution and storage. Labels are Áat and feature an integrated USB connection point which can be plugged directly into the USB port of a computer. It then automatically generates a PDF data Àle containing complete time and temperature history including a graph and summary statistics. XpressPDF Labels are optimal in situations that require fully independent operation, including exports and distribution center to retail location. PakSense Inc.: (208) 489-9010 or visit www.paksense.com

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Knife Sharpening For professionals who prefer a steeled edge, Edgecraft’s commercial precision steeling device features super-hardened miniature steels and highly precise angle guides to consistently provide incredibly sharp knives. The ChefsChoice Commercial SteelPro quickly and easily delivers an edge far superior to conventional manually steeled edges. Made in the USA. ChefsChoice: (800) 342.3255 or visit www.chefschoice.com

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

Metal Detection

Oven

Material Discrimination X-ray (MDX) and SimulTask™ image analysis technologies from Eagle boost product inspection capabilities on food manufacturing lines through enhanced contaminant detection and ease of use. MDX technology enhances traditional x-ray inspection to allow detection of materials previously unseen by x-ray or other conventional inspection means. MDX discriminates materials by their chemical compositions (atomic number). This allows detection and rejection of historically undetectable inorganic contaminants such as glass shards, rocks, rubber, and plastic.

The Double D Searing Oven from JBT FoodTech provides unique color and texture to products from Panini bread to grilled chicken breasts. A special “Áame wash” produces dark highlights on the top and bottom surface, while an optional Bar Marker allows processors to create grill lines along a product in a straight line or zigzag pattern.

Eagle Product Inspection: (877) 379-1670 or visit www.eaglepi.com

Friedr. Dick GmbH & Co. KG: Visit www.dick.de

JBT Food Tech: (419) 626-0304 or visit www.jbtfoodtech.com

Stainless Steel Drill The Silver Steel HyperDrill is made from hardened stainless steel. The Silver Steel ensures that no small fragments of plastic end up in the meat. The sharpening unit consists of 2 x 2 replaceable HyperDrill rods: the result will be a precise cutting edge with a perfect angle. The extreme Àne cuts of the HyperDrill rods smoothen the Ànely ground edge. It can be used fastened at workplace or as handheld device.

Industry News In recognition of completing the Àrst year of its “On Our Way to Ending Hunger” program, Hormel Foods Corp. announced that donations to hunger-relief organizations throughout the United States and abroad totaled more than $5 million during its Àscal year 2011. Formalized in 2010, On Our Way to Ending Hunger focuses on collaborating with retailers, nonproÀts and government agencies on hunger relief efforts; nourishing the hungry domestically and internationally; and motivating individuals and corporate partners to take action to Àght hunger. “Hormel Foods is committed to combating the persistence of hunger in the United States and the world,” said Julie H. Craven, vice president of corporate communications at Hormel Foods. “Through the On Our Way to Ending Hunger program, Hormel Foods assisted two hunger relief organizations in Iowa and Minnesota, provided food to areas hit hardest by natural disaster, shipped 1.3 million cans of Spammy, a shelf-stable poultry product fortiÀed with vitamins and minerals, to supplement the local diet of the malnourished in Guatemala and donated funds

to local food banks and charities in 16 U.S. communities where the company has manufacturing facilities.” The Smithfield Packing Co. Inc., a subsidiary of SmithÀeld Foods Inc., announced that it would shift production from its Portsmouth, Va. plant to Kinston, N.C., and permanently close the Portsmouth facility in early 2013. The Portsmouth plant produces hot dogs and lunchmeat. The Portsmouth plant closure will affect approximately 425 hourly and salaried employees. Transfers to other facilities will be offered to some employees and the company will negotiate with union ofÀcials regarding potential opportunities related to this transition. “We deeply regret having to close this facility. We recognize that layoffs and plant closings are difÀcult for everyone concerned. But at the same time, we believe this is a necessary business decision. We are committed to our workforce and will work diligently to transfer as many employees as possible to our other operations in North Carolina and Virginia,” said Tim Schellpeper, president of

SmithÀeld Packing. Rock musician Huey Lewis and his friend John Tyson, chairman of Tyson Foods, teamed up for a major donation to a network of Montana food banks. Through Tyson Foods, the two initiated the shipment of more than 30,000 pounds of chicken to the Montana Food Bank Network (MFBN), Montana’s only statewide hunger organization. The donated food is enough to produce 120,000 meals. “I’m thankful for my friendship with John and his willingness to help feed people in need here in our state,” said Lewis, who calls Montana home. “Like many other parts of the country, hunger is a serious concern here, especially with rising food and fuel costs.” “Our company has been active in hunger relief for more than a decade and we appreciate Huey’s interest in joining us in this effort,” said John Tyson. “In addition to feeding people, we’re hopeful this donation will also help increase hunger awareness and prompt more people to step forward and get involved.”

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TechShowcase Supplier News Foodmate US Inc., the North American distributor for Netherland-based Foodmate B.V., has promoted Matt Foster to regional sales manager for the Central States. Foster will assist Foodmate customers in Arkansas, Texas, Missouri, Oklahoma, Iowa, and Nebraska by helping them design and implement equipment installations and upgrades to help increase production on meat and poultry processing lines. “Matt brings years of hands-on experience to the role of regional sales manager,” said Scott Hazenbroek, president of Foodmate US. “His experience in the Àeld allows him to truly understand problems and to provide day-to-day solutions for managers and supervisors at the processing plants.” Foster has more than 15 years of experience in the poultry industry having worked for two poultry equipment and three processing companies. Foster previously served in sales and technical support for Foodmate US. GEA Convenience-Food Technologies had announced the promotion of Steven E. McGady to vice president of sales for the Americas Region. McGady comes to this new position with over 20 years of industry experience. Previously, he has held a key customer manager position within CFS for multiple accounts. “With his inside knowledge of the organization and exceptional customer relationships GEA Convenience-Food Technologies looks forward McGady to continued success as we strive to provide our customers with the best support and performance in the business,” the company said in a statement. PMMI reports good news for U.S. packaging machinery shipments in 2010: a 12 percent jump from 2009, bringing the shipments totals to $5.5 billion, up from $4.9 billion the year before. PMMI’s annual U.S. Packaging Machinery Shipments Report also indicates exports, as measured in U.S. dollars, increased 9 percent, from $89.1 million in 2009 to $97.5 million in 2010, while imports jumped 13 percent, from $1.17 billion to $1.32 billion. “In recent years, the packaging machinery market has reÁected trends in the general economy,” says Charles D. Yuska, president and CEO, PMMI. “2008 shipments were generally Áat from 2007, and 2009 shipments dropped by about 16.3 percent. The increase in 2010 shipments mimicked the slow economic recovery, however preliminary data shows signiÀcant growth in 2011.” Multivac has opened a new HPP (High Pressure Processing) testing facility for perishable food products at its world headquarters in Wolfertschwenden, Germany. The new testing center will enable Multivac’s customers to conduct comprehensive evaluations 60

of the technology on a variety of product and package types. “Our customers can bring their food products to the testing center either packed or unpacked, since we obviously also pack the products here on site. In this way our customers can test various packaging concepts in conjunction with high pressure treatment,” says Dr. Tobias Richter, head of the HPP program at Multivac. Ecolab has launched a Poultry Export Program featuring Inspexx 150, a peroxyacid-based antimicrobial food additive for treatment of poultry carcasses, parts and trim. Inspexx 150 is a direct contact food tissue treatment that reduces levels of Salmonellae, Campylobacter, Escherichia coli and total bacteria on poultry surfaces, and can help U.S. poultry processors meet the unique microbiological and chemical requirements when exporting products to Russia. “Poultry producers face many challenges including increased reporting and regulations, as well as magniÀed incidents of food safety,” said Timothy P. Mulhere, senior vice president and general manager, Ecolab Food & Beverage North America. “We are committed to helping our customers meet these challenges, expand their poultry exports and improve the quality, safety and productivity of their operations.” Spirax Sarco, a supplier of steam systems, has completely refurbished its Blythewood, S.C. training facility. The revamped center will offer world-class training to help steam system operators address key issues, such as improving energy efÀciency, reducing downtime and operating costs, and ensuring safety. The center’s courses offer ‘hands-on’ experience that provide ‘real-world’ training, leading to formally recognized qualiÀcations. A highlight of the center is a fully-operational state-ofthe-art steam system that will be open for technology demonstrations as well as being used to support training courses. Using leading-edge steam control technology, the facility will showcase modern approaches to process control and energy efÀciency. For more information and a list of training facilities courses, visit www.spiraxsarco.com/us. Z Trim Holdings Inc. announced that Skidmore Sales and Distributing has recently added Z Trim Ingredients to its broad specialty product portfolio. Skidmore Sales and Distributing presently services over 3,000 customers in the Midwest and Atlantic regions of the United States. Doug Skidmore, President of Skidmore, said, “We look forward to working with Z Trim Ingredients to provide our customers with a wide range of economical, textural, structural and nutritional beneÀts from their products. We anticipate our customers will proÀt greatly from Z Trim’s multi-functional ingredients.” “Our new relationship with Skidmore ensures our customers will have prompt, uninterrupted shipments of our products; and the ability to leverage the advantages of Skidmore’s technical sales expertise, superior logistics systems and 11 convenient warehouses,” said Steve Cohen, CEO of Z Trim.

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DECEMBER DEC E EMB M ER ER 201 2011 20 1 | PPROVISIONERONLINE.COM ROV OVISI OVISI S ONE ONERON RON ONLIN LINEE.C LIN E COM | TH THEE NATI N NATIONAL ATIONA ATI AT ON L PPROVISIONER ONA ROVISI ROV ISIONE ISI ISIONE ONERR

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Meat Processing & Packaging AUCTIONS: JANUARY, 2012 - (2) PLANTS! The Industry’s Most Modern, Efficient Facilities! Mountain City Meat Co. - Denver, CO & Nashville, TN

(2) State of the Art Ground Beef & Steak Packaging Plants! MANY MAJOR ITEMS NEW 2006-2010! • • • • • • • • • • •

2006 Marel Automated Steak Trimming & Portioning System 2006 Marel 21-Station & 18-Station Pre-Trim & Trim Tables (12) 2007-2009 Formax M-700 & other Patty Formers (26) Mulitvac, Koch, Dixie & other Vacuum Former / Sealers (3) Safeline X-Ray Inspection Systems & (14) Metal Detectors 2010 & 2009 RMF/Amtek 30’ S/S Microwave Thawing Tunnels (15) Weiler S/S Grinders • Freeze Tunnels & Spiral Freezers (12) MTC & RMF S/S Mixers & Blenders - Column Dumpers 2009 Core Drill Samplers - Foss Scan Analyzers - Fat Analyzer Portioners, Vacuum Stuffers, Tumblers, Slicers, Dicers & More! Extensive Conveying Systems, General Plant, Trucks & MORE!

HARRY

DAVIS & COMPANY

www.harrydavis.com 412-765-1170 [email protected]

On-Site & Online Auction!

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www.ipeweek12.org | www.ife12.org JANUARY 24-26, 2012 | GEORGIA WORLD CONGRESS CENTER, ATLANTA, GEORGIA USA

GLOBAL MARKETPLACE FOR THE POULTRY AND FEED INDUSTRIES

The 2012 International Poultry Expo and International Feed Expo will be held January 24 – 26, 2012, and the week of the Expo has been officially designated as “IPE Week” with an emphasis on educational programs rounding out the weeklong event. The Expo is shifting to a TUESDAY, WEDNESDAY, THURSDAY format to increase the education programs available to attendees.

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The World’s Largest Poultry and Feed Technology Exposition Over 20,000 Industry Leaders from Over 100 Countries Over 14 Acres of Exhibits Exceptional Educational Programs Planned for IPE Week - International Poultry Scientific Forum - Hatchery-Breeder Clinic - Pet Food Conference - Animal Agriculture Sustainability Summit - Workshops on Safety and Environmental Issues - Symposium on Egg Production - Pre-Harvest and Food Safety Conference - Executive Poultry Outlook

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

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

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

0610NP_AGRIAssociates.indd 1

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

RECRUITMENT

Slaughter Supt. (Bf) ......................................$80K Slaughter Sup. (Bf) .......................................$56K Sup. (CaseReady GB) ...................................$50K Night Mgr. (PC Steaks) .................................$65K Op.’s Mgr. (PC Steaks)..................................$75K Mnt. Mgr. (Slice/Pkg Meat) ..........................$90K Asst. Mnt. Mgr (Bf Sl/Fab) ...........................$70K QA Mgr. (Sausage) .......................................$90K QA Sup/Proc. Food .......................................$55K

TREIF USA, USA, Inc. Inc. isis aaleader TREIF leaderinin manufacturing food in in manufacturing foodcutting cuttingmachines machines meat, poultry WeWe areare looking meat, poultryand andcheese. cheese. for Salesforand Service people inincapital looking a sales person(s) capital investment goods investment goodsfor forthe theUSA. USA. Qualifications: min. Sales and/or Qualifications: min.55years years sales Service experience for processing experience for processing equipment in equipment in the food industry. Highly and the food industry. Highly motivated motivated andsales professional sales and professional drive. Excellent service driven. Excellent communication communication and customer service and customer servicetoskills; who are willing skills; who is willing travel extensively. to travel extensively. TREIF USA is a growing sales and TREIF USA is a still growing and service company offering an sales excellent service company offering an excellent benefit compensation package. benefit compensation package. For more information please go to: For more www.treif.com information please go to: www.treif.com Interested candidates should forward Interested candidates should forward their their resume and compensation requireresumetoand compensation requirements ments [email protected]. to [email protected].

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EQUIPMENT FOR SALE

*Handling both Contingency and Retained Searches* National Openings available including but not limited to: • Plant Management • Operations Supervisors and Managers • Maintenance and Engineering • Quality Control Supervisors and Managers • Sanitation Supervisor and Managers • Warehouse Supervisor and Managers • Engineering Project/Process/Management • Positions available at various levels! To submit resumes or engage searches please contact: Kelly Meaney, Associate VP

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DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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

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Handtmann Mdl. VF200 Vacuum Stuffer, touchscreen controls, portion control, linker attachment, bucket lift, several horns, spare parts Meat Processing Equipment & Supplies Phone: 800-467-1201 • 402-597-5777 [email protected] www.mbasuppliers.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | DECEMBER 2011

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

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APS # SRB 3000 DIMPLE JACKET,W/INJECTION RIBBON MIXER ...............................................STOCK VMAG HP15 S , VMAG 1000 DC , VMAG 500 VACUUM STUFFERS .............................................STOCK HOBART HEAT & SEAL W/ AUTO L-BAR SEALER & SHRINK TUNNEL .........................................STOCK KOCH ULTRAVACS #’S 2000, 2100 & 3500 VAC. PACKAGERS ..................................................STOCK FPEC 2500 # & RMF CHALLENGE 3000 # VACUUM TUMBLERS ................................................STOCK KOCH 500#, GLOBUS 750 & 1000 LITRE VAC. TUMBLERS .....................................................STOCK CRYOVAC 8600-14CS, 8600-14E, 8610-14E & 8600-14ST ROTARY VACS. ...................................STOCK OLARI & CONTI TRIPE WASHER & REFINER .......................................................................STOCK 2- HOLLYMATIC 865 PATTYMACHINES ..............................................................................STOCK S.S. DUAL LANE POULTRY CONE EVISCERATE LINES FROM 15’ TO 6O’ ......................................STOCK STEAM JACKETED KETTLES WITH ADGD. & SCRAPERS FROM 80 TO 250 GAL. ............................STOCK BH 15 & BH20 SLICE-N-TACTS (5) IN STOCK VARIOUS SIZED HARP SETS ...................................STOCK RYOWA RC7800, THURN JR, GROTE 640E & ROSS 950-3 SLICERS ...........................................STOCK MULTIVAC M860 EPC ROLLSTOCKS .................................................................................STOCK REISER SUPERVAC 803B ..............................................................................................STOCK

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DECEMBER 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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

PACKAGING

FOR SALE

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

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1 Axle trailer, -20DG F, 120 cu.ft. 115 volt cold plate system. 2,000 lbs. payload.

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AdIndex Company

Page

Web site

Ajinomoto Ashworth Bros., Inc. Beacon, Inc. Birko Biro Manufacturing Company CSB-System International, Inc. Framarx / Waxstar Fristam Pumps USA Gleeson Constructors & Engineers LLC GPI USA Handtmann Inc. Hawkins Inc. Henry & Sons Inc. Hollymatic Ingredients Solutions, Inc. International Poultry Expo/ International Feed Expo Innophos James V. Hurson Associates Inc. Jarvis Products Corp. Kemin Niagara Tying Service, Inc. OSI Patty Paper Inc. QMS International Reiser Treif USA, Inc. UPEMI West Liberty Foods Wire Belt Company World Technology Ingredients Yamato

17 21 45 37 15 32 29 3 41 72 2 19 14 30 20 63

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PROCESSOR INDEPENDENT

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SERVING SMALL AND MIDSIZE MEAT, POULTRY, AND GAME PROCESSORS

PUBLISHER

Also publishers of: Beverage Industry, BrandPackaging,

Dave Lurie

PRINT, EVENT AND INTERNET ADVERTISING Dave Lurie

Candy Industry, Dairy Foods,

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

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

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GPI USA. More than you expected.

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

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

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PROCESSOR INDEPENDENT

December 2011

SERVING SMALL AND MIDSIZE MEAT, POULTRY, AND GAME PROCESSORS

Sam Edwards III, president and curemaster of S. Wallace Edwards & Sons

A cure for the Commonwealth

Also Inside NPC Processing new facility IPE show preview, booth profiles A Supplement to

“At J&G Foods, Inc., Reiser is much more than a supplier. They are a valued partner.” J&G Foods is a solidly positioned, successful niche supplier of case-ready meats for retail supermarkets and wholesale clubs. The company’s product focus includes natural, grass-fed and organic beef, marinated meats and Australian lamb. “Our strategic plan demands that we partner with equipment suppliers who provide the very best machinery, technology, reliability and service. When we completed our due diligence, we knew we had found a great partner in Reiser,” said Joe Piperato, President, J&G Foods, Inc. “Over the past two years, we have acquired six pieces of new equipment from Reiser. We use the Vemag HP10 Stuffer with an FM250 Loaf Former and a ProcessCheck checkweigher to produce high-end, perfectly portioned one- and five-pound ground beef blocks. We package it all using the Repak RE20 form/fill/seal packaging machine. We also use Reiser’s Holac Cubixx 100L Dicer to produce precision cut meats for stew and julienne slices for stir fry. And we recently purchased some additional equipment to help us produce MAP packages for fresh Australian lamb,” Piperato continued. “We couldn’t be happier with the performance of each of these machines,” added Piperato. “The folks at Reiser are professional, knowledgeable and easy to work with. Reiser has played a key role in the growth and success of our company.” Ed Briggs, QA Manager; Wayne Morin, Maintenance Manager; Joe Piperato, President; Ralph Babcock, Operations Manager; and Matt Pollard, Production Manager

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

Leading the food industry in processing and packaging solutions.

PROCESSOR INDEPENDENT

C O N T E N T S

DEC EMBE R

2 011

VOLUME 004 NO. 06

F E A T U R E S

10 14 16 20

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A cure for the Commonwealth S. Wallace Edwards & Sons keeps alive the tradition of Virginia country hams..

Getting a fresh start NPC Processing plans on big dividends from a new facility.

Lending labeling expertise Moore Brothers uses its graphic design abilities to help processors develop a brand image.

IPE Show Preview Poultry industry’s future on display at IPE ’12.

14

D E P A R T M E N T S Sam Speaks. . . . . . . . . . . . . . . . 4 Cordray’s Corner . . . . . . . . . . . . . 6 Processor Perspective . . . . . . . . . . 9 AAMP Report . . . . . . . . . . . . . . 17 NAMP Report . . . . . . . . . . . . . . 18 NMA Report. . . . . . . . . . . . . . . 18 SEMA Report . . . . . . . . . . . . . . 19

16

SMA Report . . . . . . . . . . . . . . . 19 Ad Index . . . . . . . . . . . . . . . . 23

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]

DECEMBER 2011 | INDEPENDENT PROCESSOR

3

SAM SPEAKS BY SAM GAZDZIAK

PROCESSOR INDEPENDENT

A SUPPLEMENT TO THE NATIONAL PROVISIONER AND OTHER BNP MEDIA PUBLICATIONS

Looking forward to 2012 ne of the side effects of having

O

a job like mine is that you develop an addiction to news. Between the press releases, newsletters, bookmarked websites and e-mail alerts I get on a daily basis, I read dozens of stories about this industry on a daily basis — some good news, some bad news, and some news that just defied explanation. The bad news was all too easy to find this year, between meat recalls, animal-handling controversies, corporate layoffs, rising corn prices and the corresponding hike in meat prices. The poultry industry, of course, had it particularly bad, as the chicken supply in the country still hasn’t dropped to meet the decrease in demand. It may take months before that industry can stop the bleeding, if it can happen at all in 2012. That’s not including the perennial problems that plague the industry: studies from “doctors” claiming that eating even a little bit of meat will cause every manner of cancer; activities of animalrights groups that value headlines more than actually defending the rights of animals; well-meaning federal regulations that would cause more harm than good if enacted. Fortunately, there was plenty of good news that could make even the most pessimistic person step back from the ledge. Many companies announced major capital expenditure projects, to modernize their operations or to enter into all new markets. Every week, we heard about new product launches, proving that companies aren’t putting their growth strategies on hold. From personal correspondence, I’ve

4

INDEPENDENT PROCESSOR | DECEMBER 2011

heard from many executives who said that 2011 was a good year. Maybe it wasn’t a record year, but any growth in troubling economic times is an accomplishment. More than a few business owners have told me that they haven’t felt any effects from the Great Recession or its aftermath. Perhaps the most heartening event I attended all year was the Meat Industry Hall of Fame. This annual event recognizes the trailblazers of the industry and was held November 1 in Chicago. This year’s honorees, like the previous classes, have spent decades in the industry, improving it with their ideas, their actions and their leadership. The times weren’t always good, and not every idea worked, but they persevered and left the industry better than they found it. Fortunately, there seems to be no shortage of leaders and innovators. Future Hall of Famers are already steering the industry and preparing it for the future. The Hall’s Class of 2050 is probably entering the business right about now. They’re out of college, they’re rising up the ranks of management, and they have some good ideas about where to take the business to make it more successful than ever. With the right mentoring, they will be well-prepared to step up when it’s their turn to lead. The economy and regulatory environments may change yearly, but the leaders in the meat industry will make sure there is always some good news in the headlines. Sam Gazdziak [email protected]

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

Publisher/Midwest Sales . . . . . . . . . . . . . Dave M. Lurie (248) 593-0337; [email protected] EDITORIAL Editor-In-Chief . . . . . . . . . . . . . . . . . . . . . Sam Gazdziak (770) 777-0058; [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] Production Manager . . . . . . . . . . . . . . . . . . .Brian Biddle (847) 405-4104; [email protected] Classified Sales . . . . . . . . . . . . . . . . . . . . Diana Rotman (847) 405-4116; [email protected] Corporate Reprint Manager . . . . . . . . . . . . . . Jill DeVries [email protected] AUDIENCE DEVELOPMENT Group Audience Development Manager. . . . Terry Owens Multimedia Specialist . . . . . . . . . . . . . . . . . . .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.

www.provisioneronline.com BNP Corporate Directors

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 Information Technology Scott Krywko Clear Seas Research Beth A. Surowiec BNP Media Helps People Succeed in Business with Superior Information

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Your label and your package: key members of your sales force e are all used to putting labels on our products. All too often we think of a label solely as a way to convey to customers information about; the product name, product ingredients, nutritional information, net weight and your company name. In reality a label can do so much more. It is often your first contact with a customer. An attractive label can influence whether or not a customer buys your product. When a customer walks up to a meat case, they have many choices. If your label and package do not catch the eye of a potential customer the probability that they will purchase your item has just decreased. Certainly for repeat customers, their previous satisfaction with your product influences repeat purchases; however, with repeat customers the label and packaging

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I feel we can learn some valuable lessons about appealing to the public from the restaurant industry. still play a significant role in overall product satisfaction. I feel we can learn some valuable lessons about appealing to the public from the restaurant industry. Restaurants are experts at mouth-watering entrée descriptions and meal presentations. You don’t purchase just a hamburger; rather you get a thick, gourmet, all beef burger expertly seasoned and cooked to perfection. The descriptions of many items are so tantalizing that you can hardly wait to try the entrée. You start to develop a positive, satisfied

 
 

 

 
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  6

INDEPENDENT PROCESSOR | DECEMBER 2011

C O R D R AY ’ S C O R N E R BY DR. JOE CORDRAY

opinion of the item before you ever see it or taste it. Restaurants are also experts in presentation. You don’t just get a slice of apple pie; rather you get a slice of pie with a dollop of whipped cream on it served on a plate that has been drizzled with caramel sauce. Think back to some of your recent dining experiences at nicer restaurants and remember the item descriptions on the menu and the way your entrée was presented to you. Think of how the restaurant’s labeling of the items on the menu and the way it packaged the entrée when it served it to you. Chances are they contributed significantly to your satisfaction or dissatisfaction with the meal. You also can improve customer satisfaction with the way you label

and package your product. Your label should not just present information. It should present it in an attractive and appealing manner. The font should be large enough that it can be easily read. Use contrast between colors on your label so it is easy to read. I recall picking up a bag of smoked rope sausage. The print on the bag was yellow and brown and very difficult to read against the background of the product in the bag. If you use a specialty ingredient in your product, whether it is honey or jalapeno, consider emphasizing it on your label. If you have a slogan for your company, use it on the label. Your label does not need to be only print copy. Consider incorporating an eyecatching graphic on it. Your package

should be easy for the customer to open. If appropriate, include suggested cooking directions on your package. Frequently, consumer dissatisfaction with a product is the result of improper preparation of it. Take a close look at your products through the eyes of a consumer. The appearance of a product plays a significant role in its success. Your label and package, in fact, be key members of your sales team. Remember: The surest way not to fail is to determine to succeed. Dr. Joe Cordray is the Extension Meat Specialist at Iowa State University.

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Where’s our Bobby Baun, eh? ecently there was a vote in

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Canada. Surprise, surprise, it was to choose the greatest hockey player. Those voting were to consider who displayed the greatest skills, courage, teamwork and—most of all—the greatest leadership. The overwhelming choice was Bobby Baun. Why? Well for all you Yanks who do not live and breathe hockey folklore, Bobby Baun was the captain of the 1964 Toronto Maple Leafs. Not unlike today, the greatest team on Earth was struggling, yet finally had their chance to win Lord Stanley’s Cup. All they had to do for the cup was to get past their archrival, the Detroit Red Wings. With 10 minutes left in Game 6, Baun slid to the ice to block a shot from Gordie Howe. Although visibly injured, Baun continued to play until he finally collapsed. The arena fell silent as the captain was taken off the ice on a stretcher at the end of the period. Needless to say the fans were ecstatic when Baun returned for the final period and then roared uncontrollably when he fought on to score the winning overtime goal, forcing a Game 7, which eventually led to the Toronto Maple Leafs winning the Stanley Cup. So why was Bobby Baun voted the greatest hockey player of all time? Given the way Bobby fought back in the third period to lead his beloved Maple Leafs to a Stanley Cup may have been enough. However, the game became hockey folklore when it was discovered that Bobby led his

beleaguered team to an overtime victory, fighting back and scoring the winning goal, all with a broken leg— a broken leg that was suffered in the third period prior to overtime. So I guess when I look at that tough third period, similarly we are all coming off the bench to play against our archrival team, nSTEC. I’m wondering where did our Bobby Bauns go? By now we are all aware of the existence of non-O157 Shiga toxin E coli, yet we still have not come together with our counterparts in the Canadian government to formulate a strategy, based on food science, to responsibly deal with these pathogens. We cannot and should not wait for a final rule from our beloved baseball-loving friends to the south. As well, we must independently consider all of the available science and based on what we learn in cooperation with the CFIA, take the appropriate actions at harvest and through the food chain. If the CFIA and Canadian industry came out for the overtime period and independently led our own scientific studies and compared our notes with our American counterparts, and then based on that science made decisions that led to responsible action, perhaps even the great Bobby Baun would be proud.

Fully automatic loading for dicing, shredding and strip cutting

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

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

John Vatri is the director of food safety at Cardinal Meat Specialists Ltd., one of Canada’s leading burger and cooked protein processors. 1.888.77.TREIF

www.treif.com

COVER STORY

A cure for the Commonwealth S. Wallace Edwards & Sons keeps alive the tradition of Virginia country hams. BY SAM GAZDZIAK, EDITOR

T

he history of the Virginia cured ham dates back to the first arrival of Europeans to America. The earliest settlers learned the process of salt-curing pork from the local Native Americans, and an industry was born. The history of S. Wallace Edwards & Sons doesn’t go back quite as far, but it has played an important role in maintaining the tradition of Virginia country hams. The company, stretching back three generations, has been producing top-quality hams, as well as bacon and sausages, since 1926. S. Wallace Edwards was originally a ferryboat captain working for his father-in-law. To make some extra money, he began selling ham sandwiches to his passengers, using ham that he had cured on his farm. The demand for the ham became great enough that he was able to quit his day job and become a full-time meat processor. At the onset, Edwards & Sons was a direct-to-consumer business, and by the 1940’s slaughtered up to 250 hogs a day. The company got out of the slaughtering business in the 1960s, and now under the leadership of president and curemaster Samuel Edwards III, it has expanded into a successful mail-order business and caters to specialty food stores and white-tablecloth restaurants nationwide. “When I came into the business, we opened two of our own ham shops and expanded the catalog business,” he says. “Today

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INDEPENDENT PROCESSOR | DECEMBER 2011

we sell all over the United States.” Edwards says that the company made a decision to stay away from major grocery chains, though it does sell to some smaller, independent/upscale grocery stores. It also has a country store on the property. “There are tons of people in that business,” he explains, “and you can lose the business over a penny. We decided to focus on the outstanding and stay away from the commodity market, because in my opinion, that’s been the demise of a lot of country ham producers in this country. We’ve shot ourselves in the foot by seeing who can produce a country ham the cheapest, and whoever sells it for the lowest wins the sale. Unfortunately, this has caused the demise of many country ham producers. Low or no profits and poorer quality is not the way to survive in the meat business.” By focusing on quality product and service, Edwards & Sons has grown both its wholesale and retail consumer side of the business. The company’s hams and other products have garnered write-ups in magazines including Bon Appétit and Martha Swewart’s Living, and they are sold to white-tablecloth restaurants across the country. Those types of placements, Edwards says, help the company gain customers who are still willing to pay for upperend foods. “The Martha Stewarts of the world, their focus is on really unique things — not foods that

S. Wallace Wallace Edwards & Sons Edwards Sons Surry, Va. Founded: d d 1926 19 926 Employees: 35 Specialties: Virgi V Virginia g nia country c t yh ham, am, sausagge, bacon

Sam Edwards III, president and curemaster of S. Wallace Edwards & Sons

companies make millions of pounds of,” he says. “It introduces to the public what they’re trying to get across, that this is something really special, and there’s usually only a small amount of it made.”

A Virginia tradition A traditional Virginia country ham is dry-

cured and has had a chance to age for 4 to 14 months depending on the type of country ham. While modern technology, including coolers and humiditycontrolled smokehouses, has made the process easier, Edwards & Sons still uses the same curing methods that pre-date electricity by duplicating winter, spring

summer and fall in the curing/aging process. The cure, which was perfected by Edwards’ grandfather more than 85 years ago, is hand-rubbed onto the hams, which are left to cure for approximately 30 days (winter). After that time, equalized for 2-3 weeks (spring) and then DECEMBER 2011 | INDEPENDENT PROCESSOR

11

COVER STORY smoked for a full week over hickory wood and sent to one of the company’s aging rooms (summer). There, they are aged under climate-controlled conditions for the required time. The company’s cured hams include a 3-month, 6-month, 12-month and 20-month variety, with the flavor becoming more intense as the meat ages. Edwards adds that the cured hams are ideal for mail order, because they are extremely shelf stable. One of the company’s more recent products, a thin-cut, prosciutto-style ham, is its entry into a certified-humane, antibiotic free, pasture-raised, breedspecific pork — Berkshire to be exact. Edwards notes that for a ham to successfully age for 12 to 14 months, it needs to be well-marbled, like the Berkshire pork. The Berkshire hams that Edwards produces, like the famed Serrano hams of Spain, are not meant to be cooked or fried. He was explaining to a New York chef the concept of these American country hams and how they should be prepared like prosciutto, Edwards jokingly called them “Surryano” hams, as a tribute to the company’s home of Surry, Va. “He took it and put it on his menu like that,” Edwards says. Since the restaurant’s menu is watched by other restaurants in New York City, the buzz about

the ham began to build, and the name stuck. The hams are available in boneless and bone-in varieties, as well as slices and tips. The company also has expanded into Berkshire bacon and sausage as well. While sales of the Surryano hams represent just about 10 percent of the company’s overall sales, it has become a successful new niche. A 7- to 9-pound boneless Surryano ham sells for approximately $180, which is still considerably cheaper than an imported Serrano ham. Along with its upper-end hams, Edwards & Sons has a diversified product

line. Bacon and sausage make up about half of the company’s sales, and its ham products also include a pumped “city ham,” along with its dry-cured country hams. “It’s definitely a growing niche for us,” Edwards says of the city hams, “but there are a whole lot of people who make those.” Along with the increased competition, Edwards acknowledges his own preference toward the dry-cured products. “I don’t know if I’ve got a ham snob problem, but why would you eat [a commodity ham] when you could have this artisan dry-cured product that’s got so much more flavor to it,” he says.

Ensuring a healthy future Edwards & Sons has expanded continuously since its start and now has 50,000 square feet of operating and office space. The largest expansion came in 1997, when Edwards added a large, partially empty building, so that when the company needed to add another cooler or a processing room, it would build a room inside the shell. “We were building something every five to seven years, and I felt like we were in the construction business,” Edwards said. As a result, expansions are able to get up and running in a matter of weeks

12

INDEPENDENT PROCESSOR | DECEMBER 2011

instead of months. Edwards & Sons has operated through the Great Depression, as well as numerous economic upturns and downturns since. Edwards recalls interest rates of 21 percent when he first got into the business after college. Nevertheless, each generation of ownership has maintained the business well and kept it growing and adjusting to the current times. Edwards’ father took over the business in the 1950s and helped shift it from slaughter to processing, while he has positioned it as a maker of upper-end, gourmet products. Edwards notes that his own start in the business began with splitting hickory logs, making sausage patties by hand and cleaning out the grease pit. While it wasn’t glamorous work, he says that the experience has been invaluable. “I understand completely the process, and when they run into a problem, quite often I can solve it pretty quickly,” he says. “My son is amazed that I still know/ remember “the trivial stuff” like where the breaker switch is in the electrical room for the receptacles in the sausage kitchen

says, helped him understand the futility of trying to compete in the retail commodity market. He tried to focus on supermarket sales when he first got out of college, and he managed to grow the company’s sales by 30 percent the first year. “I was actively going out and getting

or what refrigeration compressors are supposed to sound like when they are running.” Edwards moved into the office when he graduated from college, and his father gave him the opportunity to see all the facets of the business. That experience, he

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13

COVER STORY new restaurant business and new grocery business, and at the end of the year we looked at the bottom line, and I said, ‘We didn’t make any more money than we did the previous year selling 30% less tonnage,’” he recalls. “If you’re selling dry cured hams, bacon and sausage against the same type products filled with water, you’re going to lose all day long. It took me a year to figure that out.” Edwards has a son and a daughter who are both out of college and deciding whether or not to get into the family business. “I told them they need to go somewhere else and work for three to five years in whatever field they want, and we’ll talk about it then,” he says. “If they decide to come back, then great. If they don’t, great. The business has changed

Edwards & Sons’ new Surryano prosciutto-style ham is a play on words on the famed Spanish Serrano ham and a tribute to the company’s hometown.

and will continue to change and I think they both have a lot of talents they can bring to the table.” Edwards notes that being a small business owner, he’s had to wear many hats. “Wearing all of these hats you get it in mind that it’s all about yourself,” he says. However, Edwards says, now the company has a number of talented

individuals on board with some that have worked here for over 20 years. For example, after searching for the right sales manager for years, he found someone who has been able to grow sales at a faster pace than the company has seen in the last 15 years, and in a weakened economy. “I feel comfortable now that if something happened to me, even without a current family member in this seat, that the company would still run successfully because we’ve got enough great people on board.” IP

FEASIBILITY STUDIES

2 Batterymarch Park 1 Pine Hill Drive, Suite 400 Quincy, MA 02169

SITE SELECTION

CONGRATULATIONS TO NPC PROCESSING ON ITS SUCCESS & BEST WISHES IN THE NEW FACILITY

WAREHOUSE LAYOUT PROCESS LAYOUT OPERATIONS ANALYSIS ARCHITECTURE ENGINEERING

RENOVATING, EXPANDING, OR BUILDING A NEW FACILITY? For More Information Contact: Nate Larose Director of Project Development Phone: 617-328-7899 x15 Email: [email protected] www.cmcassociates.com

CONSTRUCTION VALUE ENGINEERING

DESIGN & CONSTRUCTION OF FOOD & BEVERAGE FACILITIES SINCE 1989 14

INDEPENDENT PROCESSOR | DECEMBER 2011

PLANT DESIGN/MANAGEMENT

Getting a fresh start NPC Processing plans on big dividends from a new facility. BY SAM GAZDZIAK, EDITOR

M

any small processors may find themselves succeeding in spite of their existing facility. It may be out-of-date or not ideally suited to their needs, but it will suffice until a better opportunity comes along. Unfortunately, the state of the economy may have kept companies from breaking ground on new facilities. The cost of construction may scare some people off, though many companies may find that the cost savings of a new plant will help to offset those costs. NPC Processing, located in South Burlington, Vt., has been operating out of a former Swift beef-packing plant that was built in the 1960s. It also has a plant for cooked products about 30 miles away. For president Dan Desautels, constructing a facility that put everything under one roof made good business sense. “As the business keeps growing, it seems like the more we do, the more it costs us, because of the way we’re set up here,” he says. NPC Processing, founded in 1995, has three different revenue streams. It produces proprietary protein products for multi-unit restaurant customers and sends products nationwide through the leading foodservice distributors. It also produces private-label products for distributors. Additionally, NPC specializes in Irish meat products, including black and white pudding, Irish back bacon and banger sausages. The company added the cooked plant in 2000 to accommodate the production of meatballs, Irish pudding and cook-in-bag products like carnitas. Desautels says that the company’s biggest logistical problem is that it has little

NPC’s new facility will condense two facilities and outside storage into one 27,000-square-foot facility.

storage in its facilities. “We have a lot of stuff in outside storage, in excess of 25 loads of product in outside storage at any given time,” he says. “There’s a lot of double- and triplehandling. We do what we’ve got to do, but it’s not like you can make it, put it where it goes and keep it there until you ship it.” After spending about three years planning for it, NPC broke ground this autumn on a new facility that will be completed by early 2012. The new building will be 27,000 square feet in size, more than three times the size of its current space. There will also be room for a 15,000-square-foot expansion in Phase Two. Although the costs of a new construction are formidable, the savings that the company is projecting makes plenty of sense. By eliminating the need for outside storage and double-handling, Desautels

says that the company will save approximately $12,000 to $15,000 a month with the new facility. “We’re also projecting about a 40 percent decrease in power for a building that’s going to be almost three times the size of what we have right now,” he adds. The new plant is located in an industrial park just a few miles from its current location. Because the company is growing so fast, Desautels has already tapped into its Phase Two expansion space to double the size of the cooler. “We have 30 employees, and we started off with four,” he says of the company’s growth. “We’re on a pretty fast track as of late, and we’ve added a couple of new accounts this year. The production area is about 30 percent bigger, and we need that, with room to grow. It’s going to be a well-oiled machine compared to how we’re operating now.” IP

DECEMBER 2011 | INDEPENDENT PROCESSOR

15

PA C K A G I N G D E S I G N

Lending labeling expertise Moore Brothers uses its graphic design abilities to help processors develop a brand image.

BY SAM GAZDZIAK, EDITOR

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ith the bevy of options available at a typical grocery store, a packaged good has about three to five seconds to capture the attention of a consumer, before that shopper moves on to the next product. Clearly, processors need packages with eye-catching designs that capture attention while still providing the information that will convince shoppers to drop the product in their shopping cart. Moore Brothers Design and Label Agency has specialized in helping small processors put together a winning brand image, from package design and logos to marketing materials, all while ensuring USDA compliance. The company has a special affinity for the meat industry, as the principals of the company, Rex and Charlie Moore, were the developers of the Maverick Ranch brand. When they licensed that brand to two other companies in 2009, they started Moore Brothers to capitalize on their expertise in brand development, marketing and brokerage. Packaging has to do more than look good, of course. USDA labeling requirements require information such as nutrition facts panels, ingredient statements and more. Stephanie Harmon, USDA label compliance services for Moore Brothers, notes that two of the most common problems she sees are labels that are missing the required regula-

16

tory information and label designs that do not adequately convey the features and benefits of the product. Getting the regulatory aspect correct is particularly critical, because USDA approval can take anywhere from two to four weeks and requires an application, a compliant label and claim support pieces. “If your label is incorrect or is missing required information, or if you fail to provide all necessary support pieces, USDA can send the rejected label back and require you to correct it,” Harmon says. “Resubmitting labels can be costly and time-consuming, especially when your consumers are waiting on the product to be released.” Harmon says that finding the balance between good design and regulatory compliance is a challenge that the company welcomes. In one recent example, the company was tasked with creating a company image, product labeling and packaging for a new company called Montana Mountain Bison. The company already had a logo in place, but needed branding and marketing help. “We created a brand image and complete family of labels for ground bison, bison steaks, bison burgers and bison franks,” Harmon says. “We also de-

INDEPENDENT PROCESSOR | DECEMBER 2011

veloped the content for those labels and obtained USDA approval for all of them.” Moore Brothers also developed a sales presentation and handouts for professional sales calls, attending some sales calls with Montana Mountain Bison. All totaled, it completed all the projects in six weeks — four of which were spent getting USDA approval. One of the most recent labeling developments is the advent of front-of-package nutritional information. While adding those new elements can create design challenges as well, Harmon says that it can be beneficial for the meat industry. “The ultimate goal of front-of-pack nutrition labeling is to help consumers make healthier food choices and prevent diet-related health problems,” she explains. “There is an abundant amount of nutritious meat choices that the meat industry can promote with front-of-pack labeling as well as other nutrition claim options. We are experts at bringing this to light.” IP

association news

AAMP encourages establishments to address potential allergens hazard

T

he U.S. Department of Agriculture’s (USDA) Food Safety and Inspection Service (FSIS) issued a pair of notices, FSIS Notice 35-11 and FSIS Notice 45-11, to its inspection program personnel after an increased number of products have been recalled this year due to the presence of undeclared allergens or other ingredients of public health concern. The agency has overseen 27 recalls for undeclared ingredients in the ÀUVWVL[PRQWKVRI 20 of which were due to undeclared allergens. FSIS issued recalls for 32 undeclared allergens in 2010 and 2009 combined. In many of these recent cases, the recalls were a result of a change in product formulation by an establishment, or a change in a supplier’s ingredients, which

had gone unnoticed on their product labels. Mislabeling for one of the eight main allergens results in a Class I recall because of the associated public health risk. The “big eight” allergens are: wheat, FUXVWDFHDQVKHOOÀVKHJJV ÀVKSHDQXWVPLONWUHHQXWV and soybeans. These recalls are costly, yet avoidable. It is every meat processor’s responsibility to ensure products are produced safely and labeled appropriately. The American Association of Meat Processors (AAMP) encourages establishments to carefully review their labels to avoid a recall due to undeclared allergens or other ingredients. Check labels for ingredient accuracy by asking yourself questions such as: have any changes to the product formulation occurred; have any changes in spice suppliers occurred; or has the

spice company changed its spice blend over the years? It is advised that processors implement a label review system in their establishments. Organize a way to regularly review labels with a method and frequency that works for you. AAMP has developed a model prerequisite program for allergens that may support a HACCP decision to deem this potential hazard as “reasonably not likely to occur.” The allergen prerequisite program addresses the following areas: Sanitation; Potential product cross contamination; IngrediHQWUHFHLYLQJ,QJUHGLHQWODEHOYHUL¿FDtion; Product rework; and Employee training program. This robust prerequisite program, complete with documentation logs, is available now to AAMP members via the Member’s Only section of www.aamp.com. To learn more about allergen control or to become an AAMP member, visit our website or call (877) 877-0168 today.

AMI Expo 2012 is altogether better

A

n old proverb reads, “To change and improve are two different things.” AMI Expo has both changed and improved in an effort to better meet the needs of our exhibitors and our attendees. The result is an exciting new partnership that gives AMI packer/processors yet another compelling reason to attend AMI Expo: thousands of their retail customers in one place. The 2012 AMI Meat, Poultry & Seafood Industry Convention and Exposition, to be held April 30- May 3 at the Dallas Convention Center, will be co-located with FMI2012, sponsored by Food Marketing Institute (FMI), the U.S. Food Export Showcase sponsored by the National Association

of State Departments of Agriculture (NASDA) and United Fresh 2012, sponsored by United Fresh Produce Association (UFPA). Attendees at the AMI Expo will DOVREHQHÀWIURPWKLVFRORFDWLRQ with access to more than 1,200 exhibitors focused on processing and packaging equipment and supplies, plus produce and retailer focused exhibits. AMI Expo has always delivered

quality education, networking and innovative exhibits that draw the industry leaders exhibitors want to see. This won’t change. Scheduled education sessions already include hot-button food safety topics such as Listeria monocytogenes and Salmonella control, nSTECs interventions and handling recalls. The quality of our attendees will also remain, with 92 percent having buying and recommending power and 42 percent with plans on making purchases over $100,000 within the next 12 months. We’ve kept the best and improved the rest. As a result, AMI Expo 2012 is altogether better. Come see for yourself! For more information, go to http://www.amiexpo.com.

association news

NMA annual convention set for February 14-18 in Tucson The National Meat Association’s 66th Annual Convention is set for Feb. 14-18 at the Hilton El Conquistador Golf & Tennis Resort in Tucson, Ariz. The NMA’s standout networking event offers excellent educational and EXVLQHVVRSSRUWXQLWLHVLQFOXGLQJÀUVWUDWHURXQGWDEOHVHPLQDUVDQGIRUXPVZLWKWRSLQGXVWU\VSHDNHUV :LWKLWVPDQ\VHPLQDUVDQGGLVFXVVLRQVWKH10$&RQYHQWLRQKDVDOZD\VEHHQDQLGHDOORFDWLRQWRNHHSXS WRGDWHZLWKWKHODWHVWWUHQGVDQGLVVXHVDIIHFWLQJWKHLQGXVWU\7KHUHDUHDOVRSOHQW\RIQHWZRUNLQJRSSRUWXQLWLHVZLWKIHOORZSURFHVVRUVDQGVXSSOLHUVWKURXJKIRUPDODQGLQIRUPDOJDWKHULQJV 7KH6XSSOLHU6SRWOLJKW6RFLDOJLYHVDWWHQGHHVDQRSSRUWXQLW\WRHQMR\FRFNWDLOVZKLOHYLVLWLQJVRPHRIWKH LQGXVWU\·VÀQHVWVXSSOLHUWDEOHWRSV7KHDQQXDO6DXVDJHIHVWDORQJWLPHIDYRULWHOHWVSURFHVVRUVSXWWKHLUEHVW SURGXFWVXSDJDLQVWRWKHUVLQWKHLQGXVWU\7KHUHZLOODOVREHWKHDQQXDOJROIWRXUQDPHQWDPRQJRWKHUVRFLDO events. 6XSSOLHUVLQWHUHVWHGLQDWDEOHWRSGLVSOD\GXULQJWKHFRQYHQWLRQVKRXOGFRPSOHWHWKHDSSOLFDWLRQIRUPDQG VHQGWRWKHDVVRFLDWLRQRIÀFH$6$37KLVLVDFRVWHIIHFWLYHHYHQWWKDWZLOONHHS\RXUEXVLQHVVYLVLEOHWR\RXU FXVWRPHUVDQGZHOODVDOODWWHQGHHV %HIRUHWKHIDOOVHDVRQFRPHVLQIXOOIRUFHPDNH\RXUWUDYHODUUDQJHPHQWVHDUO\WRHQVXUHORZDLUIDUHUDWHVWR 7XFVRQ$UL]$OVRFDOOWKH+LOWRQ(O&RQTXLVWDGRU*ROI 7HQQLV5HVRUWIRUURRPUHVHUYDWLRQVDW &KHFNRXWZZZQPDRQOLQHRUJHYHQWVIRUPRUHLQIRUPDWLRQ

Controlling the “Big 6” non-O157 STECs in Beef Processing And Other Industry Partners

E N AR O L TI Y CE

Food Safety Mini-Conference March 15, 2011 · 1 pm - 6 pm The Drake Hotel · Chicago, IL

With the announcement by FSIS that six additional strains of E. coli will be considered adulterants beginning March 5, 2012, this timely conference will bring together top industry experts to share the latest information processors need to control these pathogens and adapt to the new regulations. Program highlights include: t t t t t t

STEC Policy Overview, Dr. Barb Masters, Olsson Frank Weeda (OFW Law), and former FSIS Administrator The Packer Perspective, Brenden McCullough, National Beef Packing. The Processor Perspective, Tim Biela, AFA Foods Update on Prevalence and Testing Methods, Dr. Wendy Warren, AEGIS Laboratories FSIS Policy and Expectations, Dr. Dan Engeljohn, FSIS (invited) HACCP Reassessments for Further Processors, Dr. Jim Marsden, NAMP Senior Science REGI Advisor and Regent’s Distinguished Professor, Kansas State University STE

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This half-day Mini-Conference is just prior to the Meat Industry Management Conference presented by NAMP. ATTEND BOTH AND SAVE!

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www.n AY AT amp.c om

Need more Information? Go to NAMP’s web site (www.namp.com) or contact Ann Wells, NAMP’s Director of Scientific and Regulatory Affairs, at [email protected] or +1 800.368.3043 ext 103 North America Headquarters Washington DC · 1910 Association Drive, Reston, Virginia 20191, USA · +1 703.758.1900 (main) · +1 703.758.8001 (fax) · +1 800.368.3043 (member services) Canada Office · 203-2525 St. Laurent Blvd., Ottawa, Ontario K1H 8P5, CANADA · +1 613.739.8500 (main) · +1 613.733.9501 (fax)

18

INDEPENDENT PROCESSOR | DECEMBER 2011

association news

   
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19

IPE BOOTH PREVIEWS

Poultry industry’s future on display at IPE ’12

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he International Poultry Expo has long been the poultry industry’s source for solutions to current industry challenges, as well as a glimpse of the future technology. The 2012 edition of the show, scheduled for January 24-26 at Atlanta’s Georgia World Congress Center, will bring together poultry and egg industry leaders from around the world. This year’s event will not only provide a look at the latest in technology and services, it will examine the future of the American poultry and egg industries. The show is the world’s largest display of technology, equipment, supplies and services used in the production and processing of poultry and eggs and for those involved in feed manufacturing. All segments of the industry are represented: feed milling, hatchery, live production, processing, further processing, marketing and all support activities. The 2011 IPE brought had more than 20,000 attendees and more than 900 exhibitors. The event is organized by the U.S. Poultry & Egg Association. Funds earned at the International Poultry Expo are funneled directly back into the industry in the form of research grants, educational programs, communications and technical assistance. The educational program has always been a key aspect of the IPE, and this year’s program will feature a conference titled, “Charting the Course: An Executive Conference on the Future of the American Poultry Industry.” The conference will be moderated by Mike Donohue, vice president of Agri Stats Inc., and will examine current economic conditions, global competitiveness, and provide a vision of the American poultry industry in the coming years. The conference is free of charge to all expo attendees. “Perhaps in no other time in the history of poultry processing and production have the challenges been greater for our industries,” commented USPOULTRY chairman, Gary Cooper, Cooper Farms, Oakwood, Ohio. “Our industry currently faces high input costs, social concerns, government regulations, and international competition, while trying to keep abreast of the increasing global demand for food. The Charting the Course poultry conference was added to the 2012 IPE/IFE educational programs to help provide industry leaders with a view to the current and upcoming challenges and opportunities facing our industry,” Cooper said. A similar conference will take a look at the future of the American egg industry. The program is co-sponsored by USPOULTRY and the United Egg Producers. For more information about IPE 2012, please visit www.ipeweek12.org. The following pages contain previews of some of the machinery and technology that will be displayed by several IPE exhibitors.

20

INDEPENDENT PROCESSOR | DECEMBER 2011

JARVIS PRODUCTS CORP. Jarvis Products Corporation produces top-of-the- line poultry processing equipment. The company specializes in pneumatic tools for eviscerating and performing several off-line processing procedures. A high-precision vent cutter that economically removes poultry vents, on any type or sized bird. Durable chicken and turkey hock and neck cutters for faster hock and neck removal. A lung gun that is ideally suited for chicken, turkey, duck and goose lungs and kidney removal. Jarvis’ picking finger installer is cost effective by eliminating rubber finger damage, and speeding the finger installation process. Three different sized, air power scissor models are available, with many different blade sizes and styles, to perform many operations currently done by ordinary scissors, knives or hand clippers. Jarvis tools are sold and serviced worldwide through 15 branch locations, and Jarvis’ Federation of Distributors. For more information about these tools, product CD’s and literature are available. Please visit us at the IPE in Atlanta, Booth # 4412, January 23-27, 2012.

Jarvis Products Corp. 33 Anderson Road Middletown, CT 06457 (860) 347-7271 Fax: (860) 347-9905 www.jarvisproducts.com [email protected] IPE Booth #4412

IPE BOOTH PREVIEWS

REISER Reiser will introduce numerous new Vemag stuffers and linking solutions at IPE.

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

Reiser 725 Dedham Street Canton, MA 02021 (781) 821-1290 Fax: (781) 821-1316 www.reiser.com IPE Booth #4024

RIG-A-LITE

FOSS

RIG-A-LITE AZZ | R-A-L Rig-A-Lite products used in food processing facilities are infused with the excellence that our engineering department began by providing the leaders in the food processing industry with solutions to their unique problems. With a global network of electrical and industrial distributors in place and our complete selection of washdown rated and heavy hosedown rated luminaries, we have the right product for your project. Since 1938, we have consistently outperformed our customers’ expectations by providing quality products, fair pricing and on-time shipping. Facility maintenance managers, operations managers, lighting technicians, facility engineers, specifying engineers and electrical contractors around the world depend on our energy efficient and easy to maintain fixtures to keep their wet location, damp location, chemical wash-down, heavy hosedown and hazardous locations well lit and safe.

Rig-A-Lite AZZ | R-A-L 8500 Hansen Houston, TX 77075 (713) 943-0340 www.rigalite.com IPE Booth #5851

Foss has the nutrition analysis solutions you need to rapidly and accurately control key parameters in your production. As the leading producer of analytical solutions to the Food and Agricultural industries, FOSS offers solutions for online, at-line, and bench analysis of ingredients, in-process production, and final products. In poultry pro-

duction the innovative FoodScan™ solution is a perfect fit for determining fat, protein, moisture and salt. In addition, the MeatScan™ is a compact and robust analyzer extending the proven benefits of routine fat analysis to small-volume producers. For feed mills, the NIRS™ DS2500 is ideal for routine control of intake; optimal use of raw materials; production control for improved efficiency and final product monitoring on diverse control parameters. Visit booth #2342 to see for yourself!

FOSS 8091 Wallace Road Eden Prairie, MN 55344 (952) 974-9892 www.foss.us IPE Booth #2342

DECEMBER 2011 | INDEPENDENT PROCESSOR

21

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

Cured Meat January 17-19, 2012

Dry & Semi-Dry Sausage April 10-12, 2012

Sausage & Processed Meat July 16-20, 2012

HACCP Workshop October 25-27, 2012

Basic Sausage November 13-15, 2012

www.ans.iastate.edu/meatcourses

FOOD SAFETY

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

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

22

INDEPENDENT PROCESSOR | DECEMBER 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 INSPECTION

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


 



 
  Call CX R COMPANY

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

Buy Sell - Nationwide - Wholesale Prices

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

PROCESSOR INDEPENDENT

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PROCESSOR INDEPENDENT

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DECEMBER 2011 | INDEPENDENT PROCESSOR

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W H E N

I T

C O M E S

T O

increasing M A R I N AT I O N Y I E L DS, WE’D LIKE TO SHARE A FEW POINTS. With the smartest engineering in the industry, the Fomaco Injector not only provides the highest performance, it also raises marination yields to new highs. From its FM80 self-cleaning filter to its unique pump-to-pipe brine transport system to its individual stripper feet, every detail has been optimized to ensure injection accuracy and consistency. The result is a new level of product uniformity with unrivaled yields. Fomaco Injectors are available with 1, 2 or 3 needle bridges for all types of bone-in or boneless product.

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

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

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

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

Leading the food industry in processing and packaging solutions.