The National Provisioner March 2011

Taste still matters Culinary creativity, technical expertise and great authentic taste is still the recipe for any quality meat product – and it’s what the industry should rightfully expect from their ingredients supplier. At Chr. Hansen, we believe that a working partnership with our customers is the natural forum for creating innovative, individual solutions. Let’s meet, discuss recipes and inspire each other on how to create tasty, healthy and safe meat products for tomorrows consumer. t
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WHOLE-MUSCLE PROCESSING

The trickledown effect 76 | Processors of whole-muscle products are weighing consumer requests for less sodium with processing realities.

40

COVER STORY

Consum

Pressure point GL Foods plans to ride the popularity of high-pressure pasteurization (HPP) and grow into a multi-facility co-packer and HPP services provider.

12 | Regulations & Legislation: PHIS: It’s coming 14 | Fight for Food Safety: Animal health and ... warfare

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Form Strateugliation es

All-New Format!

Read Us Online

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

MARCH

er meat trends

2011 | A SUP PLEMENT TO A BNP PUBLICA TION

SPECIAL ECIAL REPORT

Formulation Strategies 25 | Value, health take the lead.

Departments Editor’s Journal ........... 10 Guest Commentary ...... 16 New Products ................ 38 Tech Showcase .......... 101 Classifieds ................. 108 Ad Index.................... 114

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March 2011

Tech

Volume 225 Issue 3

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 H. Russell Cross Texas A&M University

Dan Emery Meaningful Solutions

EXCLUSIVE FOOD SAFETY INTERVIEW |18

Q&A with Dr. Elisabeth Hagen

The FSIS Under Secretary for Food Safety updates readers on the industry’s progress in food safety and on the agency’s current initiatives.

John E. Johnson JBS

Huston Keith Keymark Associates

Lynn Knipe

FARM TO PLATE

PROCESSING TECH

PACKAGING TECH

72 | Battle lines have

93 | Food-grade

been drawn in the pre-harvest fight against E. coli O157:H7.

lubricants are achieving better results and meeting more stringent foodsafety certifications.

98 | Don’t rule out the power of nutrition labeling at the meat case.

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

Ohio State University

Gary McMurray Georgia Tech Research Institute Dan Murphy Meat Industry Hall of Fame

CONTRIBUTING THIS MONTH Mark Reed Border Management Strategies Steve Valesko Butterball LLC

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Barbara Young The National Provisoner

      


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editorial

Editor-In-Chief > Andy Hanacek [email protected] Editor > Sam Gazdziak Editor emeritus > Barbara Young This month’s contributors > Donna Berry, Cheryl Hendricks, Dennis Johnson, Megan Pellegrini, Mark Reed, Olivia Sant’ Angelo, Shawn Stevens, Kurt Vogel Art Director > Mary Ann Lawrence

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Editor’sJournal

ProvisionerOnline gets a makeover

B

y now you’ve noticed our completely redesigned Web site, ProvisionerOnline.com, which launched Feb. 28, 2011. I am truly excited about the polish and finish this new design brings to our content, which we continue to build in support of the print product. The first thing you will notice is the improved content organizational tabs -- Topics and Proteins. Content will be collected into these categories, allowing you to easily search and find related content by clicking a link. For example, if you’re reading a story about beef production and are interested in more beef-related stories, you can simply click on the Beef tab, and the site will display the most recent content tagged under Beef. Or if you’re interested in Packaging stories, just click on “Packaging” under the “Topics” tab. It’s simple and straightforward. Not only does the redesign change the look and feel of ProvisionerOnline, but the new contentmanagement system it employs allows us to significantly upgrade our graphics capabilities. On the new site, we can bring you more, better-quality photos from our plant and corporate visits, giving you unmatched access to the facilities of the top processors. Furthermore, we can replicate data tables and charts in ways we could not in the previous design. Now, that doesn’t mean The National Provisioner and Independent Processor have moved or will move to the backburner — far from it.You can expect the same in-depth reporting and storytelling here in these pages. What our redesigned Web site allows is excellent complementary coverage of the issues that mean so much to you, in state-of-the-art media formats, such as podcasts, webinars, videos and the like. Registration also allows us to customize our online coverage to meet your needs and expectations — which certainly may be different than those of the print product. We know you will find the new design to be slick and user-friendly, and we hope that you will share any feedback you can with us. We’re just a phone call or email away — don’t hesitate to let us know what you like or don’t like.

ANDY HANACEK [email protected]

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

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Regulations&Legislation

PHIS: It’s coming By Dennis Johnson

B

eginning this spring, the Food Safety and Inspection Service (FSIS) will implement its new Public Health Information System (PHIS). This new system will replace the current Performance Based Inspection System (PBIS) at all establishments, as well as serve as the new procedure for imports and exports. At its core, PHIS is an integrated data program. This single database will gather, collate and use all data generated by the inspection system. The data includes information such as a more detailed plant profile, non-compliance records (NRs) and any appeals, results of Food Safety Assessment (FSA), agency test results, recall actions, and memoranda of interviews (MOI). By analyzing this data, FSIS can respond either industry-wide or at a specific plant to address any public health issue identified. When the predictive analytics component of PHIS is finalized, the potential exists for responding to an issue before it occurs.

When implemented, inspection personnel will have access to all data on the establishment to which they are assigned.This will include the new plant profiles which are more detailed in terms of HACCP plans and products produced. Inspection tasks will be generated based on the plant profile and the results of previous inspection tasks. FSIS inspectors will no longer receive “scheduled” inspection tasks. Instead, the inspector will be given a list of tasks to perform on the “personal calendar.”This gives inspectors the ability to determine when to perform the task. Documentation of NRs and other data in PHIS will be more structured, such as the use of a “pick list” to specify the regulation violated. Importantly, PHIS will automatically generate follow-up tasks based on data entered into the system. The actual inspection tasks themselves will not change, with two exceptions: there will be a specific task for zero-tolerance checks and inspectors will combine the HACCP 01 procedure (verification of specific component of HACCP plan) and the HACCP 02 procedure (verification of entire plan). There will be one new task: Hazard Analysis Verification (HAV).With this procedure, inspectors will verify that the establishment’s hazard analysis considered the appropriate hazards in the HACCP, especially when there are “changes” in the process. A HAV procedure will be performed at least once per quarter or more frequently based on the establishment’s performance. Establishments will have access to data in PHIS. In terms of gaining authorization, the establishment must obtain an e-Authentication (eAuth) from USDA to access the system, and will be given a “key” to access the establishment’s specific information. Establishments will be able to see their plant profile (and request corrections), NRs and MOIs (and respond/appeal to these documents), and

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certain reports (not yet specified). In terms of implementation, domestic PHIS will come first. Although the timing is dependant on completion of negotiations with the inspectors’ union, startup could begin as early as April and will take approximately eight months to roll out by circuits to cover all establishments. Imports are next and will begin approximately 60 days after the start of the domestic implementation. Export implementation will be last and not begin until after the domestic module is completed. The dynamics of this new system should not be underestimated. The creation of a complete data base in terms of all data and all plants, will allow FSIS to focus on the establishments performing below the norm. As these plants improve, the bar will be raised and new plants will populate the lower levels. In addition, the establishments will likely have access to industry-wide reports. Given the inherent competitiveness of this industry, once establishments know where they stand, they will strive to do better with the result of driving up overall industry performance. PHIS is coming and it has promise. For now, an establishment would be well-advised to review the data that will likely be entered into the data base (e.g., existing NRs, sample results, FSA results, etc.) to identify opportunities for self-improvement. Getting ahead of the PHIS database will minimize any extra regulatory attention once the system goes live. Dennis R.Johnson is a principal with Olsson FrankWeeda Terman Bode Matz PC inWashington,D.C. Johnson has 30 years experience in food-safety law and regulation,representing large and small meat and poultry companies.

FightforFood Safety

Animal health and … warfare By Shawn K. Stevens

W

hat do E. coli O157:H7, Salmonella, Listeria and Campylobacter each have in common? All can be transmitted from animals to human beings. It’s no secret these (and other) diseases significantly affect human health. And, aside from the potentially devastating impact on humans, the more common of these diseases are also responsible each year for hundreds of millions of dollars in losses due to recall costs, business interruption, lawsuits and bad publicity. Fortunately, with strategic planning, the risks they create can be significantly limited. It is up to slaughter establishments, however, to ensure that the animals they receive are as healthy as possible, and that the production areas through which they ultimately pass remain sanitary.

As we all know, science-based procedures and protocols, which form the foundation of HAACP, must be continuously refined and reassessed. In turn, the first (but most often overlooked) line of defense against the potential for disease is likely to be a veterinarian. In slaughter operations, USDA veterinarians are tasked with identifying incoming animals that are, as a result of poor health or other reasons, not fit to enter the food supply. Because of their education (they receive an eightyear degree), veterinarians may be uniquely situated to offer additional, valuable insight regarding animal procurement and health, which could potentially help slaughter facilities enhance their existing food-safety programs. Armed with their unique perspectives, slaughter establishments could either refine their systems internally or seek input from outside consultants to resolve any weaknesses which are identified. This could include, at its most basic level, the development of more robust procurement specifications (directed toward the prevention of zoonotic disease) and supplier audits. From a litigation standpoint, the outcome of any lawsuit likely will hinge upon whether the company being sued can show a tireless effort to improve its systems. Such a company will be far more likely to

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

obtain a desirable result (and less likely to earn the ire of a jury) than a company who cannot. Moreover, companies that incorporate state-of-the-art protocols and procedures into all facets of their foodsafety programs (including animal procurement) are, by nature, much less likely to be involved in outbreaks, recalls and expensive litigation. In any event, veterinarians may be one of the best front-line resources a slaughter facility has, and their breadth of knowledge should be recruited. Indeed, working on the front lines, they might be compared to a military recon unit that serves to alert friendly forces of enemy positions and tactics. Armed with the insight they have to offer (one need only ask), slaughter facilities may ultimately find themselves better suited to bring the fight to an enemy otherwise difficult to defeat. 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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GuestColumn

Immigration in 2011: Reform or enforcement

O

ver the past decade, the meatpacking industry has bore the brunt of worksite immigration enforcement and witnessed government tactics change erratically as the nation wrestled with immigration policies. Gone, for now, are headlines showcasing raids of employers that served as the backdrop for the last ramp up to immigration reform during the Bush Administration. Instead, in another push for immigration reform, we have headlines about fines against employers and termination of unauthorized workers. In neither instance have there been headlines about stopping the employment of unauthorized workers. So, here we go again — and history shows us that the only certainty is that employers will suffer the consequences as the volume of the debate grows. Comprehensive Immigration Reform in 2011 will not happen. The numbers of the “undocumented” are still unmanageable to even process for legalization, and unemployment is still too high. And, despite bipartisan support for reform, the new Congress likely will drive the immigration-reform dialogue toward more enforcement and jobs for authorized workers, demanding that the nation deal with “first things first.” Immigration and Customs Enforcement (ICE) tactics and statistics likely will be challenged in terms of their accuracy and protection of lawful workers. Ability to bar unauthorized workers Mark Reed, from employment (not Border Management Strategies (BMS) fines) will become the Editorial Board litmus test for measuring Member effective worksite enforcement necessary to enable immigration reform. In spite of extraordinary efforts by the Department of Homeland Security (DHS) over the past two years, neither the border nor worksites are secure. And, until the American public has confidence in the government to manage illegal immigration, there will be no immigration reform, regardless of widespread pandering for the Hispanic vote. During the past three decades, whenever these issues

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

have surfaced in a push for reform, the result has been a greater surge of enforcement at the border and against employers of unskilled workers. During the last two years, ICE discreetly expanded their presence in the meatpacking industry through service of Notices of Inspection (NOI) on employers. Substantial, record fines were levied against employers, and thousands of employees were terminated as a result of this enforcement action. Although ICE established a much broader footprint in the industry, few employers were indicted and no known company had to shut their doors as the result of these notices. The true scope and impact of this new enforcement tactic is unknown. Employers engaged by ICE do not want others — particularly customers and competitors — to know they have received a NOI, and ICE has been able to thwart numerous disclosure requests from the media and others seeking the names of companies targeted, the amount of fines and the number of employees terminated. As the year progresses, Congress and the media should be expected to press much harder to acquire that information in order to measure government performance and impact. Regardless, the Administration realizes that its efforts toward barring unauthorized employment must be recognized and compelling in order to gain public support for immigration reform. They are also aware of the lines of thousands of authorized workers waiting to displace unauthorized

workers in this industry throughout the country. They will step up enforcement activity. The government also will continue its campaign to encourage employers to sign up to E-Verify for electronic employment eligibility verification and the IMAGE program for designation as a “trusted employer.” Although E-Verify does not effectively bar the employment of unauthorized workers as claimed, it is clearly a best-practices tool that participating employers like and endorse. That said, although cooperation with the government is highly recommended whenever possible, employers should carefully consider the consequences of attempting to join the IMAGE program. The qualification process is rigorous; the politics can be challenging; and administration of the program will change with changes in leadership. As 2011 progresses, we will see worksite enforcement again move from the shadows and into the limelight of

the immigration-reform debate. Many employers have learned that they can manage this risk effectively by building immigration-compliance programs that provide for technical compliance and eliminate the potential for major disruptions associated with unauthorized workers. Vigilance toward an authorized work-

force as well as technical compliance will be important and valuable to employers as the run up to the elections in 2012 unfolds. Mark K. Reed was the highest-ranking career government official in the Immigration and Nationalization Service. Since retirement in 2001, he helped found BMS, a work-site compliance consulting company in Tucson, Ariz. Contact him at [email protected].

MARCH 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

17

Q&AFood Safety

Hagen updates FSIS progress Prior to her Feb. 10, 2011, presentation at the National Turkey Federation’s annual convention, Dr. Elisabeth Hagen, Under Secretary for Food Safety for USDA Food Safety and Inspection Service (FSIS), provided updates to several agency initiatives in a one-on-one interview with Dave Lurie, publisher of The National Provisioner.What follows is their conversation:

Q& A

Lurie: What is the status of the draft guidance for the validation for HACCP systems, which was released in 2010? Hagen: We got a lot of comments on that, and that’s probably putting it gently. I think the message from our stakeholders was clear — particularly our industry stakeholders — that those guidelines were a necessary and important step, but that we probably had a long way to go in terms of making them more useful and more understandable. That’s what we’ve focused on: analyzing those comments and moving on to the next step. I can’t give you a date, but we’re pushing to get them out this spring sometime. I think what the industry will see is a reflection of the input they gave us — I think it will be a much more useful document for the industry. Lurie: How did the industry respond? Hagen: I would say the response was mixed. There were a lot of questions about

With Dr. Elisabeth Hagen, Under Secretary for Food Safety, USDA Food Safety and Inspection Service

Photo by Bob Nichols, USDA.gov/flickr

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TH THE HE NA NATIO NATIONAL TIONAL TIO NAL AL PR PROVISIONER ROVI OV O VISIONER V SIO SIO ONER NERR | PROVI PPR PROVISIONERONLINE.COM ROVI OVI OVISIO OV V SIO SIO SI SIONER ONER NERONL ERRON ONLINE ONL IN NE.C NE .CO CO C OM | MAR MA MARCH CH 201 CH 2011 1

By Dave Lurie, publisher

“When it came to our new high-speed hot dog packaging line, no one could keep pace with Reiser and Repak.” “At Berks Packing Company, we are a thirdgeneration, family-owned and operated meat processor. We supply the food service industry and retailers with a wide variety of high-quality hot dogs. We were looking for a flexible, high-speed, automatic loading and packaging system that would allow us to easily produce upwards of twenty different package sizes. After talking with all of the potential suppliers, we chose the Repak RE25 form/fill/seal packaging machine from Reiser. “Reiser came to us with more options and better ideas. They took us to see a similar high-speed installation in Canada. The more we talked with Reiser, the more confident we became that the Repak would be the race car we needed. And they delivered! “The Repak works perfectly with our high-speed automatic loader to produce attractive, wrinkle-free, perfectly sealed packages. Depending on the package size, we can now package up to 1,400 hot dogs/minute. From sales, to support, to delivery, to installation, to their guarantee, our family couldn’t be happier with the Reiser team. In fact, we’re so pleased with the performance of our new RE25 that we just placed an order for an additional machine!” Pete Boylan, Product Development Manager, Berks Packing Company, Inc.

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Joe Schmidt Reiser

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Q&AFood Safety specifics and the way it was rolled out. But this is something that industry essentially has been requesting for some time, some clarification on what validation means. And that’s one of the biggest misunderstandings about this, that it’s some kind of new set of requirements or regulations. It’s not at all; it’s part of the foundation of HACCP. It’s always been there, that a foodsafety plan can work in theory and does

Photo courtesy of the National Turkey Federation

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work in practice. It’s always been a requirement, and there has been confusion around how do processors show that it can work in theory and does work in practice? That’s what these guidelines were meant to do, and if they were not received in that way, then we need to take a look at the way they were put out there. I think we’ll be in a good place with industry when they get out in the spring. Lurie: Where does FSIS stand on the issue of non-O157:H7 varieties of E. coli? Hagen: I’ve gone on record about this and I’ll say it again here: O157:H7 is what we’ve known about and targeted since 1993. That organism took entire nations and the world by surprise, and we had an outbreak that impacted as many as 800 people, and four children died. So we reacted and declared O157 to be an adulterant in ground beef, and that kind of evolved into ground beef components. And I think the industry has done great work. The agencies continue to build strong policies around that. But now it’s 2011, and we know an awful lot more about all the threats in ground beef. And we know that there are close cousins to this organism that cause the same range of illness and can kill people. These are dangerous actors, and we don’t explicitly address them in our policies. If we are a prevention-based organization with a prevention-based mission, we need to think about how to prevent as many illnesses as possible. So, our position is that we need to look at the risks as they exist today in 2011. Lurie: Which of the additional subtypes fall into FSIS’ main focus? Hagen: There are probably hundreds of subtypes of the shiga toxinproducing E. coli, so there are many, many subtypes that fall into that category.What we’re focusing on are those that are known to be pathogenic, those that are known to cause illnesses in humans, those that have been recognized by the Centers for Disease Control and the World Health Organization as emerging threats. So there are a number of them, but some of them may not cause any harm at all, so we’re focusing our efforts on how to detect those that do and prevent illnesses from those six. Lurie: What is the latest news regard-

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Q&AFood Safety We want to innovate as an agency and promote that within the industry we regulate. ing FSIS’ progress on low-dose carcass irradiation as a processing aid? Hagen: There has been a petition before the agency for more than five years

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now, and I think that’s more than enough time to make a decision. I can’t speak to why the decision has taken as long as it has, but it’s a tough issue, because on the

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

one hand, we don’t want to prevent innovation.We want to innovate as an agency and promote that within the industry we regulate. This technology has some promise, yet it is an unproven technology. There isn’t a single company out there right now that could implement this tomorrow, and there are some concerns with this petition about whether we really could call this a processing aid.We’ve expressed this concern repeatedly to the American Meat Institute, we’ve asked for more data and still hope we can get more data from them, but right now there are things that would prevent us from moving forward, not the least of which is that we have a regulation that requires that meat products that are irradiated and then go on to be furtherprocessed must be labeled. That exists. It’s a regulation. So there are a number of concerns about this, but at the same time, there is some promise in this technology and a lot of us, I think, would like to see this move further down the line. It’s just a matter of how we get there. Lurie: Where does FSIS stand on high-pressure pasteurization as a foodsafety tool? Hagen: We don’t really take a stand on one technology versus another. It’s a technology that is highly effective in the ready-to-eat environment in particular, so there’s no barrier in place at all right now to using that technology in the industry. It’s very effective for pathogen reduction, so we don’t really take a stand on that compared to other technologies. It’s available, it’s out there, and companies can use it.We recognize it as highly effective, particularly on ready-to-eat products. Lurie: What are the primary goals you have set for the meat industry and FSIS, in terms of preventing foodborne illness? Hagen: Well, that answer is fairly simple, but it’s not simple to get there. Forty-eight million people get sick every year from food disease. That’s not all from the products we regulate as FSIS or the meat and poultry industry produce, but

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Q&AFood Safety that’s a lot of people getting sick every year. So that’s our goal: to reduce that number. It just shouldn’t be a fact of life that American consumers accept that people will get sick and die from what they eat. That’s our only goal, along with how we bring down those numbers, particularly for key pathogens that we focus on — E. coli, Salmonella and Listeria — and the products we regulate. Lurie: What is the most challenging hurdle to overcome to reach that goal? Hagen: I would say that dealing with meat and poultry, particularly raw products, there’s an inherent level of risk there. Not just with raw meat and poultry, but really with food products in general. Finding new ways every year to combat that risk and bring those numbers down as close to zero as possible, that’s an inherent challenge. There are so many good ideas out there about how to make food safer, how to make people safer, and for me the challenge is how do you bring all those

things together, work with all the partners you need to work with, and how do you do that in the span of an administration. For me, that’s a personal challenge. But I think Hagen this is a unique time. We have an industry that wants to move forward and make food safer, we’ve gotten calls from consumers, Congress and everyone to do the same thing, to get ourselves to a place where we do not have 1 in 6 Americans at risk from the food they eat every year. Lurie: Can meat processors get help from FSIS on some of the labeling requirements that have been enacted recently? Hagen: We have every intention of providing help.We have webinars planned, we have all sorts of outreach activities planned. There will be label examples that will be available to be

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obtained from the agency, and we can — I think those things might be included somewhere in the press release, and we can give you that information and a link for people to go to see all the things that are going to come up. But we recognize that particularly for smaller processors, that’s going to be an issue.We focus all the time on how to reach out to small and very small establishments particularly.We have an entire office set up at FSIS that was created in the last five years that just focuses on outreach to small and very small plants, so we have every intention of making this transition as seamless as possible for them. I know they have a whole rollout of outreach planned. Lurie: President Obama put forth an executive order after the first of the year to have agencies look at reducing the number of regulations and obstacles for businesses.Was FSIS included in that, and if so, are you in the process of doing that? Hagen: I think this administration as a whole shares in this goal of how do we do the essential work of government? In my case, the most essential thing is keeping people safe from harm, and so how do we do that without unnecessarily burdening the businesses that do this work? So I think the entire administration is looking at that. In my case, Secretary Vilsack has said to me that we’re going to leave no stone unturned. We’re going to look at everything we have: our legislation, our regulations. There will be places where we may need new legislation, but there may be places where we need to look at what we’re doing, and see if it makes sense and is still effective and efficient. I’ve said over and over again, we’re not looking to get more laws, regulations and policies on the books just so we can have them. They need to make sense in today’s climate. One of the things that we talked about this morning was the Salmonella Initiative program. At FSIS, I think this is a great example of collaboration between industry and FSIS that allows the production of safe products without over-regulation of industry. So I think you’ll really see the administration not just in food safety taking positive steps in that direction.

Formulation Strategies Consumer meat trends

MARCH 2011

Formulation Strategies g

Value, health take the lead By Olivia Sant’ Angelo, Innova Market Insights

onvenience, health and “clean-label” trends have been dominating innovative recent product development in meat. An Innova Market Insights analysis of the top positioning of new tracked U.S. meat products in 2010 (see Figure 1) was led by “ready prepared,” followed by the clean-label positioning of “no/additives preservatives” (155) and “natural” (138). Innovative recent launches have included Perdue Whole Grain Chicken Breast Nuggets, which are whole-grain chicken breast nuggets in a plastic pouch containing 4g of fiber. There were also a high number of products featuring a “low fat” (150) or “gluten free” claim (117). As 2011 begins with escalating food prices and continued fears over job security, consumers looking for value or to return to basics will drive new product activity trends.

C Gaining value

Contradictory trends have come about as a result of the tough economic environment, with consumers looking to eat out less, yet spoil themselves with something truly special at home. Consumers are looking for value from their food products, which could relate to price

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FORMULATION STRATEGIES | THE NATIONAL PROVISIONER | MARCH 2011

Consumers continue to demand positive value, quality and health benefits when it comes to the protein products they purchase for their families.

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Formulation Strategies Figure 1 Top positioning categories for new meat products (U.S. 2010)

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FORMULATION STRATEGIES | THE NATIONAL PROVISIONER | MARCH 2011

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As mentioned earlier, the need for austerity in tough economic times has led consumers to eat out less, but in turn spoil themselves with true indulgence at home. One potentially positive result of the downturn is a rising interest in quality home-cooking and improved kitchen skills. There have been rising numbers of repositioned and completely new products designed to cater to the creative home cook. Nielsen recently noted that U.S. consumers place more attention on at-home meals and in-home entertainment options, as evidenced by more time spent visiting cookingrelated Web sites, watching food-related TV programming and reading cookbooks. Strong sales were noted for celebrity chef-inspired brands on the grocery shelves. Dollar sales for a broad set of selected restaurant and celebrity chef brands are up 12.6%, and unit volume is up 10.6% versus two years ago, with annual sales just shy of $4.75 billion. The trend towards celebrity chef-branded or -endorsed meals and meal components, has progressed markedly in recent years. Prepared-foods categories seeing particular activity in celebrity-chef endorsement include ready meals, soups, sauces and accompaniments across frozen, chilled and ambient products.

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or size, but may also mean opting for something of outstanding natural quality at a good price that is “value for money.” Logically, use of the word “value” has risen dramatically in the last 24 months. Innova Market Insights tracked 1,936 products using the word “value” from October 2009 through September 2010, which was level with the previous 12 months (1,934), but up dramatically from before the downturn (October ’07-September ’08), when 887 products were tracked globally using this word. If consumers believe they are getting value for money, they will be willing to pay for it. It is the crowded center market that needs to be careful, as consumers turn to either budget or value-added premium products. “Processed is Out” and “Offering Real Value” were Innova Market Insight’s top two trend choices for 2011 (see Table 1). Two of the other top 10 trends had particular relevance for the meat industry; “Culinary Expansion” and “Try a Little Respect.” These two trends, together with the continuing reduction in sodium are key drivers for innovation in the meat space.

Source: Innova Database, Innova Market Insights

Chef endorsement Using the endorsement of a chef can add an authentic edge to a product, and Innova Market Insights tracked 322 new products in the U.S. featuring the word “chef,” compared to 232 in 2009. Innovative products introduced last year included Chicken and Vegetable Chinese-style dumplings from Wolfgang Puck. The products are “filled with fresh chicken and vegetables and are beautifully complemented by my garlic chili ponzu dipping sauce.” Also new is Sanjeev Kapoor’s Khazana Chicken Aachari Spice Mix, a chicken aachari spice mix in a 75g sachet, endorsed by the world-renowned Indian chef. Chicken aachari is a traditional chicken curry dish from India with a twist of pickling spices. The launch of chef-endorsed protein products has not been limited to the U.S. In Germany, activity has been limited, although the influence of TV chefs is obviously growing, with a number of interesting launches over the past year.

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Formulation Strategies

Interesting for its use of unusual flavors was the premiumstyle delicatessen meat products range under the Zacherl’s branding, endorsed by Ralf Zacherl. The range features the Chef’s Mediterranean Corned Beef, Orange-Calves-Salami With a Pepper Mixture, Green Tea Sliced Meat with a Herb Coating, and Fine Calves Bratwurst with Lemongrass. In the UK, most success seems to have been generated by longer-term relationships between retailers and chefs, with Sainsbury’s link with Jamie Oliver one of the best examples of this. Perhaps more surprising was the March 2010 announcement by up-market retailer Waitrose, which had never used celebrities before, that it had signed Delia Smith and Heston Blumenthal to star in ads featuring, in effect, mini cooking programs with one or both of the personalities demonstrating a new recipe. Following this, Waitrose announced in October 2010 that it was launching an up-market “Heston from Waitrose” foods range in collaboration with Blumenthal, featuring a range of unique flavors and combinations of ingredients, a talent for which he is particularly noted. The range includes pies, stocks, dressings and seasonings, including Beef, Ale & Kombu Pie.

Fair treatment The sustainability trend continues to gather pace, whether for environmental reasons or for care for human welfare through programs like Fair Trade. Manufacturers are answering consumer calls for more sustainable practices, with Unilever expanding to the U.S. market its Hellmann’s program for mayonnaise created using cage-free hens, after its implementation in European markets. In an analysis of new meat/fish products with an ethical positioning, Innova Market Insights tracked 101 new U.S. products with this positioning in 2010, up from 74 in 2009. Most of the launches related to sustainably caught fish. 32

FORMULATION STRATEGIES | THE NATIONAL PROVISIONER | MARCH 2011

Whole Foods offers Mary’s Free Range air-chilled chickens, which are individually cooled using cold air, “rather than placing the chickens in a communal bath of water.” The free-range chickens are produced without added water, antibiotics, salt or preservatives, and the chickens are fed a vegetarian diet. Nature’s Promise Naturals Buffalo Style Glazed Chicken Wings Fully are cooked, buffalo-style glazed chicken wings in a resealable plastic bag. The chickens are raised with no antibiotics, no added hormones. The brand includes the following claim: “Nature’s Promise products represent what nature intended. No artificial ingredients to deliver true flavor, great taste and made with respect for the environment.”

Developed markets The trend towards animal welfare in meat is more developed in European markets, and the recent dioxin scandal in Germany is only likely to fan the flames. The Dutch market in particular has featured a high amount of recent activity in this area. In December 2010, retailer Albert Heijn began offering pork products with 1 Good Farming Star (Beter Leven Kenmerk) as a standard. The products with animal welfare in mind come from pigs that were born, reared and slaughtered in The Netherlands. The range came about as a result of collaboration between Vion Food Group, Albert Heijn, animal-welfare organizations and farmers. Peter Beckers, COO of Vion Food Group, explained the concept at the recent Protein Summit in Amsterdam. “The pigs have 20-25% more space, and there is material to play with in the form of straw or wood. Importantly the pigs are not castrated, and they are fed with sustainable soy,” he noted. As well as pork meat with 1 star, Vion also offers meat with 2 or 3 stars. Two stars is for “free range” meat, where the pigs have been outdoors. Organic meat

Formulation Strategies earns 3 stars. Also in this space, veal manufacturer VanDrie Group has developed a European welfare monitor for veal calves, together with other Dutch veal producers, the Ministry of Agriculture, Nature and Food Quality and the Netherlands Society for the Prevention of Cruelty to Animals. This allows for an “objective, scientifically sound and practically feasible assessment of the level of welfare of veal calves.” Of course, there remains a group of consumers who avoid meat and dairy products altogether, cutting back for either environmentally conscious or health reasons. Innova Market Insights tracked 55 new products globally in 2010 that featured the word “meatless,” down from the 82 tracked in 2009, but up from the 42 tracked in 2008. A blend of meat and other proteins — or scientific innovation — may be one successful way to address some members of this group, as was proven with

meats. The extra lean meat contains 30% vegetable-based ingredients. The extra lean meat is available in various formats including hamburgers and mince meat.

Innova Market Insights’ Top Ten Trends for 2011 1. Processed is Out 2. Offering Real Value 3. “Proven” the New Buzzword 4. Return to Softer Claims 5. Getting Connected 6. Culinary Expansion 7. New Relaxation Paradigm 8. Fruit & Veg Revival 9. Try a Little Respect 10. Selling the Technology

Reducing sodium

some highly innovative 2010 launches. Vion used wheat protein in a new mince product with 30% less meat (Hackplus, Germany). Albert Heijn was awarded with the Dutch Nutrition Center prize for 2010 for the creation of a new meat with 30% less fat than other low fat

The trend towards reducing sodium has been one of the most important in the last two years, and this is not slowing down. Recent launches include Sara Lee Fresh Ideas Lower Sodium Virginia Brand Ham, a self-service deli sliced meat claimed to have 32% less sodium than USDA data for ham. Also from Sara Lee is Hillshire Farm Deli Select Lower Sodium Ultra Thin Honey Ham, with 25% less sodium than USDA data for ham. Innova Market Insights tracked 21 new meat/fish products with a “low sodium” positioning in 2010, compared to 19 in 2009. Globally, Innova Market Insights tracked 107 new meat/fish products with this positioning in 2010. However, with consumers associating low sodium with low taste, the actual numbers of launch-

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Formulation Strategies es that have reduced their sodium content without promoting it is much greater. In November 2010, for example, Nestlé Prepared Foods Co. (U.S.) announced a comprehensive plan to decrease the sodium content in its products by another 10 percent, from reductions made earlier this decade. This major initiative will carry through 2015 and includes the company’s Stouffer’s, Lean Cuisine, Buitoni, Hot Pockets and Lean Pockets brands, “which will undergo gradual but steady recipe changes in order to bring down sodium levels without impacting taste.” Many other protein and prepared-foods businesses have set forth similar plans and goals, keeping their plans under the radar. Regulatory pressure will likely push sodium-reduction strategies even further. In January 2011, the American Heart Association (AHA) issued a

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call to intensify efforts to reduce the amount of sodium Americans consume daily. In an advisory, published in Circulation: Journal of the American Heart Association, the association set out the science behind its recommendation for the general population, which is to consume no more than 1500mg of sodium a day because of its harmful effects — elevated blood pressure and

FORMULATION STRATEGIES | THE NATIONAL PROVISIONER | MARCH 2011

increased risk of stroke, heart attacks and kidney disease. Sodium consumption is currently more than two times higher than that recommended upper limit, with 77 percent of that consumption coming from packaged, processed and restaurant foods, the AHA noted. Developing a “clean label” product that can meet consumer demands for health and sustainability, while also allowing them to test their own creativity in the kitchen, will hit all the right notes in the creation of a true meat innovation. The author, Olivia Sant’ Angelo, is a Market Analyst at Innova Market Insights (www. innovadatabase.com) a leading supplier of new product and trend information in the food and beverage space. Innova Market Insights is organized by food industry professionals to rapidly record new product activity and identify the trends driving the industry today and in the future. For more information contact [email protected].

Ingredients&Formulations

Spicy secrets By Donna Berry

pices have long been recognized as ingredients that provide flavor to foods, in particular, meat, poultry and fish. But some of them also possess hidden talents. Some can act as a shelf-life extender, and a number of spices, as well some ingredients from the closely related category known as herbs, have antimicrobial and antioxidant properties.

S

This is great news to formulators trying to clean up ingredient legends by removing chemical-sounding additives, regardless if they are artificial or natural. Depending upon the usage level and form, as well as the application, herbs and spices are either declared by name or sometimes simply as “natural flavor.” Over the past 50 years, numerous investigations have shown that herbs and spices can effectively inhibit growth of foodborne bacteria and yeast. This antimicrobial activity is directly related to specific chemicals in the herb and spice, components typically concentrated in the oil fraction. For example, carvacrol, eugenol and thymol are phenol compounds that are found in cinnamon, cloves, oregano and sage. The essential-oil fraction is particularly high

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Antimicrobial Components of Select Herbs and Spices Herb/Spice Antimicrobial Component(s) Carvacrol, Cinnamon Cinnamaldehyde, Eugenol, Thymol Cloves Carvacrol, Eugenol, Thymol Garlic Allicin Mustard Allyl isothiocyanate Oregano Carvacrol, Eugenol, Thymol Borneol, Camphor, Rosemary Carvacrol, Eucalyptol Eugenol, Pinene, Quinine Sage Carvacrol, Eugenol, Thymol Thyme Carvacrol, Thymol

in cloves, and eugenol comprises 95% of the fraction, making cloves an excellent antimicrobial. And because cinnamon is a concentrated source of the aliphatic aldenhyde cinnamaldahyde — the compound that gives cinnamon its unique flavor profile and has also been shown to prevent oral bacteria growth when delivered through cinnamon-flavored chewing gum — it too is an effective antimicrobial. The problem with many of these spices and herbs, and their extracts, is that the flavor profiles can be intense and overwhelming in center-of-plate protein applications. This brings us to one of my favorite herbs: rosemary. Rosemary has always been known as a versatile, aromatic herb, particularly with poultry. Unlike most other herbs and spices, the active chemicals found in rosemary function not only as antimicrobials, some also have antioxidant properties. Specifically, rosemary extract contains phenolic compounds that retard oxidation, making them very effective inhibitors of the development of warmed-over flavor in precooked meat products. These compounds also keep fresh meats a vibrant red color. Rosemary’s antioxidant properties are also implicated in various health benefits, ranging from being an anti-inflammatory to having anti-carcinogenic activity. In recent years, suppliers have been able to produce rosemary extracts with minimal flavor. That minimal flavor is either not apparent in most applications because usage levels to obtain maximum antioxidant and antimicrobial activity are very low, or the flavor profile complements the application. Some suppliers are also blending rosemary extract with green tea extract, another well-known antioxidant. The minimal flavor contributed by each ingredient cancels the other out, and the end product has a very neutral taste. Rosemary extract’s effectiveness in proteins depends upon the meat quality and the other ingredients used in the formulation and process. To maximize its oxidation-management properties, it is best to add the rosemary extract as early on in the process with typical usage levels ranging from 0.05% and 0.20%. Before you run out and start spicing up your product, remember that even though antimicrobial and antioxidant activity of some spices and herbs is documented,

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.

the normal amounts added to foods for flavor is not typically sufficient to reap the benefits. Thus, essential-oil extracts are useful complements to whole herbs and

spices. Further, regarding antimicrobial functionality, this varies by herb and spice, application, microorganism, and as always, quality of raw materials and good manufacturing practices. For these reasons, herbs and spices should not be considered as a primary preservative method, but rather as a natural way to extend the shelf life of foods held at refrigeration temperatures, at which the multiplication of microorganisms is slow.

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NewProducts

Ripken Power Shred jerky snack makes its debut Florio Sports LLC has teamed with Major League Baseball Hall of Fame shortstop Cal Ripken Jr. to launch Ripken Power Shred, a new, high-quality, protein-rich jerky product made from lean American beef. Ripken Power Shred debuted at the 2010 National Association of Convenience Stores (NACS) trade show in October and is anticipated to be available in retail outlets this spring. The shredded beef jerky snack is sourced and made in the United States, and offers three flavors — original, sweet n’ spicy, and teriyaki. Ripken Power Shred can be purchased online in a six-pack of 0.75-oz. cans or 3-oz. pouches, as well as cases containing 84 cans. www.chewjerky.com

Oscar Mayer offers luncheon meats replicating carved-roast experience The Oscar Mayer brand introduces new Oscar Mayer Carving Board Meats. Made from high-quality cuts and slowly oven-roasted, these packaged meats make it easy to create sandwiches that deliver that “day after Thanksgiving” type of sandwich any day of the year. Carving Board Meats are sliced, packed and sealed immediately after they are roasted, and come in four varieties: Oven Roasted Turkey Breast, Rotisserie Seasoned Chicken Breast, Slow Cooked Ham and Slow Roasted Roast Beef. They are available in the refrigerated meat case in most grocery stores nationwide. www.oscarmayer.com

Jimmy Dean adds Pancake Griddlers to breakfast line Jimmy Dean® is expanding its Jimmy D’s breakfasts to include the new Pancake Griddlers. Microwaveable and ready in less than two minutes, Jimmy D’s breakfasts now include four products: Pancake Griddlers, French Toast Griddlers, Griddle Sticks and French Toast Duos. New Pancake Griddlers are maple pancake breakfast sandwiches with Jimmy Dean turkey sausage in the middle. All Jimmy D’s breakfasts contain 230 calories or less and seven or more grams of protein per serving. Pancake Griddlers are slated to be in the frozen breakfast section at grocery stores across the country in April/May 2011. www.jimmydean.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Koch’s Turkey Farm introduces all-natural turkey burgers Koch’s Turkey Farm’s Turkey Burger line, first introduced last year, is adding All Natural Burgers to the fray. Koch’s Turkey Burgers have no artificial ingredients, contain a minimal amount of fat and are delicately flavored with rosemary. The burgers go from the skillet to the plate in about 7 minutes, making them a quick healthy meal for families on the go. Sold at Whole Foods and other fine natural foods stores, Koch’s turkeys grow naturally without the use of hormones, stimulants or antibiotics. Each turkey is fed a special all-natural vegetarian diet and allowed free-range access, weather permitting. www.kochsturkey.com

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CoverStory

Pressure

GL Foods plans to ride the popularity of high-pressure pasteurization (HPP) and grow into a multi-facility co-packer and HPP services provider. By Andy Hanacek, editor-in-chief Photos by John Shipes Studio

I

n less than one decade, high-pressure pasteurization (HPP) has developed into a legitimate, effective food-safety intervention and shelf-life extender for protein products. Processors such as Hormel Foods, Cargill, Sadler’s Smokehouse and J Bar B Foods, among others, have incorporated the technology over the years, and some in the industry predict 2011 will be “The Year of HPP” in the meat industry. Furthermore, the business of HPP contract services (also known as “toll processing”) has grown to meet the demands of processors who cannot afford to jump on the HPP bandwagon with their own equipment just yet. One such company, Global Leading Foods (GL Foods) — which opened its doors in October 2010 in Coppell, Texas — hopes not only to ride the HPP wave, but also redefine what it means to be an HPP services provider. GL Foods certainly is not the first business of its kind, and it is in the early stages of its existence, but its location, its goals and the timing of its startup place the company in an intriguing position to make a mark on the industry. 40

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

point Kelley Battles, founder and president of Global Leading Foods, stands in front of the high-pressure pasteurization equipment in his Coppell, Texas, facility.

MARCH 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

41

CoverStory tion history through a wide variety of retail and product companies, including Sears and Mattel. Battles says that HPP weaved its way into GL Foods’ business plan is the career of Kelley Battles, a reflection on DeHerder’s founder and president of expertise and experience. GL Foods, during his time “It comes back to all as a salesman for an Austin, of us pooling together our Texas, beef processor from strengths,” he says.“They’re 2004 through 2008. HPP was all complementary to each a developing technology other.” when he first started selling With the company’s proteins, with a high-cost leadership in place, it was barrier to entry for most time to source and build processors. the facility, and Battles once “The company I was again turned to his network working for started to of contacts, managing to discuss having prodextract as much value from ucts high-pressured,” he Employees at the GL Foods facility pack brisket that has been sent through the the relationships he had explains.“But really, at that HPP machine into cases for shipment. cultivated during his years as time, the only realistic way to there was a supply/demand gap, and an a broker. get HPP was to go get product opportunity for him to fill that gap. He points out that his relationships with toll-processed.” “Retailers were even saying to Castle & Cooke Cold Storage and Avure Battles left the company in 2008 to processors,‘If you have something highTechnologies -- a manufacturer of HPP build a food-brokering business that pressured, bring it,’” he adds.“I saw an systems -- have been integral to bringing would focus heavily on HPP products, opportunity for quality toll-processing in a GL Foods online and helping it thrive in including a guacamole product imported good strategic location.” its infancy. Battles says that the technical from Mexico. Growth came quickly, expertise and business leads that Avure spurred on by the popularity of the brought him and the value-added sertechnology.When Battles would get an Just do it vices he can leverage being housed in a audience with a retailer to pitch his prodPartnerships played a key role in the Castle & Cooke facility already have paid ucts, the conversation would often turn to development of GL Foods from Day One, dividends to GL Foods. the overall capabilities of HPP technology. Battles explains. First, his father — and They are relationships that he believes And Battles took advantage, becoming a his “best investor” — Timothy J. Battles, will help him quickly fine-tune the Coppell champion of it. helped him push through the initial plan, facility and replicate it in other regions of the “I would say,‘HPP is great:You can do and has helped him throughout the entire U.S. down the road. sausages, ham, fruits, etc.’ And the customprocess. ers would ask to see those products,” he Kelley Battles’ first inclination was to explains.“Well, at that point, I had to say,‘Let get products toll-processed in another Customer service me get back to you.’” facility and shipped to him in Texas to While GL Foods has been operational Those meetings with the retailers laid a display to his retailer customers.While for less than six months, it already has foundation upon which Battles developed discussing the logistics with his father, been a wild, roller-coaster ride. solid relationships. Further, as the poputhey decided that wasn’t going to be fea“It’s been a breakneck pace, but with larity of HPP grew, Battles began to hatch a sible for their product to travel that far. screeching brakes too,” Battles says of plan to bring the technology to the Dallas “It came to a point that [my father] the first five months of production at the area — an obvious choice, given its logisti- said,‘Why don’t you just do it?’” Battles 23,000-square-foot facility.“It was boom, cal advantage over Austin, his residence says.“So before I knew it, my father was right out of the gate. Then, in January, all of at that time. my partner and investor, and here we are a sudden, the brakes hit and brought us to “[Austin] didn’t make sense from a today.” a stop.” distribution perspective,” he says.“You Battles knew he needed a strategist Battles admits he is happy the compalook at Dallas in terms of getting most any- with business and production experiny had a few weeks of slow time to catch where in the U.S. by truck, it’s a two-day ence to really make GL Foods go, and he up on some of the smaller, cosmetic-type haul or less.” tapped Rick DeHerder to be that partner. projects that had to be delayed in the The more Battles discussed HPP with DeHerder, who is also an investor in GL beginning — such as installation of hooks his retail contacts, the more he realized Foods, has an extensive retail and producto hang mops and tools on, among other

Hot on the HPP trail

42

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

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Weary of Wear & Tear on Your Forming Machine? CoverStory things. “Is that earth-shattering or going to hurt my business?” he asks.“It won’t, but now we have those little things, and my pump room is organized like a kitchen.” At presstime, GL Foods was preparing for production to ramp up again in March — anchored by the same customer that accounted for the majority of GL Foods’ capacity in late 2010. Battles knows his production schedule could fluctuate wildly, especially as HPP technology becomes more affordable and some processors move their business in-house, but he has other ideas to help temper some of the volatility. Today, most typical HPP contract service providers accept packaged product, treat it with high pressure and ship it out the door, with a few value-added services in the realm of logistics, case-packing, labeling and the like. GL Foods currently follows that same model. Most of these companies, however, do not undertake front-end, pre-HPP handling of product — something GL Foods plans to do in order to differentiate itself in the marketplace. This spring, GL Foods will be installing bagging systems, checkweighers, scales and metal detectors, so it can accept combo bins of product to be packaged, sent through the HPP system and put into master cases in the Coppell facility — all based on its customers’ requests. The brand new, USDA-inspected clean room will run perpendicular to the HPP

44

Compare the Provatec 27,000 Patties Per Hour 45 Strokes Per Minute on Parts & Labor lines and will be completely separated from Coppell’s high-pressure processing area. “It will give us the ability to do two things simultaneously because the clean room will keep them separate,” Battles says.“It gives us the ability to do co-packing.We can take bulk product, bag it and checkweigh it, all while high-pressuring something else.” When his customers inquired about the feasibility of the project, Battles saw the expansion as a way to further solidify his relationships. “It boils down to partnerships and commitments,” he says.“If they want us to do something, then we need reciprocation and a commitment that they’ll partner with us, and we’ve been fortunate to be involved with great partners so far.”

HPP at the core Despite all this business diversification, GL Foods will not abandon HPP toll processing as its core offering. Battles

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

90 Cycles Per Minute?

It's time to bring down costs. Booth and his partners continue to sell the service, and they hope to add more HPP lines to the Coppell facility as demand grows. “This facility is 110 feet wide and 160 feet deep, and it’s

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An employee prepares product to be sent to the case-packing area of the facility.

CoverStory a perfect fit for these machines,” he says. “We believe that three, maybe four lines is the magic number before we move on and drop this concept and model in a different location.” Depending on the product, GL Foods’ single HPP line can handle about 350,000 pounds per week. Battles believes demand for more capacity will eventually force the addition of more lines. “I have a lot of what I call ‘pregnant opportunities,’ by which I mean, they’re going to deliver, it’s just a matter of timing,” he explains. These opportunities, Battles says, have been both solicited by GL Foods and referred by his contacts. “It’s been great to have contacts and people around me that know the business and can help by referring me to different folks,” he says. One of Battles’ close contacts, Pete Beckwith, senior vice president of sales for J Bar B Foods, believes GL Foods has adopted a good strategy of promoting the benefits of the technology with retailers. “Now you have this buzz in the market on the technology, and you start to hear retailers say to processors,‘If you have high-pressured products, let’s see them,’” Beckwith explains.“Then GL Foods can go to the processors and tell them,‘We are within a couple hundred miles of your location, offering this service.’ “The retailers can be GL’s voice to the manufacturers, especially the ones he

MARCH 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

45

CoverStory

GL Foods’ Coppell facility currently features one HPP line, but the floorplan is large enough to house as many as four. With demand for HPP contract services building, GL Foods expects to add those machines sooner rather than later.

might not reach directly.” Whether or not 2011 proves to be as successful for GL Foods as its first few months were, Battles appears to have a variety of options in front of him for his business — each one an attempt to capitalize on HPP technology and the relationships GL Foods parlays into new opportunities.Yet, for all his plans, Battles remains thankful for the success thus far and wary of the pitfalls of taking

46

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

on too much, too quickly. “The goal is to perfect this facility over a 24- to 36-month period, and then take that model to other regions,” he concludes. “It’s amazing how quickly things have come together and gone well, but I don’t want to grow too quickly and be a company that people say,‘Woulda, coulda, shoulda, if they’d done it right the first time.’”

Cargill’s ground-beef breakthrough As high-pressure pasteurization (HPP) has grown through the years, the food industry as a whole has found it to be compatible with a wide variety of products. In the protein industry, too, compatibility across product varieties has been far-reaching. However, ground beef always had been found to be incompatible with HPP. Justin N. Segel, president of American Pasteurization Co. (APC) in Milwaukee, Wis., knows the situation well, harkening back to his days at Emmpak Foods (now a part of Cargill). “When we started [APC, in 2004], we kind of thought,‘Wow, it would be interesting if someone would test ground beef,’” he says.“Cargill was one of our first customers with roast beef, a pre-cooked product, and to their credit, they kind of picked up the challenge and started sending ground beef product in to test.” In late February, Cargill introduced its new Fressure brand of ground beef patties, which have double the shelf life of traditional fresh burgers and benefit from the enhanced food safety that HPP brings to the table. Brent Wolke, vice president of Cargill’s Wichita, Kan.-based foodservice meat business, called the Fressure product a “technological breakthrough.” During a visit to the APC facility by The National Provisioner, Segel discussed the challenges that faced ground beef in terms of applying HPP technology. “High pressure tends to denature the product, changing it to a dramatically lighter color,” Segel explains.“If you just take ground beef and run it under [standard HPP] parameters, it’s a safe product and you get some shelf life, but it looks more like veal and tastes more like meatloaf.” Faced with that challenge, Segel adds, many processors could not commit the time or resources to the R&D needed to solve the problem. “To Cargill’s credit, they wanted to know how they were going to make it work,” he says.“They weren’t going to accept that it just wouldn’t work. Two years of testing later, they did crack the code.” Segel says APC is seeing more processors willing to invest in the research and development needed to formulate protein products that can withstand the rigors of

HPP. And his facility, the first to offer HPP contract services in the U.S., welcomes processors who want to test their products and “finesse” the formulations to get a high-quality, safe product with an improved shelf life. The APC team has worked with many processors in the past on these types of projects and expects to continue. As for Cargill’s Fressure product, Segel says it may be just the first of many

breakthrough initiatives. “We’re starting to see more companies experimenting with raw meats and raw, marinated meats,” Segel says.“We’re doing a variety of party trays and products like that, where in the past one item had a shelf life that would expire the whole tray before the other parts. “This is a brave new frontier,” he says. — Andy Hanacek

Visit us at AMI, April 13-16, booth 2320

This is our second decade on the forefront of elimination of food borne pathogens through high pressure technology, offering you the broadest range of HPP equipment and services to bring successful HPP products to market.

Let Our Customers Tell You! The vast majority of HPP food products available worldwide today are created using Avure HPP equipment and technology. But don’t take our word for it! Hear actual customers discuss how they created sustainable advantage with Avure HPP.

We are proud of the Avure QFP 350L, the most popular high production HPP food Go to www.responsetrack.net/secret12 system worldwide. Our Avure QFP 215L is the most successful vertical press available. And the recently released QFP 100L has already become the most widely accepted mid–range system ever offered. So, it's not surprising that Avure continues to lead in horizontal, vertical and laboratory systems and total HPP solutions. With the capacity, reliability and low operating costs of our equipment, unmatched food science knowledge and lab services, and a growing network of HPP contract services providers, Avure is uniquely positioned to help YOU deliver successful HPP products. © 2011 Avure Technologies, Inc. All rights reserved. 800.959.1135

MARCH 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

47

AMIPre-show

AMI show springs ahead AMI Expo moves to April to help processors get a jump on the competition.

Want to go? AMI EXPO April 13-16 McCormick Place, Chicago Show Hours: Wednesday, April 13: 10:30 a.m. - 5 p.m. Thursday, April 14: 10:30 a.m. - 5 p.m. Friday, April 15: 10:30 a.m. - 5 p.m. Saturday, April 16: 10:30 a.m. - 2 p.m. More Information: www.amiexpo.com

After years as an autumn tradition, the AMI International Meat, Poultry & Seafood Industry Convention and Exposition has moved to April. Now scheduled for April 13-16 at Chicago’s McCormick Place, the AMI Expo will help attendees get an advantage over their competition, says J. Patrick Boyle, AMI president and CEO. “They will be among the first to see the latest equipment and technology innovations,” he says. “It’s been 18 months since our industry met under one roof.” More than 400 exhibitors will be on hand at the AMI Expo, displaying the latest technology and machinery for the industry. One of the benefits of attending the show, Boyle notes, is that visitors can do side-by-side comparisons of products to ensure that they get the best value for their business. The Expo will also feature a “Meat Tech” presentation prepared by exhibitors on operational issues critical to all aspects of meat, poultry and seafood processing. These presentations, held in a classroom on the show floor, will cover topics such as food safety interventions and ingredients, packaging technologies and application of sanitary design principles for processing equipment and facilities. The AMI has also prepared a slate of networking opportunities, so that attendees can make connections with others in the industry. The scheduled events include a networking reception co-sponsored by the Chicago Midwest Meat Association, the AMI Awards Breakfast and the AMI Washington Insider Breakfast, featuring keynote speaker William Kristol, editor of The Weekly Standard. Along with the new products and services available on the show floor, the AMI Expo also boasts a full slate of educational opportunities, from intriguing general sessions to tracks on sustainability, food safety, product development and plant operations. “We work closely with processors to develop world-class education that we know that they need for their teams — because they developed it,” Boyle says. Among the speakers at this year’s show are Michael Hayden, former director of the Central Intelligence Agency and the National Security Agency, and Carlos Gutierrez, former CEO/chairman at Kellogg Co. and former U.S. Commerce Department secretary. Other experts speaking during the education seminars represent companies such as Johnsonville Sausage, Kraft Foods, Mintel and Duke University. Boyle says that with the new spring dates, the future of the show is very bright. “The spring date also makes co-locating with other organizations easier, dramatically improving our ability to expand our audience,” he notes. The 2012 show, for instance, will be co-located with the Food Marketing Institute and the United Fresh Produce Association. AMI Exhibitor Profiles, pg. 50-71

48

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

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AMIPre-show

AMI Booth Profiles

Ajinomoto Food Ingredients LLC For 100 years, Ajinomoto has provided both tasty and healthful quality products to consumers around the globe. Following the decades of success of monosodium glutamate, Ajinomoto continues the tradition of great taste with an array of amino acids, sweeteners, savory and specialty ingredients. In planning for tomorrow, Ajinomoto is focused on making significant advances in food and health ingredients. Ajinomoto’s philosophy is committed to providing products that not only taste good, but provide the health benefits your consumers demand. Ajinomoto Food Ingredients LLC 8430 W. Bryn Mawr Ave. Suite 635 Chicago IL 60631 (800) 456-4666 Fax: (641) 969-4409 www.ajiusafood.com AMI Expo Booth #873

Beacon Inc. Beacon Inc. offers more than 60 years of experience in the process of designing and manufacturing stainless steel processing racks that will work for each processors specific requirement. Beacon has engineered trucks and screens to process a wide range of products and weight loads, from jerky to hams and everything in between. Beacon has probably custom engineered and built more unique racks than any supplier in the industry. Our design process includes; gathering the correct information, designing the most efficient racks, supplying detailed engineering drawings, working through the details and possible changes, and then manufacturing the perfect rack based on all this critical customer interaction. Whether a customer is looking for two or 200 trucks, Beacon gives each customer high-quality service throughout the design process which results in all of our customers getting equipment that gives them maximum yields at the best possible cost. Beacon Inc. 12223 S. Laramie Alsip IL 60803 (708) 544-9900 Fax: (708) 544-9999 [email protected] www.beaconmetals.com AMI Expo Booth #2375

50

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Biro Mfg. Co. The Biro Manufacturing Company, established in 1921, is an Ohio, USA, corporation, with three manufacturing/assembly plants. Biro designs, manufactures, and markets safe, durable and reliable power operated, stainless steel, food and meat processing machinery. Biro is committed to satisfy specific needs of all segments of the food and meat industry: the food retail stores, the food service, and the food processing, including portion control and the seafood processing operations. Biro’s product line includes a broad selection of models and variations of Power Saws, Tenderizers/Knitters, Cubers, Strip Cutters, Poultry Cutters, Horizontal High Speed Meat Slicers, Meat Room/Deli Slicers, Grinders, Mixer/Grinders, Marinating Vacuum Meat Tumblers, and Food Formers. The Biro Co. will be displaying (Booth #3035) the new Mechanical Version (Md 109PC-M) High Speed Horizontal Slicer. This model is a simplified model of the earlier Model 109PC electronic version. All other features remain the same; stainless steel construction, sicklestyle stainless steel cutting blade or optional serrated blade, machine mobility, interlock features, power lock-out, 2.75 slices per second and easy cleaning. The Biro Manufacturing Company 1114 W. Main St. Marblehead OH 43440-2099 Tel: (419) 798-4451 Fax: (419) 798-9106 www.birosaw.com AMI Show #3035

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AMIPre-show

AMI Booth Profiles

Busch LLC Busch Vacuum Pumps and Systems offers a comprehensive line of vacuum pumps, expertise in designing and building vacuum systems and an extensive service network, making it easy to provide comprehensive solutions to fit your specific needs. For years, the Busch model RA 0630 has proven to be the vacuum pump of choice for food packaging and processing machinery and applications. As the workhorse of the industry, the RA 0630 has continually delivered what others can’t; quality, performance and reliability. Like all of our industry-leading R 5 series vacuum pumps, the RA 0630 is designed for the unique conditions of the food packaging and processing industries. To learn more about Busch, or any of Busch’s high quality vacuum pumps, call 1-800-USA-PUMP, visit www.buschusa. com or stop by booth #1039 at the AMI Show April 13-16. Expect the best when you specify Busch. Busch USA 516 Viking Drive Virginia Beach VA 23452 (800) 872-7867 www.buschusa.com AMI Expo Booth #1039

52

CFS All you need for a world of changing tastes CFS specializes in performance focused solutions for the food industry. From a single machine or packaging material to a complete production line for the preparation, marination, processing, slicing and packaging of primarily, poultry, fish, seafood and cheese based products. Lifecycle Performance CFS is here to create results for you. We have defined a unique approach to optimizing your performance and have aligned our entire company to deliver it. Lifecycle Performance is a holistic approach to managing the variables that contribute to performance. We have redefined how we plan, how we innovate, how we develop solutions and how we support and partner with our customers to deliver performance Lifecycle Performance means that CFS is focused on all factors that contribute to your performance – from start to finish. Come see us at the AMI Expo April 13-16th booth 2028 where we will be showcasing our PowerPak ST thermoformer and Projector Injection system. CFS Americas 8000 N. Dallas Pkwy Frisco TX 75034 (800) 388-2601 Fax: (214) 618-1200 www.cfs.com AMI Expo Booth #2028

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

CSB-System International Inc. With more than 33 years of experience, CSB-System is the leading provider of innovative software solutions for the protein industry. Our industry specific fully integrated solutions provide our global client base with longlasting competitive advantages by increasing efficiency, reducing costs and maximizing profits. It is our unparalleled capabilities relating to Traceability & Recall Management, Recipe Management, Yield Management, Costing and Gross Margin Analysis that emphasizes our focus on the protein industry. We are committed to providing functionality for the entire enterprise, including Scale, Labeling & Scanning, Inventory Management Systems, Livestock Solutions and Enterprise Resource Planning. Take advantage of our expertise – contact us in order to learn more about our stateof-the-art software solutions for the protein industry. Success is a Matter of System Maximizing Profits with CSB-System Software Solutions CSB-System International Inc. 625 Plainfield Rd. #322 Willowbrook IL 60527 (800) 852-9977 [email protected] www.csb-system.com AMI Expo Booth #1984

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AMIPre-show

AMI Booth Profiles

Curwood Inc. Curwood just upped the steaks with our new FreshCase® packaging! This film offers all the advantages of vacuum packaging, with the fresh red color consumers prefer. Also highlighted in the booth is our new Liquiflex® bulk liquid packaging system, which combines our Liquiflex® AV Series machine with our Liquiflex® Advance™ bulk liquid film to form a total systems solution for items such as meat slurry. The booth also features packaging solutions for In-Plant Bag Making. Also showcased are our expanded line of rigid and CPET packaging, as well as our many exciting convenience technologies including EZ Peel® Reseal™ reclosable packaging, EZ Peel® opening feature, and IntegraPeel® peel-away technology for inline couponing and promotions. Visit us at www.CurwoodInnovates.com to learn more! Curwood Inc. 2200 Badger Avenue Oshkosh WI 54903 (800) 544-4672 [email protected] www.curwood.com www.CurwoodInnovates.com AMI Expo Booth #413

54

Diversey Inc. As a leading provider of cleaning and hygiene solutions for more than a century, Diversey is committed to a cleaner, healthier future. For customers in the meat and poultry processing, dairy, beverage, processed food, and pharmaceutical industries, we supply innovative sanitation products and processes that help make food, drink, and facilities safer, while improving efficiency and sustainability. Our company has a long and successful history with its foundation dating back to 1886. We are always aiming to improve and better address the needs of the global cleaning and hygiene industry. While our legacy companies did well, we are collectively moving forward as Diversey to do even better. We listen to your needs, take time to understand them, and strive to address them in a way that meets, and often exceeds, expectations. For more information, visit us at diversey. com or call us at (800) 233-1000. Diversey Inc. 8310 16th Street P.O. Box 902 Sturtevant WI 53177-0902 (800) 233-1000 AMI Expo Booth #2003

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Eriez Eriez features a complete line of vibratory feeders, conveyors, magnetic separation, metal detection and inspection equipment for use in food processing. Feeders and Conveyors: Rugged, efficient, high capacity units move large volumes of bulk material reliably in mechanical and electromagnetic models. Magnetic Separators: Highperformance Rare Earth magnetic separation equipment includes plates, grates and traps. Protect equipment and product purity by removing fine particles and larger metal. Metal Detectors and X-Ray Inspection: Eriez Metal Detectors find ferrous, nonferrous and stainless steel metals utilizing the highest level of sensitivities available. Eriez’ E-Z Tec XR Series X-Ray inspection equipment delivers the highest level of product and packaging integrity. They feature superior sensitivity, speed and realtime analysis. The equipment can monitor packages for count, weight, fill level and product integrity and is able to detect metals, stone, glass and plastics. Eriez 2200 Asbury Road Erie PA 16506 (888) 300-ERIEZ (3743) [email protected] www.eriez.com AMI Expo Booth #844

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AMIPre-show

AMI Booth Profiles

Fiberstar Inc. Visit Fiberstar Inc. at AMI booth 1281 to learn about Citri-Fi®, our line of unique multi-functional food ingredients. Meat processors use Citri-Fi to improve profit margins, quality, nutrition, and label declarations. Citri-Fi helps accomplish these objectives by tightly binding moisture and fat; improving yields; partially replacing oil, fat and meat, as well as synthetic ingredients such as phosphates, emulsifiers, stabilizers and complex gum systems. Citri-Fi also helps improve the yield and quality of the processed meats when added at 0.25%-0.75% on top of existing formulations without compromising taste and label declaration. Citri-Fi is used in processed meat, meat fillings, sausages, marinated meat, and tumbled or injected whole muscle meat and poultry. Citri-Fi is made from dried citrus pulp and is all-natural, non-allergenic, GRAS, non-GMO, gluten free, kosher, halal, and has a neutral odor and taste. Citri-Fi is a product of the USA. Fiberstar Inc. 713 St. Croix St. River Falls WI 54022 (715) 425-7550 [email protected] www.citri-fi.com AMI Expo Booth #1281

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Food Safety Net Services Food Safety Net Services is a network of ISO/IEC 17025/A2LA accredited laboratories. We provide expert consultation services: food safety audits; customized educational & crisis management programs; regulatory support; and microbiological & chemical testing including nutritional labeling. FSNS laboratories are located in San Antonio, Dallas, Phoenix, Green Bay, Atlanta, Fresno & Los Angeles. A2LA ISO accreditation ensures that each laboratory meets stringent technical requirements. FSNS also has accreditations and/or is approved as a GFSI: BRC auditing body; FSIS; AMS; VASP; USDA; ASTA and UEP’s preferred partner. All our laboratories are open 24/7, year-round. FSNS implements official methodologies of analysis, including, AOAC, USDA, AOCS, FDA, and ASTA. Our laboratory experts work with you to develop and choose an effective testing program and methodology to verify food quality and safety based on your needs. FSNS is your reliable food safety support system. Food Safety Net Services 199 W. Rhapsody San Antonio TX 78216 (888) 525-9788 Fax: (210) 525-1702 www.food-safetynet.com AMI Expo Booth #2034

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Fortress Technology Inc. Fortress Technology Inc. is pleased to participate as an Exhibitor in the 2011 AMI Trade Show. Find solutions to food safety by visiting Fortress Technology, who will be displaying the “all-in-one” Vector Conveyor with PHANTOM metal detector (as shown) and Pipeline units. Fortress PHANTOM metal detectors can also be customized to suit a company’s unique production line. Detectors are designed to withstand the harshest washdown environments and have a certified IP69K rating on stainless steel units. System enhancement via CONTACT Data Logging software with wireless connectivity enables communication with a PC to make the metal detector a critical control point in HACCP programs.

Fortress Technology Inc. (888) 220-8737 or (416) 754-2898 [email protected] www.fortresstechnology.com AMI Expo Booth # 2373

THE ONLY USDA ACCEPTED OVES METAL MESH GL EN AND GARM TS

Visit us at

Booth 435

AMIPre-show

AMI Booth Profiles

framarx/waxstar framarx/waxstar is a waxed paper company manufacturing since 1966. We are a family run business specializing in the conversion of waxed and coated paper for use as hamburger patty paper, bacon layout paper, cheese interleaving paper, sausage interleaving paper, deli meat interleaving paper and much more. Our experienced staff will help you select the best and most efficient paper products for your unique applications. We offer a wide array of sizes, shapes; roll widths, core diameters and coatings. We have the product to fit your needs and are proud to be a part of your quality product. All framarx/waxstar facilities are GMP certified. Stop by our booth for some FREE samples.

framarx/waxstar 3224 Butler Ave. South Chicago Heights IL 60411 (800) 336-3936 www.framarx.com AMI Expo Booth #735

Hollymatic Corp. Inc. From grinding to cutting to tenderizing to forming, Hollymatic has a wide range of quality equipment for the meat processing industry. Its Grinders feature output rates that range from 3000 lbs/hour up to 9900 lbs/hour. Various horsepowers and options enable processors to choose a model that’s just right for their operation. Hollymatic’s Hi-Yield Meat Saw optimizes the use of power, resulting in reduced energy costs of up to 11%. It also offers significant safety features with a Quick Stop Brake that stops the blade within 1 second of shut-off to dramatically reduce the risk of injury. The Tender-Rite Tenderizer offers power, safety, efficiency, and a competitive price to make it a real profit center for all processing applications. Hollymatic also has a variety of Food Formers with varying capacities from 1200 patties per hour to 7800 patties per hour to form and portion beef, poultry, fish, vegetables, and more. For the first time, Hollymatic will be exhibiting at AMI with its three sister companies: NuTEC, Rollstock, and Former Associates. It’s a “4 of a Kind” event that you don’t want to miss. If you stop at each one of the 4 companies exhibiting at Booth #2419 and collect a different Ace from each company, you can enter a raffle to win a new iPad. Hollymatic Corp. Inc. 600 E. Plainfield Rd. Countryside IL 60525 (708) 379-5700 Fax: (708) 579-1057 www.hollymatic.com AMI Expo Booth #2419

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Hydrite Chemical Co. A major issue facing the meat and poultry industry is consumer safety. Hydrite Chemical Co. delivers outstanding chemistry programs with the highest safety in mind. At the same time, our focus continues to be your continuous profit improvement. Hydrite Chemical Co. offers unprecedented service and scientific expertise in plant sanitation, wastewater treatment, meat intervention, ingredients, defoamers, commodity chemicals and equipment. You will notice our unparalleled technical emphasis and passion for true customer service. If you’re looking for a chemical partner with your best interests in mind, call Dave Simyak at (262) 792-1450 and learn about Hydrite Chemical Co.’s customized and comprehensive sanitation program. Hydrite Chemical Co. 300 N. Patrick Blvd. Brookfield WI 53045 (262) 792-1450 Fax: (262) 792-8721 www.hydrite.com

Shouldn’t your slicer be talking to your packaging machine?

Come see us AMI Expo Booth th 2028 Open the lines of communication Having access to real-time data regarding your machine’s performance enables you to fine-tune the process for optimal output. CFS CostFox software provides the performance feedback you need to get the best out of your equipment.

Come see us at booth 2028

CFS CostFox

AMIPre-show

AMI Booth Profiles

Ingredients Solutions Inc. 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 finished 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] AMI Expo Booth #2173

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International Plastic Engineering Co. Ltd. International Plastic Engineering proudly introduces Eco-Friendly Vacuum Shrink Bags. The Austlon multilayer barrier shrink bags have: • Superior clarity and transparency to enhance product appeal • Good barrier properties to reduce weight loss and prevent color change and extend product shelf life • Strength and durability to protect your products every step of the way from transport to sales • Uses stronger materials to cut packaging material by up to 20% without compromising strength and puncture resistance • Completely chlorine free products and eliminates PVDC which can contaminate recycling streams and release carcinogens International Plastic Engineering, established in 1998, is a wholly Australian-owned company specializing in the manufacturing of shrink bags and plastic casings. In addition, there is a full range of in-house printing, shirring, and bag converting services all to exceed customer expectations. All International Plastic Engineering products are chlorine free and the production lines are HACCP/ISO approved. International Plastic Engineering Co. Ltd 2 Chang Qing Road Changle Industrial Zone, Haimen City, Jiangsu Province, China TEL: (+86 513) 82735018 82735003 [email protected] www.hq-plastic.com AMI Expo Booth #1878

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Mepaco For decades, Mepaco has been a worldwide leader in the development of mixing, stuffing, dumping and conveying technologies. We continue to expand our products and services to remain on the cutting edge of food equipment manufacturing. As pioneers in this field, we take great pride in continuing this legacy of excellence. At the 2011 AMI Show, Mepaco will be exhibiting its 420v Continuous Vacuum Stuffer. The 420v pulls and maintains full vacuum while gently agitating the product to expose more area to deaeration, resulting in considerably greater density and yield. The company will also feature the 11-10 high capacity grinder. The 11-10 is best known for its high capacity, trouble-free grind with superior bone collection capability. Mepaco is continually engineering new processing solutions that are designed to address food safety, productivity, ergonomics and automation concerns. To learn more, stop by Booth #456. Mepaco P.O. Box 538 200 Industrial Drive Beaver Dam WI 53916 (920) 356-9900 [email protected] www.mepaco.net AMI Expo Booth #456


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AMIPre-show

AMI Booth Profiles

Mettler Toledo Mettler Toledo provides in-line product inspection solutions for the food processing industry with Hi-Speed checkweighers and Safeline metal detectors and x-ray inspection systems. Our broad product inspection line ranges from very basic and economical systems to sophisticated, state-of-the-art systems with customized material handling solutions. Depending on your specific requirements, our systems can ensure weight range compliance, detect physical contaminants and inspect contents inside the closed package. Checkweighing: Mettler Toledo Hi-Speed dynamic checkweighing systems ensure 100% quality control, minimize costly giveaway and give total peace of mind. Metal Detection: Mettler Toledo Safeline metal detection systems prevent costly recalls by ensuring your products are free of ferrous, non-ferrous and stainless steel contaminants which can be introduced during processing. X-ray Inspection Mettler Toledo Safeline x-ray inspection systems can detect ferrous, non-ferrous, stainless steel, glass and stone contaminants, detect mass and check for missing or damaged product inside closed packages. Visit www. mt.com/pi today to learn more. Mettler Toledo Inc. 1900 Polaris Parkway Columbus OH 43240 (800) 221-2624 [email protected] www.mt.com/pi AMI Expo Booth #1922 62

NDC Infrared Engineering Inc. Designed for the processing environment, but equally at home in the lab, NDC’s InfraLab is the industry’s most cost effective, easy-to-use benchtop meat analyzer, delivering accurate, robust measurements of fat, moisture and oil content in just 10 seconds. Optimized to meet the processor’s need to check incoming or production batch samples, the InfraLab’s open ergonomic design makes sample presentation easy. Measurements are displayed clearly on the color touchscreen. User interaction is passcode-controlled to allow access only to permitted functions, and each measurement is time, date, user and product code stamped. InfraLab can store up to 10,000 sample files and data can be downloaded via USB, or transmitted via the analyzer’s Ethernet port for remote viewing and storage. For more information visit www. ndcinfrared.com/meat or to arrange a demonstration email: enquiries@ ndcinfrared.com NDC Infrared Engineering Inc. 5314 North Irwindale Ave. Irwindale CA 91706 (626) 960-3300 [email protected] www.ndcinfrared.com/meat AMI Expo Booth #2504

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Nebraska Public Power District/ Economic Development Department Nebraska offers food processors a proven recipe for productivity and profitability. An attractive business climate, competitive industrial electric rates, a well-educated and productive labor force, abundant access to raw materials, and a location central to the national consumer market allows companies to significantly improve their competitive position and bottom line. Hungry for more information about Nebraska’s food processing industry? Nebraska Public Power District’s Economic Development Team can provide valuable assistance. Services range from quickly responding to informational requests from interested companies, to guiding them through the entire site selection process. Visit www.sites.nppd.com, and get easy access to research data through an online searchable database. You will also find available sites, buildings and community data as well as industry profitability studies. Nebraska Public Power District Economic Development P.O. Box 499 Columbus, NE 68601-0499 (402) 282-6775, ext. 5534 [email protected] AMI Expo Booth #2281

Stainless Steel Trucks & Screens

Beacon Can Customize Its Standard Designs For Your Processing Needs.

You can trust a Beacon expert to design a unit that will provide the maximum amount of efficiency at the lowest possible cost. Our Trucks & Screens are built to hold your weight requirements. We don’t over design resulting in added costs or under design resulting in a unit that will not last or hold the weight load needed. Call us with your dimensions and Beacon will engineer Trucks & Screens that fit your requirements.

Stainless Steel Trucks • Nesting Trucks • Cages, Racks & Trees • Bacon Trucks & Trees • Rib Racks • Four Post Designs Stainless Steel Screens • Mesh Screens • Wires One-Way Jerky Screens • V-Screens • Rib Screens

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

AMIPre-show

AMI Booth Profiles

Niroflex USA Niroflex2000 is the only USDA accepted Metal Mesh Glove! Last year USDA approved Niroflex2000 metal mesh gloves and aprons for the USDA accepted equipment list, becoming the only personal protective equipment on the list. Being listed means that USDA confirms that Niroflex products meet or exceed ANSI/NSF/3-A 14159-2, Hygiene Requirements for the Design of Hand Held Tools Used in Meat and Poultry Processing. Niroflex2000 gloves are 100% stainless steel, replacing the traditional fabric strap wrist closing system with the patented Niroflex clip closure. Since the Niroflex2000 was introduced more than 10 years ago as the first and most hygienic metal mesh gloves, meat and poultry processors worldwide have seen the benefits of a glove without fabric. Visit us at AMI2011 in booth 435. Niroflex USA P.O. Box 90 Deerfield IL 60015 (847) 400-2638 Fax: (847) 919-3809 [email protected] www.niroflex.com AMI Expo Booth #435

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NuTEC Mfg. A phenomenal innovator of food forming and portioning depositing equipment, NuTEC will have at least four machines on display at the AMI Show. This equipment forms hamburger patties, veggie patties, meatballs, sausage links, chicken nuggets and chicken rings among other things - all with perfect shapes, great texture, and consistent quality. NuTEC’s portioning depositors assure minimal product damage and accurate, consistent portions for products like burritos, empanadas, fajitas, chicken kiev, egg rolls and other ethnic foods. What visitors will find truly unique at NuTEC’s booth is its Automatic Direct Depositing and Tray Indexing Conveyor. When set up with their 720 Forming Machine, the Tray Indexing Conveyor efficiently portions and deposits patties directly onto trays at speeds of up to 65 trays per minute. It can also deposit fillings onto tortillas. For the first time, NuTEC will be exhibiting at AMI with its three sister companies: Hollymatic, Rollstock, and Former Associates. It’s a “4 of a Kind” event that you don’t want to miss. If you stop at each one of the 4 companies exhibiting at Booth #2419 and collect a different Ace from each company, you can enter a raffle to win a new iPad. NuTEC Mfg. 908 Garnet Court New Lenox IL 60451 (815) 722-2800 www.nutecmfg.com AMI Expo Booth #2419

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Ossid Corp. With more than 40 years of manufacturing experience, Ossid’s line of horizontal thermoform fill and seal (HFFS) and tray seal machines will fit your specialized needs, no matter the specification. - Robust - American made with durable stainless steel frame construction that ensures a repeatable process necessary for validation ■ Versatile - A full range of machines and cycle rates (up to 30 per minute) ■ Servo Technology - Help your sustainability efforts with compressed air cost savings over pneumatic presses ■ Easy to Use - Open architecture system with Allen Bradley controls and intuitive operator interface ■ Connectivity - Collects and analyzes package data and allows for remote troubleshooting ■ Wide Range of Package Types - Flexible, Foil-Foil, Semi-Rigid, Rigid, Ambient, Vacuum, and Tyvek® Packaging ■ Package Development Program - Concept and/or machine made packages for test samples to help ensure a successful product launch ■ Aftermarket - Unmatched parts, service, maintenance and training for your machine Ossid P.O Drawer 1968 Rocky Mount NC 27802 (800) 334-8369 Fax: (252) 442-7694 [email protected] www.ossid.com AMI Expo Booth #3013

Rooted. Reliable. Respected. If you’re looking for a company to listen to you and take the me to understand your needs, Hydrite Chemical Co. should be your business partner. We provide the best chemical products and technology in the meat and poultry industry and have the passion to cra creave soluons to increase your profitability. You will receive unprecedented service and scienfic experse in plant sanitaon, wastewater treatment, ingredients, intervenon chemistry, commodity chemicals and equipment. Hydrite Chemical Co. is rooted with family values since 1929, reliable to hundreds of prosperous companies across the country, and respected for our superior customer service. To learn about the innovave things we can do together call Dave Simyak at 262‐792‐1450.

AMIPre-show

AMI Booth Profiles

PPI Patty Paper Inc.

Petro Canada Lubricants

PPI offers a wide variety of waxed, coated, and printed papers that are converted for many uses including separating meat, poultry, cheese, bakery items, and deli foods. Its complete line of quality converted papers includes patty paper interleave, deli waxed interfold paper, picking paper, sheeted waxed paper, bulker or roll stock paper, steak paper, and meat board. Products that PPI will have on hand at the AMI Show include interleave waxed paper that is compatible with all food forming paper-fed machines. The company offers standard and custom sizes for any application. Bulker/Roll Stock for any roll paper style machines will be displayed in single or laminated, wet wax or dry wax. Sheet paper in wet wax or dry wax, single, laminated or randomly printed in various paper and coating weights will also be at Booth #1881. All papers can be packaged and cut to customer specifications.

Petro-Canada’s food-grade lubricant product line – PURITYTM FG – fits perfectly into a HACCP and GMP plan. PURITY FG food grade lubricants are designed to provide industrial strength lubricant protection in food processing plants. They are effective under severe operating conditions — from food acids and juices to by-products and temperature swings. Petro-Canada also offers a line of lubricants that contain MICROL – an EPAregistered antimicrobial preservative for use in food grade lubricants. The PURITY FG with MICROL product line has all the required industry credentials and it addresses a number of factors including lubricant deterioration, fouling and odor caused by microorganisms. Petro-Canada blends and packages more than 350 lubricants, specialty fluids and greases that are exported to more than 70 countries. The company specializes in offering products and services proven to increase productivity and lower operating costs.

Patty Paper Inc. 1955 North Oak Drive Plymouth IN 46563 (800) 782-1703 or (574) 935-8439 www.pattypaper.com AMI Expo Booth #1881

Petro-Canada Lubricants 2310 Lakeshore Road West Mississauga, ON L5J 1K2 (866) 335-3369 www.lubricants.petro-canada.ca AMI Expo Booth #1481

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

PolyConversions Inc. PolyConversions Inc. (www.PolyCoUSA.com) manufactures personal protective wear, and no-rinse wipes and spray. PolyCo products are latex/vinyl free, odorless, non-toxic, and made in the USA. VR™ Protective Wear: A PolyCo proprietary material with properties equal or superior to Vinyl, Tyvek, Hycar, and Neoprene. VR, designed to protect employees against exposure to hazardous materials, offers superior resistance to chemicals such as nitric, sulfuric, hydrochloric, and hydrofluoric acids. VR is lighter in weight and softer than traditional PVC materials, yet stronger and more durable. PolyWear™ Disposable Gowns: Designed to provide lightweight, full frontal barrier protection against chemicals and blood borne pathogenic contaminants. Gowns feature contoured thumb loops securing gown sleeve under gloves. Tear-away neckloop facilitates quick gown removal and disposal. PolyWog™ No Rinse Pre-Moistened Wipes and Spray: Formulated to remove greases, fats, oils and bio-load from work surfaces. Contains surfactants and quaternary compounds which meet FDA standards with no color additives or fragrances. PolyConversions Inc. 505 Condit Drive Rantoul IL 61866 (888) 893-3330 Fax: (217) 893-3003 info@PolyCoUSA www.polycousa.com AMI Expo Booth #2604

No other liquid food ingredient supplier is this solid. Hawkins always delivers what you need, when you need it. You can’t afford to have your supply source interrupted. That’s why it’s good to know that no other supplier is more reliable, especially during tough economic times. Our customers know they can rely on us — no matter what size they are — to deliver what we promise. They appreciate our innovative approach, unbeatable quality and unmatched service. And they know we always strive to provide the best possible price. We’ve invested in people and facilities, including our newest plant in Centralia, Illinois. And we’re committed to being one of the nation’s foremost food ingredient suppliers.

Once you experience our relentless focus on providing the best service, you’ll understand why customers stay with us. For example, we don’t simply offer three or four major products. We often alter and test different blends until we find the specific solution our customers require. If you want the most solid resource for your liquid food ingredient supply, find out more about our unique UltraLac formulation along with the rest of our high quality products.

We bring so much more to the table

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

AMIPre-show

AMI Booth Profiles

Provisur Technologies | Beehive Beehive® is coming to the AMI as a proud member of the Provisur® family which also includes Cashin®, Formax® and Weiler®. Recognized for its leading meat recovery and separation technologies, Beehive® will exhibit the Piranha™ Desinewer/Filter for beef, lamb, poultry, produce and fish. The Piranha™ increases production volume by extracting high quality ground meat from bone collection materials. It returns 95 percent of the product as a clean, ground meat product. Such innovations are the key to Beehive®’s reputation for systems that both preserve product quality and contribute to the bottom line. In addition to the Piranha™, Beehive® produces the AccuPump, the BeeMax® System and a complete line of separators – all backed by worldwide 24/7 technical support from Provisur®. Provisur® Technologies | Beehive® USA 11814 S. Election Road Suite 140 Draper UT 84020 (801) 561-8438 or (800) 621-8438 [email protected] beehive-provisur.com AMI Expo Booth #1013

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Provisur Technologies | Formax Formax® is coming to the AMI as a member of the Provisur® family joining Beehive® and Weiler® together as an integrated solution from raw materials to finish product. As the first name in forming and slicing equipment, Formax® will exhibit the Maxum700® forming system offering the world’s largest capacity, plus its Ultra26® with servo knock out drives. Formax®’s advanced technology enhances product quality and texture with its various mold plate actions. The mid-sized PowerMax3000™ slicing system promises unmatched performance with up to three independent product drives, a generous 15” slicing throat (380mm) and a fast loading center rear load design. It is fully compatible with the PowerScanner™ option. All Formax® systems are backed 24/7 by Provisur® technical support worldwide.

Provisur® Technologies | Formax® 9150 191st Street Mokena IL 60448 (708) 479-3500 [email protected] formaxinc.com AMI Expo Booth #1013

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Provisur Technologies | Weiler (Weiler Logo.jpg; Omni V 1107 MultiGrinder.jpg) Always a favorite at the AMI, the Weiler® brand is celebrated for its rugged line of grinders, mixers, mixer/grinders and material handling systems. Now a member of the Provisur® family, Weiler®‘s latest innovations include the Dominator® 11 Mixer/Grinder with Balanced Flow™ and OMNI V™ 1107 Multi-Grinder. Balanced Flow™ technology virtually eliminates roll back, turbulence and unnecessary work to raw materials. It provides consistent particle definition, great texture and a better product overall. The OMNI V™ 1107 allows for quick speed adjustments so operators can better optimize production quality and volume with fresh or frozen applications. Both promise outstanding reliability and both are backed 24/7 by Provisur® technical support worldwide.

Provisur® Technologies | Weiler® USA 1116 East Main Street Whitewater WI 53190 (262) 473-5254 or (800) 558-9507 [email protected] www.weilerinc.com AMI Expo Booth #1013

VISIT US AT THE AMI FOOD EXPO BOOTH 873

The latest transglutaminase innovation from Ajinomoto When you use ACTIVA® BF, you can count on processing advantages for protein extension that result in more visually appealing ham, beef, poultry and pork products: aÚÚÚ£»Ð¬ëvlÚӟ˜bvÚî˜vŸlÓÖڟvÓÓÚÓbÐJ»ÚJ¨lÚXÐvJžJv aÚÚÚ
»»Ÿ˜bJXŸvژ¨Ú•˜•ÚvíÜv¨Ó˜¬¨iڟ¬ìÚÓ¬l˜å£Ú»Ð¬låbÜÓÚ like deli meats and hams aÚÚÚB¬ÐžÓÚìvŸŸÚ˜¨ÚŸ¬ìÚÓ¬l˜å£Ú»Ð¬låbÜÓÚì•vÐvÚ structure and sliceability are an issue ACTIVA® BF was specifically designed for use in brine, intended for either the injection or tumbling process. With ACTIVA® BF, transglutaminase activity is delayed until the brine is injected, even when high levels of protein extension are required. The enhanced handling time frame is an advantage when injecting in a high volume plant setting.

Easy-to-incorporate

ACTIVA® BF In the injection process, just add to dry seasoning blend during reconstitution with water In the tumbling process, reconstitute brine according to usual protocols –– it will not cause gelation To watch a video demonstration, visit www.ajiusa.com

Want to learn more about how to include transglutaminase in your bonding process? Contact an Ajinomoto technical professional. Call 1-800-456-4666

AMIPre-show

AMI Booth Profiles

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

Remco Products 4735 W. 106th Street Zionsville IN 46077 (317) 876-9856 Fax: (800) 585-8619 www.remcoproducts.com AMI Booth #836

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Rollstock Inc. AMI attendees are invited to visit Rollstock to learn more about the company’s line of packaging equipment. One of the pieces of equipment featured at the booth will be the RC300 Rotary Vacuum Chamber Machine that features all stainless steel construction and a patented sealing system that provides quality seals time after time. The company will also have information on its 12-foot and 16-foot Rollstock models that offer simple reliability in low cost machines. They feature programmable PLC controls with readable diagnostics and vacuum leak check programs. Each machine comes with training from a factory technician and a one-year warranty. In addition, Rollstock will be offering sales literature on the Zipper Packaging Machine. This machine is designed for seafood, luncheon meats, bacon, and any food or non-food products that require reliable, consumer-friendly recloseable features. For the first time, Rollstock will be exhibiting at AMI with its three sister companies: Hollymatic, NuTEC, and Former Associates. It’s a “4 of a Kind” event that you don’t want to miss. If you stop at each one of the 4 companies exhibiting at Booth #2419 and collect a different Ace from each company, you can enter a raffle to win a new iPad. Rollstock Inc. 1728 N. Topping Avenue Kansas City MO 64120 (800) 954-6020 [email protected] www.rollstock.com AMI Booth #2419

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Sandvik Process Systems Wherever there’s a need for maximum hygiene – from surgical tools to catering equipment – the material of choice is stainless steel, so why should your conveyor belts be any different? Inert, corrosion-resistant and easy to clean, a pre-welded endless stainless steel belt provides an immediate hygiene upgrade. And no crevices, joints, textures or fibers means nowhere for bacteria to hide. ■ Lowest levels of bacteria growth ■ Easy to clean by pressure, brush, steam or chemicals ■ Fast cleaning with low water/chemical consumption ■ Long working life with low maintenance requirements

Sandvik Process Systems 21 Campus Rd Totowa NJ 07512 www.processsystems.sandvik.com AMI Expo Booth #1341

AMI Booth Profiles

Experts in Spray Technology

Solae LLC Solae is the world leader in developing innovative soy-based technologies and ingredients for processed beef, poultry, seafood and vegetarian products. We provide solutions that deliver a unique combination of functional, economic and nutritional benefits to our customers. Our solutions and in-house professionals (technical, sensory and nutrition science support) can deliver value across all types of products including whole muscle, formed, emulsified, ground, vegetarian and processed fish. Stop by and visit us, taste our sample products and let’s discuss how we can help you… • Optimize Formulation Costs • Improve Yields and Efficiencies • Enhance Quality and Nutrition • Support Sustainability

Spraying Systems Co. Visit Spraying Systems Co. in Booth #2070 during AMI and learn: • How to improve food safety on RTE, sliced and fresh meats through precise antimicrobial application. Typical cost for Alt-2 status with our AutoJet® Antimicrobial system is $0.01/lb. for RTE, $0.003/lb. for fresh meats. • How to clean tanks, mixers and blenders more thoroughly in less time. See the newest technology — motorand fluid-driven units that provide 360° and 180° cleaning coverage. • About a new system that produces environmentally-safe cleaning agents economically from water using plain salt and electricity. The PathoSans™ System requires no chemicals, eliminates worker exposure to dangerous chemicals and produces cleaning agents on demand.

Solae LLC 4300 Duncan Avenue St. Louis MO 63110 (800) 325-7108 www.solae.com AMI Expo Booth #1073

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Wire Belt Co. of America Wire Belt, the leading developer of open mesh stainless steel conveyor belts, has been keeping your lines running for over 60 years. Our conveyor belts are extensively used for breading, battering, frying, blanching, cooking, coating, dusting, and cooling. Wire Belt’s entire line of belting products are accepted by the USDA NSF/ ANSI/3-A hygiene standards. This is the only acceptance that can assure you that you have the cleanest, safest conveyor belt available. Wire Belt’s latest innovation CompactGrid™ conveyor belt is engineered specifically to replace heavier balanced weave belts and difficult to clean plastic modular belts. Engineered with 70% open surface area, CompactGrid conveyor belt provides optimal performance in processes where product coating, drainage, and liquid or air circulation are factors. To learn more about Wire Belts complete line of products, including our CarrySmart conveyors, please stop by Booth #1155. Wire Belt Co. of America 154 Harvey Road Londonderry NH 03053 (603) 644-2500 [email protected] www.wirebelt.com AMI Expo Booth #1155

JANUARY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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FarmtoPlate ANIMAL WELFARE

When worlds collide The concerns of food safety, management and animal welfare battle for position in the pre-harvest fight against E. coli O157:H7. By Kurt Vogel

IF YOU’RE INTO RIDDLES, HERE IS ONE TO THINK ABOUT: What has a single source that varies? If you’re into food safety, your answer should be “E. coli O157:H7.” Depending on your specific sector of the industry, E. coli O157:H7 may come from the cattle in your feedlot, the hides and digestive tracts of the cattle you slaughter in your plant, the combo of beef trim you will be further processing, or the box of frozen patties in your retail display. So, depending on your place in the meat industry, E. coli may come from an animal, a hide, a digestive tract, a combo or a box. If your source of the issue is the combo or box, it may be time to investigate the pathogen’s origins. E. coli O157:H7 is a bacterium that nat-

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urally inhabits the large intestine of cattle. Not all cattle are carriers of the pathogen, and the occurrence of animals that shed the bacteria in their feces varies greatly. A study1 of shedding prevalence in Irish beef cattle found 1.7% to 18% of cattle in the study to be shedders. Other studies have found similar variability.2 3 Research has shown that the major risk factor in E.coli O157:H7 carcass contamination is a contaminated hide. To help prevent and remediate cross-contamination, multiple procedures are used during the slaughter process. Some of these include the use of hide-wash cabinets after stunning and bleeding, knife sterilizers and knife rotation procedures to allow ample sterilization time, steam

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

pasteurizers, steam vacuums, and hot water and organic acid carcass washes. To ensure that the pathogens that came into the plant on the animal do not make it to the cooler, combinations of these intervention steps are implemented. Ultimately, the efficacy of the intervention strategies is at least partly dependent on the pathogen loads on the hides of the animals at the time of slaughter. This is where management, animal welfare and behavior, and food safety collide. An interesting study4 was conducted in 2004, in which six confirmed E. coli O157:H7 shedding Holstein-Friesian steers were introduced — one per pen — to six pens of five non-inoculated Holstein-Friesian steers to study how

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the pathogen was transmitted. The authors found that the water troughs, pen barriers and some of the hides of the non-inoculated steers tested positive within 24 hours of the introduction of the shedding animal. Within 48 hours, 66% of the animals had hide swabs that tested positive. The authors also video-taped the behavior of the cattle. They reported an average of 13 bouts of grooming in each of the six pens per hour. From this study, it appears that the hide is a vector in inoculating new animals with E.coli O157:H7, and the animals can easily ingest the pathogen by licking themselves or pen mates during grooming. In addition, environmental contamination can be a factor in transmitting the pathogen, as cattle commonly lick the barriers and structures within their pens. This study was conducted in a facility that was much smaller and more confined than typical North American feedlot systems, but it helped to confirm the interaction of environmental and hide contamination with grooming behavior. Multiple research studies have focused on the impact of transportation and pre-slaughter lairage on the incidence of E. coli O157:H7 on the hides of cattle. There is disagreement over whether transportation increases or decreases the amount of animals that shed E. coli O157:H7, but a growing consensus believes hide contamination increases as transit distance increases. A group of researchers5 with the USDA Meat Animal Research Center reported that E. coli O157:H7 prevalence on the hides of feedlot cattle increased from 50.3% of animals at the time of loading to 94.4% of animals at hide removal in the plant. The cattle were hauled approximately 125 miles from the feedlot to the packing plant. Another study6 found that cattle on loads hauled greater than 100 miles were twice as likely to test positive on hide swabs upon arrival at the slaughter establishment than cattle on loads hauled less than 100 miles. Lairage pen cleanliness

also was a risk factor: Cattle held in pens with fecal contamination were three times more likely to have positive hide swabs than cattle held in pens that were cleaned prior to lairage. The researchers found that the greatest risk factor for E. coli O157:H7 hide contamination was the presence of the pathogen in the lairage pen prior to cattle occupancy. Cattle were eight times more likely have a positive hide swab when E. coli O157:H7 was found in the pen before a load of cattle was placed in the pen. We can all agree that food-safety interventions are necessary throughout the slaughter process to prevent pathogens from making it to the cooler. However, the ultimate efficacy of the intervention steps depends, to a great extent, on the pathogen load that exists on the carcass before the interventions are applied. Recent research has identified a couple of pre-slaughter factors that can help to reduce the E. coli O157:H7 loads coming into the slaughter establishment on cattle hides. Interestingly, they also can impact animal welfare. If we let the data speak, the take-home message is this: Keep your pens clean and hauls as short as possible.

Kurt D.Vogel is an assistant professor of Animal Science with an emphasis in livestock behavior and welfare at the University of Wisconsin River Falls. For more information, contact him at [email protected] or (715) 425-3704.

ENDNOTES 1) Minihan, D., M. O’Mahony, P. Whyte, and J. D. Collins. 2003. An investigation on the effect of transport and lairage on the faecal shedding prevalence of Escherichia coli 0157 in cattle. J. Vet. Med. 50:378-382. 2) Arthur, T. M., J. M. Bosilevac, D. M. Brichta-Harhay, M. N. Guerini, N. Kalchayanand, S. D. Shackelford, T. L. Wheeler, and M. Koohmaraie. 2007. Transportation and lairage environment effects on prevalence, numbers, and diversity of Escherichia coli 0157:H7 on hides and carcasses of beef cattle at processing. J. Food Protect. 70:280-286. 3) Stanford, K., S. J. Bach, T. H. Marx, S. Jones, J. R. Hansen, G. L. Wallins, H. Zahiroddini, and T. A. McAllister. 2005. Monitoring Escherichia coli 0157:H7 in inoculated and naturally colonized feedlot cattle and their environment. J. Food Protect. 68:26-33. 4) McGee, P., L. Scott, J. J. Sheridan, B. Earley, and N. Leonard. 2004. Horizontal transmission of Escherichia coli 0157:H7 during cattle housing. J. Food Prot. 67:2651-2656. 5) Arthur, T. M., J. M. Bosilevac, D. M. Brichta-Harhay, M. N. Guerini, N. Kalchayanand, S. D. Shackelford, T. L. Wheeler, and M. Koohmaraie. 2007. Transportation and lairage environment effects on prevalence, numbers, and diversity of Escherichia coli 0157:H7 on hides and carcasses of beef cattle at processing. J. Food Protect. 70:280-286. 6) Dewell, G. A., J.R. Ransom, R.D. Dewell, K. McCurdy, I.A. Gardner, E. Hill, J.N. Sofos, K.E. Belk, G.C. Smith and M.D. Salman. 2005. Prevalence of and Risk Factors for Escherichia coli O157 in Market-Ready Beef Cattle from 12 U.S. Feedlots Foodborne Pathog. Dis. 2:70-76.

SpecialReport

WHOLE-MUSCLE PROCESSING

The trickle-down

effect

Processors of whole-muscle products are weighing consumer requests for less sodium with processing realities. By Megan Pellegrini

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A

ccording to the recent National Cattlemen’s Beef Association’s (NCBA) “2010 National Meat Case Study,” whole-muscle beef products are holding their own in the meat case, representing 40 percent of packages at supermarkets and club stores. Whole-muscle products today generally encompass ready-to-eat products, such as cured hams and turkey breasts, which physically take up 37 percent of the case, an increase of 3 percent from 2007. What’s inside the package has changed tremendously, however, in the past couple years (or will change soon), as consumers demand less sodium, more natural ingredients and

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

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marinated enhancements. How are processors handling the delicate balance between consumer requests and marketplace reality? “There are many continuous improvements by equipment and materials suppliers to improve efficiency [and] safety, and lower costs,” says Andrew Milkowski, Ph.D., adjunct professor, animal sciences, muscle biology laboratory, University of Wisconsin-Madison. As with all products, there is a search for novelty in forms and flavors to introduce popular new products. The NCBA study noted, for one, that there has been an increase in case-ready product; consumer product information such as nutritional claims, cooking information, country-of-origin and bilingual labels; and natural claims. So far, rotisserie pot roasts and roast beef, which would utilize whole-muscle product, haven’t made it back to grocery stores, but there are always rumblings of new product development on the horizon, says Lynn Knipe, Ph.D., the extension processed meats specialist and associate professor in food science and technology, and animal sciences at Ohio State University, Columbus, Ohio. “I have always thought that this type of product needed to be developed to compete with all of the rotisserie chickens in supermarket delis,” says Knipe. “Probably 10 years ago or longer, Sara Lee tried a rotisserie pork roast, which was excellent, but apparently too expensive to compete

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SpecialReport with the chickens.” Latin flavors are also being incorporated into meat products as the nation has more families of Hispanic origin, says Josh Herring, Ph.D., assistant professor, department of food & animal sciences, Alabama A&M University, in Normal, Ala. “More functional foods — containing antioxidant ingredients — are being and will continue to be introduced to retain meat quality, as well as add to the health of those consuming those food products,” he notes. Processors have faced challenges over addressing current concerns about sodium content based on the 2010 Dietary Guidelines for Americans targets, says Milkowski. In addition, the recently passed Healthy, Hunger-Free Kids Act, which re-authorizes the Child Nutrition Act, sets improved nutrition standards for school meals, such as gradually

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

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SpecialReport reducing the amount of sodium in meals over 10 years, with the eventual goal of reducing sodium by more than half. “Reducing sodium while maintaining product quality and safety is a definite technical challenge,” says Milkowski.

Less sodium, more natural ingredients The drive to reduce sodium and use more natural ingredients is challenging for processors due to the nature of how whole-muscle products are created today. According to Knipe, most whole-

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

muscle products are made using a process called tumbling, massaging or mixing. Either way, processors are applying a physical treatment that won’t cause damage to the meat. Salt and phosphates actually help whole-muscle products retain the juiciness, flavor and yield that consumers expect. Processors have traditionally kept salt and phosphate levels at 1 percent to 1.5 percent, but are now attempting to hit 0.5 percent to 0.7 percent to meet consumer demands for low-salt food items, says Christine Alvarado, Ph.D., assistant professor, poultry processing, animal and food sciences, Texas Tech University, in Lubbock, Texas. “Phosphate-free ingredients use other ingredients that can carry a natural label. These ingredients are just starting to come out and become more popular for niche markets,” she says. Unknown to most consumers, explains Alvarado, meat actually contains a lot of water. Most of this water is

Controlling yield loss (and food safety) It’s unknown if tampering with salt and phosphate levels will affect wholemuscle products’ bacterial loads and safety, and in what way. Whenever there is an increase in water activity (free water), there is a chance for bac-

teria to grow, which can decrease shelf life and potentially cause food-safety problems. If the free water is bound by functional ingredients, however, then food safety and shelf life are improved. “The question of whether low-salt and natural marinades affect food

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“free” and can be lost during cooking, pressure or stress, and the rest of the water is immobilized and more tightly bound. Phosphates have charges that attach to meat protein and this immobilized water in order to retain and improve juiciness. By cutting back phosphates or using natural ingredients that don’t contain phosphates or that don’t bind as tightly to water, processors will have to find another way to provide a quality product. “From the industry perspective, these new low-salt and natural products can offer consumers more alternatives when purchasing meat products,” she says. Phosphates are certainly a relatively cost-effective solution for processors since they increase marinade retention. “If [phosphates] are taken out of the equation, ingredient suppliers and processors have been coming up with different mixes of functional ingredients to increase yield and functionality,” says Alvarado.

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SpecialReport safety is difficult since processors use many food-safety interventions,” says Alvarado. There is a reason the American Meat Institute Foundation still regards E. coli as a major threat to food safety, especially from fresh beef, says Herring. “Pathogen control will always be an issue in wholemuscle cuts as producers will always want to increase yield, which continues to be via massaging, injection and tumbling — which are ways to increase contamination and internalization of external pathogens,” says Herring. Portion-controlled products, such as nuggets and battered pieces or products, can use leftover meat, which increases food-safety concerns, as well.

Another constant challenge for whole-muscle processors is iridescence, or rainbow of colors, that appears on the surfaces of some wholemuscle products, and is particularly noticeable on beef. “These colors cause concern with consumers, because the most common colors are green, yellow, etc., which you don’t expect in sliced roast beef

or ham,” says Knipe. There appear to be many potential causes for this phenomenon, but there are no sure solutions to this problem. “Iridescence appears to increase with lower pH, when products are injected to higher levels, when whole-muscle products are sliced with sharp blades, and when sliced perpendicular to the muscle fiber orientation,” he says. Pre-portioned and precooked whole-muscle products also face challenges with yield levels. Cooking causes moisture loss, which can lead to a reduced yield for processors. When product is par-fried or even cooked at the plant, yield loss can be significant, says Alvarado. To retain moisture, processors may use high moisture or steam to cook the

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Use Citri-Fi to improve profit margins, quality, nutrition, and ingredient declarations. Citri-Fi helps accomplish these objectives by tightly binding moisture; improving yields; partially replacing oil, fat and meat; and replacing synthetic ingredients such as phosphates, emulsifiers, stabilizers and complex gum systems. • Stabilize and tightly bind free fat and water to reduce purge, drip loss and syneresis • Tightly bind added water in processed meats to improve yields • Replace phosphate salts to make foods more natural • Combine with phosphates, carrageenan and other fibers and fillers to improve yields and profits • Use in processed meats, meat fillings, tumbled, marinated and injected meats Citri-Fi is a unique multifunctional food ingredient made from orange pulp. Citri-Fi is all natural, non-allergenic, non-GMO, GRAS, gluten free, kosher, and halal. Citri-Fi has a neutral odor and taste and is labeled as dried orange pulp or citrus flour in meat applications.

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SpecialReport product. However, this method of cooking often prevents browning from occurring, which can lead to a decrease in consumer acceptance. In order to create a char-grilled or browned appearance, processors add a browning step with some new technologies. “There is more browning, chargrilling equipment today for color development, which prevents yield loss and has an added benefit of increased juiciness and better color for consumer appearance,” says Alvarado.

Weighing health concerns In the next few years, whole-muscle processors will have to balance bacterial loads and safety concerns with making more green or “clean label” products, which are perceived as safer and more healthy by the general public, notes Herring.

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“As soccer moms continue to desire healthier foods for their children, the sodium issue will persist, as well as fat concerns — saturation, hydrogenation, etc.” – Josh Herring, Ph.D., assistant professor, department of food & animal sciences, Alabama A&M University “As soccer moms continue to desire healthier foods for their children, the sodium issue will persist, as well as fat concerns — saturation, hydrogenation, etc.,” he says. However, these altered products will not come cheap, and cost may skew product selection. “Many consumers will skip the marinated whole-muscle cuts as the sodium levels are too high or the

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

seasoning may be too new to risk the purchase price, as the whole-muscle cut will cost more and the size will drive up the unit price,” says Herring. Finally, fresh seafood, though not generally a major focus when discussing whole-muscle foods, also will face increased scrutiny as the oil spill in the Gulf of Mexico continues to alter the safety and security of seafood from that region, says Herring.

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Grote Company As founder of Donatos Pizza, a Columbus, Ohio-based chain with 200 stores in five states, Jim Grote was driven to find a better way to slice and apply pepperoni to his pies. He created the Peppamatic, the world’s first automated pepperoni slicer/applicator, in the late 1960s. The Peppamatic’s unique ability to cut labor cost, while increasing productivity and efficiency, inspired Jim to found the Grote Company. Since 1972, Grote Company has established itself as the world leader in slicer/applicator innovation and technology, and continues to revolutionize the way food processors and manufacturers slice, stack, portion, count and arrange virtually all types of food products. Grote’s extensive product line includes equipment to handle simple applications, such as bulk slicing and portion control, and is ideal for slicing most boneless and non-frozen deli and whole muscle meats. The delicate cutting action of Grote’s patented Accuband® blade makes it one of the most versatile slicing systems in the industry. Grote’s 613 and 713 multi-purpose slicers offer two of the most diverse cutting platforms on the market today. Grote’s more complex systems provide solutions for automating food manufacturing processes. In these applications, Grote equipment is ideally suited for precisely slicing & applying products onto moving production line targets, as well as for applying sliced products directly onto moving oven belts. Today, Grote’s High Speed slicer is the industry standard for precooked bacon lines, while Grote’s Peppamatic and Slicer/Applicators are staples in the frozen pizza and snackfood industries. Grote’s UK-based Advanced Food Technology (AFT) division, located in Thame, Oxfordshire, is world renowned for its ability to engineer tailor-made automation machines and assembly lines for the sandwich production industry. Since developing the food industry’s first commercial potato peeler in 1954, Grote’s Iowa-based Vanmark Equipment division has become synonymous with the highest quality industrial peeling, washing and material handling systems in the industry. www.grotecompany.com 614-868-8414 888-534-7683 [email protected] 88

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

FPSA & Process Expo FPSA has taken another step to make certain that PROCESS EXPO 2011 as well as future shows will provide the highest quality experience for both exhibitors and attendees. The show has contracted with a company named ethnoMetrics, a leader in fact-based services in face-to-face marketing that offers traffic measurement, and an analysis of timing and attendee movements on the tradeshow floor. Individual exhibitors will be able to measure the effectiveness of their booth and personnel in drawing in and engaging customers who walk by their booth. There will be two upcoming seminars on ethnoMetrics, the first of which will be held on Friday, March 11, 2011 at the FPSA Annual Conference in Palm Desert, CA, while the second seminar will be held at the FPSA Annual Operations Conference in August in Chicago. PROCESS EXPO 2011 will be held November 1-4, 2011. Attendee registration will open in January. For more information on all FPSA events go to www.fpsa.org Editor’s Note: The National Provisioner, in conjunction with the Meat Industry Suppliers Alliance, will spotlight a member company and the many outreach activities of MISA every month as a service to the industry.

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TechProcessing

Don’t overlook stuffing and grinding processes By Andy Hanacek, editor-in-chief THE TERM “TIME-TESTED” MAY NOT PROPERLY DESCRIBE the processes of grinding and stuffing meat, simply because it may not infer enough distance in time. To be certain, grinding protein is an art and skill that dates forever, and stuffing of meat into casings is just as longstanding a tradition as far as protein-processing goes. Although an untrained eye might assume that grinding and stuffing are simple, unscientific, straightforward processes, those in and around the meat industry know that there’s much more than goes into the making of

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ground meat and sausages, particularly in the grinding and stuffing phases. Whether a company is producing bratwurst, Italian sausage, liver sausage or hard salami, there are many factors that can change the stuffing process considerably, in order to create the proper bite, texture, taste and sliceability (if required) in the product. In The National Provisioner’s Sausage Technology Journal (full text available on our Web site, www. provisioneronline.com), Wesley N. Osburn, Ph.D., associate professor in the Department of Animal Science at Texas A&M University, walks read-

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

ers through the different methods of stuffing, the types of equipment used and the reported results processors can expect from them. Common sausage stuffers, Osburn says, include piston, auger or screw and rotary vane stuffers. Rotary vane stuffers are ideal for smaller applications that experience frequent product changeovers, because they minimize product loss. They also minimize product friction, Osburn adds. Augers come in a variety of configurations to handle evacuation of a variety of meat grinds, including emulsions, coarse grinds and restructured meats. The process of grinding meat

“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.

TechProcessing requires sharp focus on the calibrations of the grinding system in order to produce the texture and visual appeal desired in the final product. Commercial grinders, Osburn says, can handle meat that is fresh or frozen (minus5°C to minus-10°C), and that many systems can grind 3,000 to 25,000 kilograms per hour, depending on the raw material and number of revolutions of the grinder system. For grinding, however, it is essential to control the in-feed raw material and know its properties in order to get the desired outcome. Furthermore, upkeep of the grinding system is important, especially along the lines of keeping knives and plates sharp and properly tightened within the assemble, Osburn states in

Photo by Vito Palmisano

the Technology Journal. Otherwise, a processor could experience product grease-out or poor particle definition in the final product. Another factor affecting final product quality is the successful removal of bone chips and gristle, particularly in coarse-ground and emulsified sausage. Osburn says that various bone collection systems exist for grinders, each using either a center or peripheral discharge

system to do its job. Grinding and stuffing is only part of the overall process involved in sausage and ground meat production. Yet, although they seem to be the most straightforward processes in the chain of production, improper focus on the details of these processes can cause unwanted properties in the final product that is produced. Close attention should be paid to these steps in the process — as close attention as a processor would delegate to the formulation, mixing, cooking/chilling and packaging steps. To read more about the sausage production process, as explained by Dr. Osburn and other technical experts, sign up at www.provisioneronline.com to read our Sausage Tech Journal.

Accurate – Reliable – Overall Effectiveness For fast and accurate performance that you can count on, Mepaco’s line of Mixer-Blenders, Grinders, and Stuffers provide the consistency you require. Mixer-Blenders: Rugged design reduces cycle times and temperature rise while providing a more homogeneous blend.

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Grinders: Efficient and durable, Mepaco grinders provide a high-capacity, quality grind with superior bone collection capability. Stuffers: Completely self-contained, the 420v delivers continuous vacuum while improving color, shelf life, and yields. Since 1932, producing “best in class” end products has been our trademark. Our unwavering service, hygienic design, and technical leadership remain Mepaco’s cornerstone.

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TH THE HEE NA H NATIO NATIONAL TIO ONAL PR PROVI PROVISIONER OVISIO OVI SIO IO ONER | PR PROVI PROVISIONERONLINE.COM OVISIO OVI SIONER SIO ON NER ERONL ERONL NLLINE INE.CO .CO OM | FE FEBRU FEBRUARY BRUARY BRU ARY 20 ARY 2011 011 11

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SYSTEMS INTEGRATION

TechProcessing LUBRICANTS

Certifying quality By Megan Pellegrini AFTER A YEAR OF INNOVATION, food-grade lubricant manufacturers are focusing on achieving more stringent certification after a new batch of food recalls in 2010. Historically, food-grade lubricants have not been viewed as highly as their non-food-grade counterparts, because generally they have been formulated to only meet voluntary H1 requirements using H1-registered components. However, some new food-grade lubricants are matching conventional greases with improved performance levels, performance at wider temperature ranges and endurance during highpressure water cleanings, says Chuck Coe, president of Grease Technology Solutions LLC, a Manassas,Va.-based consulting firm. “We observe that lubricant formulators are constantly innovating by developing new and improved chemistries that extend the life and enhance the performance of food-grade lubricants,” says Jessica Evans, business unit manager, Nonfood Compounds, NSF

Photo courtesy of NSF International

International, a not-for-profit and non-governmental organization dedicated to standards development, product certification, education and risk-management for public health and safety, based in Ann Arbor, Mich. “Today food-grade greases and lubricants can often have the same functional properties and durability as traditional industrial lubricants, so that processors don’t have to compromise performance for safety,” she says. While H1 lubricants have been widely used in food process-

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TESTIMONIAL: PETRO-CANADA LUBRICANTS

ROSE POULTRY FINDS THE RIGHT LUBRICANT SOLUTIONS FOR THEIR WORLD-CLASS OPERATION. “When Petro-Chem visited our factory, they suggested that if we switched to Petro-Canada’s REFLO™ 68A,** our fluid consumption would be significantly reduced,” – Claus Foldager With three production facilities processing approximately 290,000 poultry products per day, Rose Poultry is Denmark’s largest manufacturer of chicken products and one of the world’s most advanced poultry processors. Their products are synonymous with great taste and quality, and are enjoyed by a growing customer base throughout Europe and the Middle East. THE LUBRICANT CHALLENGES Lubrication is a very important part of Rose Poultry’s systematic preventative maintenance protocol. For example, processing equipment, conveyors and trolley systems are systematically high-pressure washed, lubricated and meticulously cleaned to ensure the highest level of food safety and operations efficiency. Unfortunately, their lubricants were not measuring up. Much of the food machinery grease and trolley fluid was being washed off after just one week. HELLO PETRO-CHEM AND PETRO-CANADA LUBRICANTS Petro-Chem, a Danish distributor of Petro-Canada lubricants, listened to

the issues Rose Poultry were having and agreed to conduct some on-site tests using PURITY FG* 00 Grease in the million-dollar spiral freezers. “We were quite surprised,” says Lars Hvass, Technical Manager for Rose Poultry. “The grease proved to have very good resistance to water washout and breakdown, and it performs exceptionally, even at -35ºC (-31ºF).” Rose Poultry was so happy with the performance of the PURITY FG 00 Grease that a factory tour was scheduled so that Petro-Chem could survey the processor’s trolley and refrigeration systems, as well. SMOOTH TROLLEY SYSTEMS Chickens are transported throughout the production facility by way of an efficient trolley system that is now lubricated with Petro-Canada’s PURITY FG Trolley Fluid. It offers a number of important performance benefits, including a special lubricity additive to help reduce bearing friction, better drip protection, and tenacious adherence properties.

KEEPING THEIR COOL Meat processing companies like Rose Poultry rely on their refrigeration systems to keep their products cool, fresh and safe. “When Petro-Chem visited our factory, they suggested that if we switched to Petro-Canada’s REFLO™ 68A,** our fluid consumption would be significantly reduced,” says Claus Foldager, Head of Repairs for Rose Poultry. “In our estimation, using REFLO in conjunction with our systematic preventative maintenance protocol has cut our total fluid consumption in half.” THE WORLD IS CHANGING. ARE YOU? For many years, Denmark’s Rose Poultry was searching for an integrated line of food grade lubricants – one that would help to consolidate inventory and streamline their supplier list. They’ve found it with Petro-Chem and Petro-Canada. You can too. To learn more about PURITY FG lubricants, visit lubricants.petro-canada.ca

* PURITY™ FG lubricants fit perfectly into Hazard Analysis and Critical Control Points (HACCP) and Good Manufacturing Practice (GMP) plans, are H1 registered by NSF, carry a full set of food grade credentials, and are fully approved for use in and around food processing areas. ** REFLO A is an ammonia refrigeration compressor fluid used in industrial refrigeration systems. It is formulated to outperform solvent refined paraffinic lubricants for our operation – and naphthenic refrigerant oils.

Rose Poultry With three production facilities processing approximately 290,000 poultry products per day, Rose Poultry, shown to the left, is Denmark’s largest manufacturer of chicken products and one of the world’s most advanced poultry processors.

lubricants.petro-canada.ca

TechProcessing ing for decades, ISO 21469 is a relatively new standard introduced to the industry within the last five years. ISO 21469 certification complements the registration program for the H1, H2 and H3 categories in the lubricant industry, but goes further by requiring a facility audit and physical testing of the products, says Evans. In addition, ISO 21469 requires lubricant formulations to comply with FDA regulations in 21 Code of Federal Regulations (CFR) and ensures ongoing compliance through annual audits and testing by an independent third-party organization. The voluntary certification program also specifies the hygiene requirements for the formulation, manufacture, use and handling of lubricants, which may come into contact with products during manufacturing or processing. ISO 21469 certification is currently gaining acceptance by the global food industry, notes Evans. “Food processors who specify ISO 21469 can be confident in the consistent quality, and compliance of their foodgrade lubricants, thus providing the best possible option for effective risk management,” says Evans. NSF International launched its voluntary Nonfood Compounds Registration Program in 1999 to re-introduce the previous authorization program administered by the U.S. Department of Agriculture (USDA), which covers all compounds used in and around food establishments such as disinfectants, lubricants and pre-processing agents. “Not many grease manufacturers have attempted or achieved the new ISO 21469 standard because they are happy making H1 certification claims,” says Coe. “Many are standing on the sidelines while they debate the advantages of the new standard: Some think it provides them with a market advantage, but the certification process is more time-consuming and onerous.” An H1 registered food-grade lubricant can also offer a safety — and market — benefit to the processor, as it should minimize the risk of food product contamination or adulteration. “Not only does the product registration provide added assurance to the processor, but the NSF Registration mark on

a product label also demonstrates that supply-chain controls are in place with these products when an auditor or inspector sees them being used in a facility,” says Evans. She notes that processors should also be concerned with other products that are brought into their facility that can poten-

tially cause contamination, such as water treatment products and sanitizers. “For now, food-grade lubricants have shown the capability to be better, though I can’t say they all are,” says Coe.“Some companies are probably still selling 10-year-old formulas, but there is a definite trend toward better performance.”

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FoodSafety

Biosecurity begins on the live side By Andy Hanacek, editor-in-chief THE TIMES, THEY ARE NOT A-CHANGIN’ — they’d changed long ago in the realm of food safety and security. as such, any processors, packers or producers who have not embraced the idea that their supply chain is vulnerable are putting their product in serious danger of anchoring all the wrong kinds of headlines. Processors can keep their facilities secure and outfit their products with anti-tampering indicators to keep consumers safe, but biosecurity starts on the farm, and for producers, there

Success is a Matter of System Maximizing Profits with CSB-System Software Solutions With more than 33 years of experience, CSB-System is the leading provider of innovative software solutions for the protein industry. Our industry specific fully integrated solutions provide our global client base with long-lasting competitive advantages by increasing efficiency, reducing costs and maximizing profits. Integrated. Pre-Configured. Tailored to your Business. Chicago, IL. Visit us at AMI in nvention Center Co ce Pla ick rm McCo April 13th-16th Booth #1984

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CSB-System software provides resources for: „ Traceability and Recall Management „ Scale, Labelling and Scanning Solutions „ Yield Management and Product Costing „ Gross Margin Analysis „ Inventory Management Systems „ Batch Processing Management „ Livestock Solutions „ Enterprise Resource Planning Take advantage of our expertise - contact us in order to learn more about our state-of-the-art software solutions for the protein industry.

are many resources available at the university level to help them maintain a secure herd or flock. When most people think of the word “biosecurity,” they might think it means keeping the food supply safe from intentional efforts to contaminate the system by terrorists or criminals. However, the meaning goes beyond that for researchers at cattle operations. Consider the following description of “biosecurity” as introduced in a University of Nebraska-Lincoln (UNL) Extension NebGuide fact sheet, titled “Biosecurity Basics for Cattle Operations and Good Management Practices (GMP) for Controlling Infectious Diseases”: “The goal of biosecurity is to stop transmission of disease causing agents by preventing, minimizing or controlling cross-contamination of body fluids (feces, urine, saliva, etc.) between animals, animals to feed and animals to equipment that may directly or indirectly contact animals.”1 In this description, intent doesn’t matter to researchers, and it shouldn’t matter to operators either. Regardless of the source, businesses need to enact a plan of identification and prevention in order to ensure a secure and safe herd, and consequently, a safe food supply. The UNL researchers admit that development and maintenance of a biosecurity program is difficult, but it remains “the cheapest, most effective means of disease control available.” The team advises operators to develop a biosecurity resource group at each facility, an idea that shouldn’t be unfamiliar to many processors who have dedicated food-safety or workersafety teams within the walls of each facility. This group would theoretically consist of biosecurity champions who take ownership of the standards, strategies and practices at the facility. Operators who focus their efforts on managing the introduction of new cattle into the herd and traffic control in the facility have hit on the key priorities, the UNL fact sheet states. Further, isolation of cattle, traffic control into and around the facility — vehicular, human

and animal — and sanitation are the three major components of biosecurity that operators must monitor and manage. For operators who can keep these aspects of their facilities under control, biosecurity becomes less of a difficult task as efficiency, quality and safety improves for the animals, consumers and workers at the facility. For more information on a variety of

topics of interest to the protein industry, visit the UNL Extension’s Web site at www.ianrpubs.unl.edu. ENDNOTES 1 Buhman, M., Dewell, G., Griffin, D.; “Biosecurity Basics for Cattle Operations and Good Management Practices (GMP) for Controlling Infectious Diseases”; University of NebraskaLincoln Extension, http://www.ianrpubs.unl. edu/epublic/pages/index.jsp.

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TechPackaging

LABELING

Seize the opportunity Don’t rule out the power of nutrition labeling at the meat case. By Cheryl Hendricks, National Cattlemen’s Beef Association CONSUMERS ARE BECOMING INCREASINGLY INTERESTED IN NUTRITION and wellness, and they view the grocery store as a key resource for nutrition information.With the introduction of the now-mandatory nutrition labeling rule for meat and poultry products, labeling alternatives still remain that can give retailers a competitive advantage. Now is the time to seize the opportunities presented by nutrition labeling. Retailers who harness the significance of nutrition information in the meat case can turn labeling into a very powerful marketing tool to build customer loyalty and increase fresh meat sales. As you develop your meat case nutrition-labeling program in preparation for the Jan. 1, 2012, implementation date, we strive to be your most valuable resource in determining compliance requirements and developing a program that delivers, through an effective communications platform, the nutritional information your customers desire and need in order to make purchasing decision for optimal health. The Beef Checkoff has conducted extensive research in an effort to understand consumers’ preferences when it comes to nutrition labeling for meat. This research shows that a meat case labeling program that follows these guidelines will increase customer loyalty and meat sales. With this research in mind, let’s outline the best practices that will help you effectively deliver a meat case nutrition-labeling program that will meet your customer’s needs. 98

Whether on-pack or at the point of purchase, communicate fresh meat’s complete nutrition package — Three out of four consumers indicate they prefer a label that includes additional relevant vitamins and minerals found in meat and poultry1. The micronutrients found in meat, other than the required iron, (e.g., zinc, B vitamins, riboflavin, etc.) can be listed either in addition to or in place of the required vitamins and minerals as long as the “Not a significant source …” statement is used. Relevance, relevance, relevance — Provide your customers with nutrition information that is relevant to how they consume the product, using “as consumed” nutrient data. The more relevant nutrition information puts fresh meat products in a more positive light and therefore can result in increased sales. Use “Dual Declaration” labels to incorporate “as consumed” data on ground beef labels If no nutrition claims are made for whole-muscle products, use “as consumed” data along with appropriate preparation and cooking instructions. The

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | FEBRUARY 2011

additional information will help ensure your customers are consistently preparing your product to deliver a great eating experience for their families. Amplify nutrition labeling as a merchandising tool — Your customers not only want to know the nutritional content of their beef/meat, but they also want to know what its nutrients provide for their health and the health of their family. There are long-term gains to be made by developing an on-pack nutrition-labeling program that includes declarations that help guide your customers to healthy meat selections. POS is critical — An on-pack nutrition labeling program allows you to extend the promotion of positive claims about beef and its nutritional benefits to point-of-sale (POS) materials to grab customers’ attention and generate a “lift” in sales. The more opportunities you use to promote the nutritional information you’re providing on your beef and meat products to your customers, the more recognition they will give you for making this information available to them. Our research shows that providing this information to consumers can increase customer loyalty and purchase intent. Use these programs to build your customer’s commitment to you and in turn, your meat department sales. Cheryl Hendricks is a registered dietitian with the National Cattlemen’s Beef Association (NCBA), which contracts to manage retail marketing efforts for The Beef Checkoff.

Integrity. It comes with the reputation Ossid has earned by forging strong customer relationships for over 30 years. Visit us at AMI in Chicago as we unveil the latest advancements in horizontal form fill seal technology. Come see firsthand how our newest line delivers on the integrity of the Ossid brand.

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SUPPLIER LITERATURE SHOWCASE PDQ PLASTICS

PDQ PLASTICS manufactures the most durable Plastic Pallets available. Our Super Plastic Pallets come in a variety of sizes and colors and are designed to last for years under the toughest conditions. For more information contact Hartson Poland at 800-447-7141 or visit us on the web at www.pdqplastics.com.

To place l your ad d iin our next Supplier li Literature i Showcase, h please l contact Diana i Rotman at [email protected] or by phone at 847- 405-4116.

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

www.ProvisionerOnline.com 100

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

TechShowcase Former

Conveyor Belts

Free four-page, full-color literature is available on NuTEC Mfg.’s 745 Food Forming Machine. A completely hydraulic, microprocessor controlled, multi-outlet forming machine, the 745 combines accurate weight control, minimum leakage, and quick changeovers with mobility. Its portable design allows the machine to be easily transported to wash-down departments or other areas in the plant. The brochure includes a step-by-step description of the 745’s features and benefits, along with product specifications, electrical specifications, and an engineering drawing.

Ashworth Bros. introduces a ¾-inch and 1½-inch pitch Omni-Pro link to complete the Omni-Pro line of spiral/ turn-curve conveyor belts. Both Omni-Pro 075 and Omni-Pro 150HD retain the same design features that allow the belt to minimize cage bar wear, maintenance costs and downtime in the most demanding hightension spiral applications. The increased strength of the Omni-Pro comes from the 360° buttonless welds utilizing a “zero tension” design which allows a higher load bearing capacity. Ashworth Bros. Inc.: (800) 682-4594 or visit www.ashworth.com

Cook/Chill Equipment The Odenberg Pallet-Link system, available exclusively through JBT FoodTech, is a variable residence time (VRT) and buffering system for chilling and freezing packaged food products. The system allows for the handling of multiple products simultaneously and features a patented link system that couples pallet shelves together for greater independence of out-feeding from in-feeding. The tilted shelf provides 20 percent more efficient freezing performance compared to competing systems alone.

NuTEC Mfg.: (815)722-2800 or visit www.nutecmfg.com

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

Weigher

Patty Paper

Quickly and accurately weigh fresh meat, poultry, and other moist, sticky products using the Ishida SFseries multihead weigher from Heat and Control. Double screw feeders keep product moving through the radial feeders. Plastic hoppers with scraper gates are available to prevent product sticking and build-up. The weigher is rated for IP65 washdown, and all product contact parts can be removed without using tools and sanitized using high-temperature cleaners.

Patty Paper Inc. offers a versatile range of paper that raises the food safety bar by being 100% USDA approved. Its wide variety of select grade papers are used in the meat, dairy, bakery, deli, snack, and grocery industries. When packaging its patty paper stacks, PPI provides a patented FDA-approved individually wrapped paper packaging system. Individual fully wrapped packages keep each stack of interleaving paper clean and sanitary until it is used for interleaving.

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

Patty Paper Inc.: (800) 782-1703 or visit www.pattypaper.com

Meat Recovery Bettcher Industries introduces the Whizard TrimVac for chicken processing, which enables processors to recover more white meat yield in high-volume poultry processing activities. The TrimVac system makes it easy to harvest subtender white meat from beneath the wishbone, along with “eye” muscle lean meat that anchors the breast muscle to the breast frame as well as lean meat along the rib, keel and back. The entire trimming and vacuuming process is simple and sanitary. Bettcher Industries Inc.: (440) 965-4422 or visit www.bettcher.com/poultry-white-meat-recovery MARCH 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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TechShowcase

Balances

Film

HK Instrument Systems’ revolutionary HK-4 NIR Analyzer is a full spectroscopy system that measures fat, protein, and moisture in beef, sausage, and poultry. It can be used on a chopper bowl, blender, mixer, or grinder. The company’s special proprietary software compensates for many of the ambient and process changes that have given NIR Systems trouble in the past. The HK-4 can help improve processes and save money by closing the control loop at a facility.

Mettler Toledo’s new Excellence XA Balance line combines fundamental functionality with high weighing performance to deliver a range of balances that are straightforward and easy to use but still excel in terms of reliability and repeatability. The line includes two analytical and six precision balances. The balances are ideal for product quality control applications on the production line, as well as for typical weighing procedures such as preparation of buffer solutions for managing pH levels.

Mylar COOK, a ground-breaking, ovenable film developed by DuPont Teijin Films, is FDA approved to 425 F and is ideally suited for “cook-in” meat applications. Developed to run on standard roll stock thermoforming equipment, it provides a wide range of operational efficiencies from production line to market. The film offers many innovations including fresh or frozen-to-oven convenience, “no-touch” cook experience, eliminating the need to handle raw meats, and strong package integrity with a self-venting feature.

HK Instrument Systems: (412) 653-7717 or visit www.hkinstruments.com

Mettler Toledo: (800) 638-8537 or visit www.mt.com

DuPont Teijin Films: (855) 383-6535 or visit www.dupontteijinfilms.com

Analyzer

You’ve Gotta Love Our Grinder! Hollymatic’s 3000 Mixer/Grinder is at the heart of many operations, from supermarkets to large processing plants. Powerful independent mix and grind gear drives provide excellent production rates. Solid stainless steel, seam welded construction puts the focus on strength and power for increased reliability. Add automatic forward-reverse mixing and local service, and you’ve got a case for true love.

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

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Packaging Oil Sac Cutter Cantrell has redesigned its oil sac cutter to run at higher line speeds and to lower maintenance costs. The OSC-1300 Oil Sac Cutter has been redesigned using less corrosive components and equipping the main chain with replacement components, allowing customers to purchase components instead of the complete chain assembly. The machine removes the oil gland from the tail of the chickens as they move along the processing line. Cantrell: (800) 922-1232 or visit www.cantrell.com

Multivac has developed a concept for integrating equipment for the highpressure treatment of foods into fully automatic packaging lines. Multivac can offer it not only for vacuum packages but also for modified atmosphere packaging. The patent-pending solution comprises a high pressure unit (one ore more autoclaves) as well as an automation concept to integrate the process into packaging lines which are laid out to meet the demands of the food industry. Multivac Inc: (816) 891-0555 or visit www.multivac.com

Flooring Stonhard has added a new, environmentally conscious product to its line of Stonclad floor systems. Stonclad G2 is a four-component, polyurethane mortar system that incorporates post-industrial recycled glass and rapidly-renewable materials into its composition, making it a good fit for sustainabilityminded projects that won’t use traditional, epoxy floors. Because it is a seamless system, with no joints for dirt to build up, Stonclad G2 requires just simple maintenance. Stonhard: (800) 257-7953 or visit www.stonhard.com

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TechShowcase Roofing Duro-Last Roofing is adding a standing seam metal product line to its roofing system offerings. With five profiles and more than 30 colors to choose from, the line will enable authorized Duro-Last contractors to provide a standing seam roofing installation to meet virtually any aesthetic requirements. The new program includes metal production capabilities provided by a nationwide network of independent regional manufacturers. All panels will be produced under the authority of Duro-Last division Exceptional Metals. Duro-Last Roofing Inc.: (800) 248-0280 or visit www.duro-last.com

Industry News

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Weber Inc. has invited processors using its slicing systems to attend Sanitation Symposium II, a three-day learning and leadership event at its North American headquarters in Kansas City, Mo., on March 22-24. Seminar presentations will be lead by numerous food safety experts and are intended to share and further develop industry best practices, while also building cross-company networks to solve mutual problems related to hygienic operations. In addition to expert presentations and smallgroup discussions, live demonstrations of both steam cleaning and wet cleaning will be conducted. There is no cost for Weber machine owners to attend the event. Registrations are being accepted on line at www.weberslicer.com/sanitationsymposium/. Questions may be directed to Deb Cline at [email protected] or (800) 505-9591. Cantrell has named Joe Cosper as account manager for the Southeast Region. Cosper brings an extensive engineering background to Cantrell, a poultry and food processing equipment sales and service company. He has nearly 15 years of engineering and project management experience Cosper in the poultry processing equipment industry. Cosper will serve Cantrell customers in Florida, Georgia, South Carolina, eastern Tennessee and southeastern Alabama.

Ross Industries Inc. has appointed Cecilie Martinez O’Gara as salesperson for the company’s South Central Territory. This region includes Colorado, Kansas, Missouri, New Mexico, Oklahoma, Arkansas, Texas and Louisiana. In this position, she will represent the company’s entire line of food processing and tenderizing equipment. O’Gara comes to Ross Industries with a wealth of O’Gara industry sales experience, business development and territory management. She worked most recently at CFS as regional sales manager and prior to that with APV, also as regional sales manager. With the introduction of its new PowerMax3000, PowerMax4000 and PowerScanner technologies, Formax states that it is exceeding the expectations of slicing customers with its innovation worldwide.

The company is now presenting processors with a guarantee called, “The Powermax Promise.” “The PowerMax Promise is a guarantee that simply says we will meet or exceed your expectations,” said Brian Sandberg, global product manager of Provisur Technologies. “Whether it’s delivering the ultimate in food safety, the lowest ownership costs or providing higher yields, The PowerMax Promise says we will be there for you. It’s a testament to what our advanced technologies are capable of achieving, and it’s our guarantee to an industry in pursuit of greater productivity, food safety and profit.” Formax is hosting a new website at www. powermaxpromise.com complete with live action video of the PowerMax3000 and PowerMax4000 in full operation.

Intelligrated, an automated material handling solutions provider, announces the recent appointment of Kevin O’Reilly to the position of sales engineer II for the company’s Somerset, N.J.-based eastern regional operation. In his new position, O’Reilly will be O’Reilly responsible for sales in the region under the direction of Eric Palotas, vice president of eastern regional operations for Intelligrated. O’Reilly will also provide sales, concepting, estimating, engineering and client relation services. Interstate Warehousing is expanding its Hamilton, Ohio facility. The 90,000-square-foot expansion, which began January 2011, is expected to be completed in May. The current facility is approximately 350,000 square feet. Interstate Warehousing’s Hamilton facility is known for its large freight consolidation program, and

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TechShowcase the expansion is a result of the growth of multiple customers. The expansion will add 11,500 pallet positions, 19 new dock doors, and will also create 25 new full-time jobs at the facility. “The city of Hamilton and the Cincinnati market have always been good to Interstate Warehousing,” said Chuck Tippmann, president, Tippmann Group/Interstate Warehousing. “We’re happy to be able to grow with our customers, and this expansion will put us in a better position to provide them with additional storage and distribution space for their frozen products, so our companies can continue to grow together.” Foodmate US Inc. is the new distributor of Netherlands-based Foodmate B.V.’s poultry processing equipment in North America. Scott Hazenbroek will serve as president of Foodmate US. He has more than 15 years of experience in the processing equipment business, having worked for companies in both the U.S. and Europe. “Foodmate is fully committed to the North American poultry industry,” Hazenbroek said. “Foodmate has made strong inroads in Europe and Asia. Now we are looking to increase our business in the North America.”

Foodmate’s poultry processing equipment line includes cut-up, deboning, portioning and weighing systems. Its food processing line includes cooling and freezing systems, frying systems, as well as cookers, hot air ovens, batter and breading machines. Foodmate US’ offices are at 135 P. Rickman Industrial Dr., Suite 200, Canton, Ga. 30115. The company’s headquarters house sales, engineering, service, warehouse and parts inventory. At a ceremony held in Las Vegas during its 65th annual MeatExpo conference, the National Meat Association awarded its 2011 Supplier of the Year award to Multivac Inc. The Supplier of the Year is selected from a list of nominations submitted by NMA general members, firms that have close interaction with suppliers throughout the year. Bob Koch, director of sales for Multivac’s food division, was singled out for his professionalism and long-time service to the meat and poultry industries. “Multivac is deeply honored to receive this distinction from the NMA,” said Jan Erik Kuhlmann, president and CEO, Multivac.

Processor News The National Turkey Federation’s (NTF) Board of Directors elected Rick Huisinga to serve as the federation’s 2011 chairman. Huisinga is executive vice president of Willmar Poultry Company in Willmar, Minn. “I’m a pragmatic person and I believe that using common sense and simply doing the right thing will serve us well to mitigate the numerous regulatory and legislative issues our industry will continue to face in this strange political climate,” Huisinga said during his acceptance speech. “Whether it is talking about environmental stewardship, the responsible use of antibiotics or food safety practices, we can all do the right thing by being a part of the public affairs process.” Huisinga discussed in detail those regulatory Huisinga and legislative challenges that will confront the turkey industry – antibiotic use in animal agriculture; food safety; environmental regulations; the Grain Inspection, Packers and Stockyards Administration proposed marketing rule; and renewable fuels policy. During NTF’s Annual Convention, the Board of Directors also elected Steve Willardsen, president, Cargill Value Added Meats, as vice chairman; and John Burkel, director, Northern Pride, Inc., as secretary-treasurer. Yubert Envia, vice president of turkey and prepared foods, Foster Farms, assumes the position of immediate past chairman. Also during the convention, the NTF honored George Nicholas, founder of Nicholas Turkey Breeding Farms, with the NTF Lifetime Achievement Award. Nicholas received the award posthumously for his long-term, unselfish dedication to creative innovation in turkey production.

106 THE NP03092JVH.indd 1 NATIONAL PROVISIONER

| PROVISIONERONLINE.COM | FEBRUARY 2/17/09 3:45:25 PM2011

Jihad Douglas and Yan Ghazikhanian of Aviagen Turkeys, accepted the award on behalf of Nicholas’ family and the company he founded. Nicholas passed away in 1985. In presenting the award, NTF Chairman Yubert Envia said, “There are many people who undoubtedly could claim to have a hand in the creation of the broad-breasted white turkey we know today. However, if you want to know who is responsible for putting the modern commercial production on the dinner plates of millions of Americans, there is only one name: George Nicholas.” The next president of the National Chicken Council will be Mike Brown, currently senior vice president for legislative affairs of the American Meat Institute, NCC Chairman Bernard Leonard announced. Brown will join NCC in March to succeed George Watts, who is retiring after 38 years as president. “The search committee considered many qualified candidates before recommending Mike Brown’s election to the NCC Executive Committee,” said Leonard, who is group vice president/Food Service of Tyson Foods, Springdale, Ark. “We believe that Mike is the person who can lead NCC as it addresses the issues that will shape the future of the industry.” Brown, 50, currently represents AMI to Congress Brown and the Administration on governmental matters. He also serves as the treasurer of AMI’s Political Action Committee, AMI-PAC. “I look forward to the challenge of working with the chicken industry and following the great tradition of service and effective representation and leadership set by George Watts,” Brown said. “I accept this position with enthusiasm.” Partnering with the National Salt Reduction Initiative, Butterball LLC joins a nationwide effort to cut the salt in packaged and restaurant foods by 25 percent by 2014 – an achievement that would help reduce the nation’s salt intake by 20 percent. While the majority of Butterball’s products already fall within the NSRI 2014 guidelines, the company is

actively working to make further sodium reductions. Even though Butterball Whole Turkey, traypack and lunchmeat products already fall within NRSI guidelines, Butterball plans to further reduce sodium in those products and has committed its deli meat and turkey franks to meet NSRI guidelines by 2014: ■ Butterball plans to reduce the sodium levels of turkey ham and turkey pastrami by 20 percent by 2012 ■ Sodium in the remaining deli products will be reduced on average by 10 percent, which will exceed 2014 goals

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

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