The National Provisioner May 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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THE NATIONAL PROVISIONER’S

TOP

100

32

COVER STORY

The right fit With an eye on the future, AdvancePierre Foods continues to navigate through the integration of its “perfect match” 2010 merger.

10 | Fight for Food Safety: We swore we would never forget 12 | Regulations & Legislation: Recalls for pathogens in raw products

Visit the new ProvisionerOnline.com

4

Consumer trends Podcast!

Read Us Online

Hear about the latest research on consumer buying habits and its correlation with meat and poultry sales in our newest podcast.

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

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

40 | Our annual processor rankings give a glimpse into the year that was in the protein-processing industry.

SPECIAL REPORT

Formulation Strategies 26 | Pushing flavors to the extreme

Departments Guest Commentary ...... 14 New Products ................ 16 Tech Showcase ........... 73 Classifieds ................... 78 Ad Index...................... 86

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May 2011

Tech

Volume 225 Issue 5

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

PROCESSING TECH |64

Software Systems

Sophisticated software systems are automating product grades, logistics and traceability.

John E. Johnson JBS

Huston Keith Keymark Associates

INGREDIENTS & FORMULATION

SPECIAL REPORT

FOOD SAFETY

60 | Efficiency of an

66 | Sanitizers play a

20 | Donna Berry

operation requires maintenance and preservation not only of operational assets, but on spare parts as well.

part in maintaining sanitary operations, but they are not a “silver bullet” solution.

offers five ways for processors to spice up their products.

Lynn Knipe Ohio State University

Gary McMurray Georgia Tech Research Institute

Mark Reed Border Management Strategies

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editorial

Editor-In-Chief > Andy Hanacek [email protected] Editor > Sam Gazdziak This month’s contributors > Donna Berry, John Butts, Tom Hoffmann, Dennis Johnson, Martijn Kesteloo, Brendan Murphy, Megan Pellegrini, Phillip Slater, Shawn Stevens Art Director > Mary Ann Lawrence

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FightforFood Safety

We swore we would

never forget By Shawn K. Stevens

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istorically, I have tried to impart a light-hearted slant on the oftenserious issues I write about here. This month, I will not. The issue is food safety as it relates to tampering. The world has changed a great deal in the past 10 years. September of this year will mark the 10-year anniversary of possibly the darkest day our nation has ever known. In spite of the decade that has passed and the incredible job our leaders have done to keep our great nation safe, we must continue to remain vigilant. Our food supply is the envy of the world. At no other time in history has so much food been so readily available as it is in America today. That is something of which anyone working in the food industry should be very proud. Unfortunately, however, our food supply may also serve as a target to those who would do us harm. As a result, the hard-working people in the food industry often serve as the last defense between our food and those who would go to great lengths to bring us heartbreak and devastation. All companies, whether producing, storing, transporting or serving food, must remain cognizant of security risks and act preemptively to keep our food safe. Although the civil ramifications of a disaster would be devastating to a company, they pale in comparison to the potential human cost. Taking proactive steps like conducting security audits, doing background checks on prospective employees, providing identification badges to employees, securely storing chemicals and cleaning

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

agents and training employees to be alert for and report signs of tampering can help to avert potential disaster. Managers must instill a culture of food-safety awareness and ensure that each employee keeps a watchful eye against any tampering. The food industry’s accomplishments epitomize the toughness and “can do” spirit of Americans. It is up to you, once again, to take the steps necessary to keep our nation safe by ensuring the security of our food. Thank you for feeding our families. And, thank you for keeping us safe. 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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Regulations&Legislation

Recalls for pathogens in raw products By Dennis Johnson

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here have been recent examples of recalls for pathogens in raw products, even if the pathogen is not generally an adulterant in such products. These recalls have involved raw ground products bearing Salmonella and E. coli O26. One can expect such recalls will become even more common and establishments should understand why. By definition, a pathogen can cause illness. However, for the pathogen to be an adulterant under the Inspection Acts, where the presence of the organism will trigger regulatory action, FSIS must demonstrate either: (1) under ordinary conditions of use, the pathogen could cause illnesses; or, (2) in a specific situation, the presence of the pathogen in the production of one particular product has directly caused illnesses.

The first class of adulterants, those causing illness under ordinary conditions of use, is much more familiar. There is no dispute that the presence of pathogens, such as Salmonella, E. coli O157:H7 and Listeria monocytogenes, in a ready-to-eat product can cause illness because the product will not receive an additional lethality treatment under ordinary conditions of use. Although not universally accepted at first, FSIS declared E. coli O157:H7 an adulterant in raw, non-intact beef in 1994. FSIS then had to defend its determination in a Federal District Court. It successfully defended its decision by proving to the court that under the ordinary conditions of use, many consumers undercooked ground beef and, as a result, there had been illnesses caused by this pathogen. Texas Food Industry Association v. Espy, (W.D. Tex., December 13, 1994). The second class of adulterants, those causing illness in discrete cases, is quite different. In these cases, there is no per se rule that if the pathogen is on the product, the product is adulterated; rather the determination is based on the facts surrounding each case. Put another way, these adulterants are adulterants only in hindsight — the product is adulterated because the product actually caused illness; whereas, the first class of adulterants is more prospective — product is adulterated because the pathogen could cause illness under ordinary conditions of use, not that any illnesses actually resulted. From the legal perspective, the second class of adulterants is not based on ordinary conditions of use; instead, the decision is based on the evidence, (i.e., illnesses) that the product from a specific production is “unsound, unhealthful, unwholesome, or otherwise unfit for food.” Given the second class of adulterants depends on the facts, establishments should know which facts must be present to support the agency’s decision in a particular case. All must be present for the stars to align: OThere must be actual illnesses which are linked through molecular DNA typing, primarily PFGE, but may include MLVA, e.g., a cluster of case-patients;

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

There must be an epidemiological link between the case-patients and a specific production of product (e.g., a known lot or lots); and

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The specific production lot/day must account for at least some of the illnesses (how many depends on the strength of the epidemiological and microbial DNA evidence).

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Without the link of specific product to specific illnesses, FSIS has not requested a recall or taken any further action because there is no specific product that has been associated with illnesses to recall. FSIS has issued a public health alert when there is known illnesses and known product type (e.g., salmonellosis associated with raw, stuffed chicken breast but the specific lot could not be isolated). However, a variety of changes has made it easier for FSIS to link a specific product to a cluster of illnesses. State investigations are generating more molecular patterns for CDC. With this, CDC has more information to identify possible related illnesses. Once a cluster is discovered, the case patients’ retail shopper cards provide evidence as to common purchases. With shopper information, especially if coupled with microbial DNA generated by FSIS in its regulatory sampling and other government sampling, FSIS can identify “establishments of interest.” At that point, all that remains is whether an establishment’s distribution data puts a particular product on the store shelves at the different locations where the case-patients could have bought (and actually did buy) the product. It is hard to be proactive in these situations. That said, an establishment should work to reduce any pathogens from its products. A pathogen in the raw product may not be an adulterant now, but it could be later if that product causes illnesses. Dennis R.Johnson is a principal with Olsson Frank Weeda 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.

GuestColumn

Not just a trade show — an event By Tom Hoffmann, chairman, FPSA Meat Industry Suppliers Alliance (MISA)

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f you’d like to rub elbows with the meat industry’s leading innovators, save the date for PROCESS EXPO, Nov. 1-4, 2011, at Chicago’s McCormick Place. Many of the companies known for being on the cutting edge of technology are exhibiting in grand fashion, some featuring their largest booths of the 2011 trade show season. This gives you the opportunity to see new technologies you may not see at other shows. The organization sponsoring PROCESS EXPO — the Food Processing Suppliers Association (FPSA) — is led by some of the key players in the industry who, along with the Meat Industry Suppliers Alliance (MISA), an FPSA industry council, have been intimately involved in show planning and setting the agenda for educational sessions.

What does this mean to you? It means a trade show event with exhibitors and programs focused on critical meat industry issues. I use the word “event” to describe a trade show that produces the results that both exhibitors and attendees seek. And this year’s PROCESS EXPO is shaping up to be such an event. PROCESS EXPO’s new biennial format is in synch with the average research and development cycle for equipment, usually two or three years. An every-other-year event ensures that exhibitors will roll out innovations that are current and relevant to attendees. A full day of Spanish-language educational sessions is an event-worthy opportunity you’ll find at PROCESS EXPO. It is important to me, as an exhibitor, that FPSA is reaching out to the Latin American market, especially the growing meat industry, and providing them a service that is respectfully presented in their native tongue. Language-specific seminars will benefit domestic meat processors employing an increasing number of Spanishspeaking workers as well. Another event-worthy characteristic of PROCESS EXPO is the diverse makeup of exhibitors and attendees that spans all sectors of the food industry. The cross-pollination that occurs between different vertical markets at horizontal shows fosters creative thinking. For example, an engineer in the meat industry might see how another industry has solved an automation or logistic or materialhandling issue and see a solution for their own situation. Cross-pollination and collaboration are key benefits of FPSA membership as well. The networking

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

that I do with my peers in the industry has developed strategic alliances from a business standpoint. My company has collaborated with other suppliers that have synergistic product solutions to provide integrated systems for customers. Not only has my company had opportunities to grow, I have grown professionally through the educational opportunities FPSA provides and my involvement on the MISA council. We are constantly keeping our membership up to speed on changes in the industry that could impact their businesses in a positive or negative way. We try to be on the cutting edge and stay out in front of issues rather than be reactionary. Education and advocacy is a soft way the council gives back to the meat industry; we give back in a tangible way through the MISA Foundation Scholarship Fund. The program awards scholarships to qualified students expressing an interest in the meat industry. These individuals will some day work for us or our customers, and the scholarships help keep that talent pool full. The MISA Council supports the meat industry. FPSA advocates for all food and beverage sectors. PROCESS EXPO brings the world’s leading food companies face-to-face with new technologies. It’s an event. See you there. Tom Hoffmann is vice president of sales and marketing for MEPACO,a worldwide leader in the development of grinding,blending,cooking and material-andling solutions.He is also chairman of the FPSA Meat Industry Suppliers Alliance (MISA).

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%$ NewProducts Hormel launches Compleats line geared toward kids

Butterball introduces Every Day frozen turkey burgers

Hormel Foods, the makers of Hormel® Compleats® microwave meals, has launched a line of shelf-stable meals speciÀcally designed to deliver a nutritious and convenient meal solution to kids. Hormel Compleats Kids microwave meals are designed for children ages 3-8 and are available in four Áavorful varieties; Macaroni & Beef, Spaghetti & Meatballs, Beef Ravioli, and Pasta & Chicken. The meals contain no preservatives, artiÀcial colors, high fructose corn syrup or trans fat, contain three grams of Àber per serving, and are a good source of protein.

Butterball® LLC has introduced Butterball Every Day Frozen Turkey Burgers, continuing the company’s commitment to providing a variety of innovative, high-quality and great tasting products that meet consumers’ needs. These new burgers offer twothirds of the daily recommended value for protein in one serving and have 70 percent less fat than beef. Butterball Every Day Frozen Turkey Burgers are perfectly seasoned to go straight from the freezer to the grill with no thawing required, and they are packaged in freezer bags with a re-sealable zipper inside the packaging. Each package of Butterball Every Day Frozen Turkey Burgers contains six, one-third pound patties. www.butterball.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

Interleaving The World

We’re proud to be part of your quality products

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

DISCOVER NEW SLICING POWER AND FLEXIBILITY Weber’s new 804 Slicing System packs big-time performance into a compact solution. Weber’s proprietary idle-cut knife head, for instance, helps assure both perfectly edged slices and flawlessly on-weight portions at involute blade speeds up to 1,500 rpm. Come see Weber at PROCESS EXPO ‘11 Nov. 1-4, 2011 Booth #5231 Chicago, IL

Overhead product guidance also ensures stability and product control, boosting yields and reducing product waste on slices from .5 to 50 mm thick. In most applications, product freezing prior to slicing is no longer necessary.

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Greater flexibility is another 804 benefit. Automatic, central loading of four 4.25-inch products up to 1600 mm long increases production speed and shortens product exchange times. Sixteen standard presentations can be produced on demand through Weber’s operator-friendly touch screen. Watch online video today or call to arrange a demonstration at Weber’s North American Technology Center.

1-800-505-9591

NewProducts Bar-S adds two new varieties to skinless sausage line Bar-S Foods has introduced Bar-S Beef and Turkey Skinless Smoked Sausages to its already popular Skinless Sausage line. The new Bar-S Beef and Turkey Skinless Smoked Sausages are offered in a 1.5-pound familysized package that is vacuum-packed for long shelf life and to preserve color, Áavor and freshness.

www.bar-s.com

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

Creminelli brings artisan deli meats to foodservice Creminelli Fine Meats has made available a new line of hand-crafted artisan deli meats to the foodservice community, through specialty food distributors including JDY Gourmet and Chef’s Warehouse. The new line includes several varieties unique to the United States and provides chefs with the opportunity to enhance their menus and recipes. It will be available immediately in California, Nevada and Illinois, and across the country by September. The 12 new Creminelli artisan deli meat offerings each feature their own natural Áavor proÀle, from garlic and wine to clove and nutmeg. The line includes a pancetta, prosciutto, mortadella, capicola and coppa, as well as several traditional, largeformat salamis such as sopressa, Ànocchiona and calabrese. Many are being introduced in the U.S. for the Àrst time. www.creminelli.com

“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.

Ingredients&Formulations

Savoring

spiced-up proteins

By Donna Berry

am a daily-deal junkie. From Groupon to You Swoop, I welcome these e-mailed invitations to explore local businesses — in particular, ethnic cuisines that I never would have tried before. In my field, I also call it “market research.” After all, it’s a known fact that trends start in foodservice, and with a few tweaks, modified offerings show up at the supermarket. This allows consumers to bring their restaurant experience into the home kitchen.

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With center-of-plate proteins, herbs, savory seasonings and spices are a simple way to add the flavors of fine-dining with minimal effort, but at times, that effort might be too much for consumers … as they may fear adding too much, too little or not the right combination. This presents an opportunity for processors to add value at the point of packaging. Trader Joe’s, Monrovia, Calif., one of my all-time favorite retailers, does an excellent job of providing varied cuts of uncooked meat and poultry packaged in marinades or rubbed with herbs and spices. Their sausage selection, too, is amazing, with an array of breakfast, chorizo, chicken and Italian encased links with varied heat levels and even particulates ranging from cheese and fruit pieces to surprising herbs and vegetables. So here are five ways to spice up your product line. Each one presents an opportunity to create a signature flavor profile.

Barbecue Americans continue their love affair with barbecue; however, barbecue has become one of the most ambiguous terms in the food industry. Pouring Open Pit onto ribs over the Smokey Joe no longer cuts it. The concept of barbecue has evolved into a family

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

of flavors and today’s consumers want to explore barbecue variations from other cultures as a result of being introduced to these flavor profiles by foodservice operators. For example, Bahama Breeze brings a Caribbean/Latin flavor profile to its menu with West Indies Ribs, which features a glaze of sweet guava barbecue sauce. El Pollo Loco now offers Tangy BBQ Buffaloco Wings spiked with chipotles, habaneros and citrus juices. And, according to Chicago-based foodservice trend tracker Technomic Inc., Los Angeles food trucks such as Kogi Korean BBQ-to-Go have set off a craze for “Korean tacos” and other fusion fare, such as

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This brings us to the cuisine of Korea. “The Korean taco — an only-in-America synthesis of Korean-style fillings and a Mexican format — signals the rise of Korean barbecue and Korean food in general,” according to a report by Technomic. Two of the more popular Korean spices are red chili pepper and ginger spice, both of which come in convenient paste and powder forms for easy addition to rubs and marinades.

Black Garlic One of the trendiest Korean seasonings, also popular in many Asian meat dishes, is black garlic, which is made by fermenting whole bulbs of garlic at high temperature. This process produces black cloves that taste sweet and syrupy with hints of balsamic vinegar and tamarind. In fact, according to the “What’s Hot in 2011” report from the National Restaurant Association,Washington, D.C., 62% of the more than 1,500 professional chefs surveyed identified black garlic as a hot trend.

Peruvian

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

Half of the chefs surveyed also said Peruvian cuisine is the big thing these days. Unlike cuisines from most other Hispanic regions, Peruvian seasonings are a unique fusion of flavors from China, Italy, Japan and West Africa, all countries with a large representation in Peru due to an influx of immigrants during the past decade. These immigrants modified their traditional cuisine using items native to Peru and those that had been introduced by the Spanish during the colonial period. Peruvian seasonings typically include at least one of the many native varieties of chili peppers, in addition to cinnamon, parsley, mint and anise.

Savory And finally there’s savory, a word with many meanings. Savory is often easiest to understand by what it is not, and savory foods are not “sweet.” To take it a step further, savory is best described as a flavor profile. It is not a basic taste, of

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Ingredients&Formulations The term savory has a more tangible meaning than being umami-like. In the culinary world, it is an aromatic herb from Southern Europe that is a cross between mint and thyme.

which humans possess five: bitter, salty, sweet, sour and umami. However, many sensory experts agree that savory is mostly umami, a taste that has long been recognized throughout Asia but only in recent years has become accepted as a basic taste by the rest of the world. Taking its name from the Japanese language, the umami taste comes from the amino acid glutamate and select ribonucleotides. All of these occur naturally in foods such as red meat, smoked and cured meats, fish, vegetables and aged cheeses. Umami is generally recognized as being the meaty or brown tastes that round out other flavors, flavors often described as savory. Savory foods often contain herbs, vegetables and peppers.When some of these ingredients are cooked, their inherent reducing sugars and amino acids undergo chemical modification through the Maillard reaction, resulting in caramelized and sautéed notes.Vegetables such as asparagus, garlic, mushrooms, onion and tomato all contain large amounts of glutamic acid, which further contributes to that umami sensation. Coming back to the term savory, in all fairness, the term savory has a more tangible meaning than being umami-like. In the culinary world, it is an aromatic herb from Southern Europe that is a cross between mint and thyme. Its name comes from the Latin word satureia (satyr’s herb), which refers to its reputation as an aphrodisiac. Fresh or dried savory is a popular flavoring for salads and grilled meat; dried savory is used to flavor soups, pâté and a number of main courses. These uses for savory further justify its definition of being the opposite of dessert. Seasoning suppliers make it easy for center-of-plate protein processors to spice up their offerings. I challenge you to offer consumers a product they can savor in the comforts of their own kitchen.

Donna Berry has a bachelor’s degree in food science from the University of Illinois at Urbana-Champaign and has been writing on food formulating for more than 15 years.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

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Formulation Strategies

Pushing flavors to the extreme By Martijn Kesteloo, Innova Market Insights

T

he ready meals sector is particularly innovative when it comes to new product activity, with creative use of packaging and flavorful creativity with proteins. A recent Innova Market Insights review of launch activity highlights key product trends; including ongoing interest in healthy options, more authentic-style ethnic recipes, more emphasis on natural, organic and locally-sourced ingredients, and more interest in restaurant-quality products for in-home dining or home entertaining as an alternative to eating out. Thus, despite the difficult economic situation in some countries, consumers are continuing to buy ready meals, in individual and family-size packs, and even trading up to premium lines, both chilled and frozen, in order to benefit from their convenience while potentially still saving money by using them on some occasions rather than home-delivery, take-out or eat-in restaurant options. Analyzing tracked U.S. new product launches during 2010 (see Figure 1) found a dominance for the convenience style

26

FORMULATION STRATEGIES | THE NATIONAL PROVISIONER | MAY 2011

positioning of “microwaveable” product launches (46.3%). Far more interesting however, is the rise in the number of products positioned on a health platform. More than 34% of the ready meals tracked in 2010 featured a “no additives/preservatives” claim.With regulatory pressure mounting around artery-clogging trans fats, nearly 20% featured a “no trans” claim.Weight management was also high on the new product development agenda, with 16% featuring a “low fat” claim and nearly 12% positioned on a “weight management” platform. More than 11% of the new products tracked in 2010 had a “wholegrain” claim. One of the key trends isolated by Innova Market Insights is the still rising levels of interest in spicy and hot products, with common flavors like “Peri Peri” that enjoyed a boost around the World Cup soccer in Africa and hot flavors inspired by Mexican or Asian cuisine. Flavor trends worldwide find an increased focus on ethnic varieties, with African-style flavors, such as Moroccan on the rise. Innova Market Insights tracked 249 new products featuring the word “Moroccan” from 2009 to 2010, with the UK (73), the U.S. (56), Australia (23), South Africa (14)

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Formulation Strategies Figure 1 Top positioning of new ready meat products (U.S. 2010). Excludes “convenience” positionings. Some products will have more than one positioning.

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Number of Products

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Source: Innova Database, Innova Market Insights

and New Zealand (13) the main markets featuring the use of this word on new products. North African and Middle Eastern flavors are increasing in popularity and Ras El Hanout, a complex, aromatic blend of spices with origins in North Africa is one of the flavors tipped for success. Ras El Hanout has a strong, spicy kick and a floral fragrance, and is ideal for use in Moroccan and North African-style starters, sauces and ready meals. Product activity featuring Ras El Hanout has been low so far, with Innova Market Insights tracking just 31 products from 2005-2010 featuring the ingredient. A clear opportunity exists, and it has been used in the UK in Moroccan-flavored soups, Alfez Ras El Hanout Classic Moroccan Rub and Tesco Finest Ras El Hanout Rub Spice. Chakalaka is an African-style sauce that enjoyed popularity during the World Cup but continues to be used in new sauces and meat accompaniments; indicating longer-term potential. For example, in Germany, Schwarmstedter Party Box Potato Pillows features

servings of Chakalaka, Tomato Chutney and Jamaican Reggae Filling. The German market included products such as Frosta Chicken Chakalaka Dish and the limitededition Wiesenhof Chicken Drums with Chakalaka African Spices during 2010. Asian and other spicy-style flavors are also on the rise in new U.S. meat products. Adding a spicy note to new chicken launches is particularly trendy right now. Kroger has introduced Asian Inspired Family Favorite Sweet & Sour Tempura Chicken, which features a tangy sauce and is offered in a 30-ounce resealable plastic bag. Kroger’s Healthy Meals Made Simple Sweet and Spicy Chicken with Brown Rice contains boneless chicken breast with rib meat in a tangy sweet and spicy sauce, with brown rice. Private Selection Seared Thai Red Curry Chicken Breasts consists of two individually wrapped entrees of seared Thai red curry chicken breasts with edamame and shallots. Market Pantry Honey BBQ Seasoned Wings are fully cooked chicken wing sections coated with honey BBQ seasoning, in a 28-ounce plastic pouch. The products

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Formulation Strategies

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feature natural smoke flavor and added caramel color. In Europe, the Birds Eye brand has also gone down the spicy route with Chicken Chargrills Peri Peri featuring marinated chunks of chicken breast in a spicy pepper glaze. Birds Eye Mini Chicken Chargrills Sweet Barbecue consists of mini chicken chargrills made with marinated chopped chicken breast, seared and coated with a sweet barbecue glaze. Several recent on-the-go introductions have incorporated barbecue flavors for a tasty “BBQ smoked” flavor note — Landshire Supreme BBQ Pork Rib Sandwich being one of those products capitalizing on this trend. T.G.I. Fridays Anytime! Sliders: Friday’s Cheeseburger with Sweet & Smoky BBQ Packet Sauce consists of four thick and juicy cheeseburgers with separate packet of sweet and smoky barbecue sauce. Caribbean flavors are another trend to watch, with Innova Market Insights tracking 143 new products worldwide featuring the word “Caribbean” in 2010. Caribbean flavors convey the relaxed lifestyle for which the region is known, and this may connect with busy consumers. Innovative launches have included those in the ready meals segment such as Findus Caribbean Ready Meal Fish Fillet, which has begun appearing in Scandinavian markets. In the Netherlands, Heinz brand Honig has launched a new Herb Paste for Caribbean Chicken. But the UK, with its traditional ties to the Caribbean region, features the highest levels of new product activity using these styles. Launches include Iceland Foods From Around The World Caribbean Chicken with Rice and Very Lazy Caribbean Chicken Cooking Concentrate. Levi Roots, who achieved popularity in the UK following an appearance on BBC entrepreneurial program Dragon’s Den for his Caribbean style sauce, has expanded his line of products with Levi Roots’ Caribbean Hot Chili Beef. Of course, more traditionally popular styles of cooking such as Italian and Indian are still the leading ethnic-based flavors and are not going away soon. In fact, these flavors are only becoming more region-specific.

New authentic regional dish and flavor specialties are emerging all the time in the Indian flavor space. Tikka, Jalfrezi, Masala and Korma variations are becoming mainstream for a variety of snack, soup and ready meal products. Newer, emerging Indian flavors include Bhuna, Pasanda, Mulligatawny and Karahi. In the U.S., Tandoor Chef Chicken Tikka Masala with Cumin-Infused Basmati Rice consists of chicken breast that is marinated, roasted and simmered in a robust, creamy sauce served with basmati rice. Tandoor Chef has also introduced spicy, roasted chicken wings marinated in an authentic Tandoori sauce. Culinary Circle Complete Skillet Meal For Two Chicken Tikka Masala is a frozen skillet meal for two featuring grilled seasoned chicken with rice and tomato, in a rich Tikka Masala sauce. Finding the right flavor to go with your protein in a new winning ready meal product could come from an undiscovered regional specialty or a hot and spicy combination to meet the consumer calls for extreme flavors. The author, Martijn Kesteloo, 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].

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CoverStory

Bill Toler, CEO of AdvancePierre Foods, sits in front of a mural at the company’s Cincinnati, Ohio, headquarters. The mural was painted by senior management during teambuilding exercises after the merger of Pierre Foods, Advance Food Co. and Advance Brands.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

The

right

FIT With an eye on the future, AdvancePierre Foods continues to navigate through the integration of its “perfect match” 2010 merger. By Andy Hanacek, editor-in-chief Photos by Ross Van Pelt, RVP Photography

F

rom its initial announcement 10 months ago, the merger of Pierre Foods, Advance Food Co. and Advance Brands was touted as a perfect fit — a unification of “wonderfully complementary” companies under one corporate umbrella. Today, while some systems integration remains on the to-do list, there is a light at the end of the tunnel for the company.Yet, long-term planning has not been put on the backburner at AdvancePierre during this transition, based on the reality that the merger has been a smooth and fast-paced integration of businesses, strategies, cultures and employees with similar goals and concepts. “The three companies just fit hand-in-glove, and they complement each other beautifully,” says Bill Toler, CEO of AdvancePierre Foods. It is a viewpoint that has played out to be true, has not changed since the merger was announced and has been adopted throughout the company.

Burgers get sprayed with water just before heading into the ovens to be fully cooked, then frozen and packed for shipment.

MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

33

CoverStory The Pierre turnaround

Most of the production lines at AdvancePierre’s Cincinnati facility are fed by two forming machines, allowing for increased production. Here, two sets of formed pork patties join together and head toward the cooking room.

Toler joined Cincinnati, Ohio-based Pierre Foods in December 2008, brought in to revive a company that had declared bankruptcy and had struggled to get itself back on track in light of extreme economic challenges. According to Toler, at the time Pierre was “a great company with a bad balance sheet.” “It was clearly a culture that had been successful for many, many years,” he explains.“But faced with an acquisition in 2007 that never got fully integrated, then the runaway raw-material prices in 2008, the company wasn’t prepared to make the decisions it needed to in order to stay ahead of that.” Toler and his team moved quickly to make those key decisions and turned Pierre’s fortunes around almost immediately. “We came out and had a record year the first year out of bankruptcy — a record for the 63-year history of the com-

pany,” he says.“We were able to fix the business quickly through a combination of shedding bad businesses, getting rid of items that didn’t make money, taking pricing to reflect commodity costs that had gone up in 2008, and also driving productivity inside our operations.”

Piecing together the puzzle Not long after Pierre got back on its financial feet, merger discussions began between Pierre Foods, Advance Food Co. and Advance Brands. From the start, stakeholders on all sides saw the benefits of bringing together the companies. “By bringing these three companies together, it gives us the ability to compete across seven different channels, and three major lines of business,” Toler explains. Those three major lines of business are cooked proteins, Philly steaks, and sandwiches, while the seven channels Toler refers to are broadline foodservice, retail,

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

schools, vending, convenience stores, club stores and industrial accounts. The transition has run smoothly, as AdvancePierre continues to integrate systems and strategies. The large-scale vision developed by the new company’s leadership remains on target, but Toler acknowledges that a learning curve exists in situations as complex as these. “Translating that vision all the way down to every individual affected by all our decisions takes time,” he says.“We’re taking three separate businesses and bringing them together to create a single corporate culture.” He admits that some changes can be painful, and because of that, the company has had to be careful not to make changes simply for the sake of change, especially given the potential effects on people and business. Thus, it pays for AdvancePierre to take its time and make the right decisions based on sound analysis, whether the final solution is in-house or not. “We have very good businesses, so how do we make them even better as one?” Toler says.“With that [mentality], you have a little more time to step back, make more careful decisions. It allows you to leave the status quo in place if you so choose, and it also allows you to have some flexibility.” AdvancePierre’s executive management team reflects the search for what Toler calls the “best of breed” in making these decisions. “This is a true merger,” Toler says. “‘Who bought whom’ is not a driver or determining factor when making our decisions.” Lisa Frick, senior vice president of marketing and product development, confirms that AdvancePierre hasn’t rushed through decisions when it comes to integrating the business. “We have a lot of options to choose from, but we’re not just picking one of the three options,” she explains.“We have teams of people who are stepping back and saying,‘OK, this is a whole new ballgame, we’re a much bigger business. Is there a different way that we should all be doing things?’ “It makes it a little tougher and probably a little slower,” Frick adds,“but in the end, we’ll be building the right kind of

Andy Hanacek, editor-in-chief of The National Provisioner, and Jeff Harris, plant manager at AdvancePierre’s Cincinnati facility, discuss the formed rib meat products that the company produces for sandwiches.

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35

CoverStory infrastructure for this type of business.” That infrastructure is led by a mix of talent from a variety of sources. Frick, Toler and Tony Schroder, who leads the convenience and vending business unit, came from Pierre Foods; Mark Allen, president of foodservice and schools, is a veteran of the Advance business; and Chris Kiser, who heads up the retail and club business unit, was an outside hire. Many of AdvancePierre’s executives have experience in the consumer packaged goods space, which AdvancePierre hopes to utilize to continue to drive product development, particularly in unique ways at the foodservice level.

An innovative edge Another uniting force in the AdvancePierre merger was the original companies’ focus on innovation. Pierre Foods, Advance Food Co. and Advance Brands used different methods to provide customers with the products they needed

36

AdvancePierre employees perform a quality and temperature check on cooked burgers as they emerge from an oven in the Cincinnati facility.

and consumers wanted, but each made high-quality research & development and product innovation a primary goal. That continues today, and Frick believes AdvancePierre’s unique approach

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

gives the company an edge in many of the channels it serves. “We think consumer insights is a real differentiator for us in the industry,” she says.“A lot of us come from packagedgoods backgrounds and are used to that brand-management world, but in the foodservice world, you don’t see as much of the consumer-insights driven or research-based product innovation.” According to Frick, AdvancePierre can offer its customers added value as opposed to simply selling product off a price list. Amanda Smeller, director of consumer insights, explains that incorporation of an innovation system had been in the works at Pierre Foods before the merger and continues to develop today. “It was a matter of checking the trends to doing the primary research among different consumers, coming up with the different ideas, and then testing those ideas across multiple channels,” says Smeller.“We had established a three-year

“We had established a threeyear pipeline of ideas that would be moving forward that were generated from a multitude of different sources...” After the burgers have been frozen in spiral freezers, they are manually packed into bulk boxes by teams of employees.

pipeline of ideas that would be moving forward that were generated from a multitude of different sources, including everything that would be line extensions or product improvements all the way to ‘new to company’ and ‘new to world’ products.” One of the first big rollouts through this new platform occurred before the merger — Pierre Minis,™ which Smeller says address consumer demands for portability and smaller sizes and shareability of foods. “We developed an entire line of mini sandwiches … across vending, c-stores, packaged in kits for foodservice,” she says. Pierre used its consumer insights and research to demonstrate that consumers would like the product and purchase it, a tool the new company expects to use on a greater scale. “We did multiple taste tests with kids to come up with the right varieties in schools,” Smeller adds.“More than 2,000 8- to 15-year-olds took part in the tests to make sure the products were right before they were rolled out.” One adjustment that AdvancePierre must make centers on the innovation, marketing and research & development teams at AdvancePierre — and the proper balancing of efforts to get the desired results, explains Bernie Panchot, vice president, research & development. “The management of projects has become a very complex endeavor,” she says. “It’s a lot to balance, and we’re looking at how do you net out to the most important projects first and put your resources in the right places.” However, as the company pulls itself through the transition and develops that balance between these divisions, Panchot thinks AdvancePierre will be strongly positioned to serve customers even better.

— Amanda Smeller, director of consumer insights, AdvancePierre Foods

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MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

37

CoverStory

An AdvancePierre employee prepares to swap bins under a stream of ground meat at the Cincinnati, Ohio, processing facility.

“When we have great consumer insights, by the time we have a customer come to us with a great request, we can answer that better than our competitors based on what the consumer wants to see and our customer needs,” she explains. “The challenge is to stay ahead of the customer demand for those critical, strategic partners out in the industry.”

Driving forward AdvancePierre hopes to leverage the relationship between its innovation, R&D and marketing divisions to find new opportunities for current products and technologies. Toler says cross-selling of product is an expected byproduct of the merger that AdvancePierre must exploit. “The sandwiches that have been so successful in retail, c-store and vending for Pierre are now being sold by the broadline foodservice team from Advance,” he says.“The Advance Philly steaks are now being sold into retail and club and put into sandwiches there through our retail business.We’re also getting ready to put it into our c-store division.” Building off that concept, Frick thinks the time is right to build categories of 38

strength into other channels and segments. Burgers, for example, is a category in which AdvancePierre considers itself to be very strong, but possibly underleveraged in some segments. So the company will investigate whether it has all the right segments of the business covered, from premium items to value or certain taste profiles, in each burger category. “It’s taking the technology, trends and processes to the other channels,” Frick says.“What people are looking for in many channels is very similar, and everybody kind of jumps on the low-sodium bandwagon or whatever is important at that time.” It is worth noting that, while AdvancePierre plans for the future, it has not reached the end of the road as far as merger integration goes. The company’s distribution and ERP systems were in the process of being transitioned at presstime. Toler says the company will move to a one-order, one-invoice capability at the end of May, which will allow customers to order products from all three origin companies on one truck. Furthermore, the company will transition from single-

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

distribution warehouses into a multiple distribution center network, to give customers more scale and the chance to buy products more easily. Yet as AdvancePierre navigates through these changes, it will maintain its focus on the basics, Toler says, which should be able to keep it on track. “We are very much a block-and-tackle kind of business that wants to keep growing through the stability of our channels, driving conversions against competition, expanding distribution and putting out new products where appropriate,” he says. With the power of three complementary business models and cultures building AdvancePierre today, Toler believes the company sits in a prime spot as the economy improves. “When you have the thinking of thousands of people across 10 different facilities,” he adds,“and you have a group that can capture the ideas and move them from plant to plant, and you have people looking at productivity constantly inside the business, that really gives you the opportunity to fuel future growth and margin expansion by saving money through sharing of best practices.”

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The National Provisioner’s

TOP 100 Processors continue to find ways to grow the industry in volatile times, through acquisitions, expansions and new products. By Sam Gazdziak, editor

For the last couple of years, the meat industry has had to deal with a slumping economy that saw more people eating at home more often or trading down in their protein purchases. Now, consumers are starting to spend more and eat out more... and the industry now has to deal with tight supplies, sky-high grain prices and rising fuel costs. In spite of the continuing challenges, the top meat and poultry processors continue to find ways to grow their businesses and strengthen their market shares. The companies in this year’s Top 100 report have: Q made acquisitions (Hormel acq. Don Miguel Foods, AFA Foods acq. United Food Group); Q improved their facilities (Godshall’s Quality Meats doubled its packaging department size and added a room for injecting and tumbling)

40

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

or built new ones (Sanderson Farms’ new Kinston, N.C. Complex began processing chickens in January) Q expanded their presence (Halperns’ Steak and Seafood Co. launched operations in the Northeast United States) and Q introduced new products (Foster Farms’ Great Bites mini chicken cheeseburgers. New challenges may be thrown continuously at the meat industry, but as the companies in this year’s Top 100 report have shown, the industry is nothing if not adaptable. For more Top 100 company highlights, visit www.provisioneronline.com. For information about appearing in next year’s Top 100 report, contact Sam Gazdziak at [email protected].

The National Provisioner’s

TOP 100 >> Name of Company

Rank

Location Chief Officer, Title

1

Tyson Foods Inc.

2

JBS USA Holdings Inc.

3 2010: 2 4 2010: 3

Cargill Meat Solutions

2010: 1

2010: 4

5 2010: 7

6 2010: 5 7 2010: 6 8 2010: 8 9 2010: 10

10 2010: 12 11 2010: 10 12 2010: 13 13 2010: 9 14 2010: 14 15 2010: 15 16 2010: 16

Springdale, Ark. Donnie Smith, President/CEO Greeley, Colo. Joesley Mendonça Batista, President Wichita, Kan. Jody Horner, President

SmithÀeld Foods Inc.

SmithÀeld, Va. C. Larry Pope, President/CEO

Hormel Foods Corp.

Austin, Minn. Jeffrey M. Ettinger, Chairman/ President/CEO

Pilgrim’s Pride

net sales (millions)

fiscal year end

No. of plants

28,430 (a)

10/10

16,056 (a)

10/30/10

15,000

5/31

11,202.6 7,200

Number of employees

106 115,000

13

33

5/2/10

31

10/31/10 20+

41

12,900

National Beef Packing Co. LLC

5,700 (est)

8/11

7

8,000

Kraft Foods/Oscar Mayer

5,000

12/11

7

140,000

7/3/10

13

137,000

4,600 (est)

3/31

15

20,500

Golden State Foods

4,500

12/09

1

4,000

OSI Group LLC

2,870 (b)

12/31

71

10,000

Foster Poultry Farms

2,200

12/31

11

12,000+

American Foods Group LLC

2,000

9/09

12

3,975

Koch Foods LLC

2,000 (b)

12/10

12

14,000

Perdue Farms Inc.

Salisbury, Md. James A. Perdue, Chairman Irvine, Calif. Mark Wetterau, Chairman/CEO Aurora, Ill. Sheldon Lavin, Chairman/CEO Livingston, Calif. Ron Foster, President/CEO Alexandria, Minn. Tom Rosen, President

Park Ridge, Ill. Joseph C. Grendys, CEO

















































NOTE: Sales data is not public information. Net revenue for U.S. Convenient Meals Sector was $5.0 billion in FY 2010.

4,691(a)

Downers Grove, Ill. Marcel Smits, CEO





12/31

Sara Lee Corp.





(b)

6,430(b)

Madison, Wis. Irene Rosenfeld, Pres. Kraft Foods Nick Meriggioli, Pres. Oscar Mayer



19,300

42,000

Kansas City, Mo. Tim Klein, President/CEO





48,000

39

West Conshohocken, Pa. Jerry Dean, CEO



35,000

12/26/10

Keystone Foods



16,500

6,800 (a)

Greeley, Colo. William W. Lovette, President/CEO

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS









































MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

41

The National Provisioner’s

>> TOP 100 Name of Company

Location Chief Officer, Title

17 2010: 17 18 2010: 26 19 2010: 18 20 2010: 23 21 2010: 20 22T 2010: 19

net sales (millions)

fiscal year end

No. of plants

Number of employees

Sanderson Farms Inc.

1,900

10/31

9

10,000+

Wolverine Packing Co.

1,500 (est)

12/10

3

375

1,434 (est)

3/31

11

8,900

1,388.3

12/31

3

4,700

Mountaire Farms Inc.

1,303

10/11

3

6,000

Butterball LLC

1,200

12/31

6

5,700

Laurel, Miss. Joe Sanderson Jr., CEO

Detroit, Mich. Jim Bonahoom, President

Wayne Farms LLC

Oakwood, Ga. Elton Maddox, President/CEO

Seaboard Foods

Shawnee Mission, Kan. Rod K. Brenneman, President/CEO Millsboro, Del. Paul Downes, President Garner, N.C. Keith Shoemaker, CEO

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS

















BH-300-CT







Patent #5,938,522

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

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

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

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

42

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011











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The National Provisioner’s

>> TOP 100 Name of Company

Location Chief Officer, Title

net sales (millions)

Boar’s Head Provisions Co. Inc. 22T 2010: 20 Greater Omaha Packing Co. Inc. 24 2010: 20 Indiana Packers Corp. 25T 2010: 27 BPI Technology Inc. 25T 2010: 25 AdvancePierre Foods 25T 2010: NA OK Industries Inc. 28 2010: 25 Sarasota, Fla. Robert S. Martin, Chairman/CEO Omaha, Neb. Henry Davis, President Delphi, Ind. Shinichiro Suzuki, CEO Dakota Dunes, S.D. Eldon Roth, CEO Cincinnati, Ohio Bill Toler, CEO

Ft. Smith, Ark. Randy Goins, Vice Chairman/CEO

fiscal year end

No. of plants

Number of employees

1,200 (est)

12/11

5

2,500

1,100

10/11

1

800

1,000 (c)

3/31

1

1,650

1,000 (est)

2/10

4

1,500

1,000 (est)

12/31

928.3 (est)

4/10

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS























9

4,800 

2

5,000











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The National Provisioner’s

>> TOP 100 Name of Company

29 2010: 33 30 2010: 30 31T 2010: 28 31T 2010: 28 33 2010: 31 34 2010: 32

Location Chief Officer, Title

net sales (millions)

Fresh Mark Inc.

No. of plants

Number of employees

796

12/31/11

3

2,000

Simmons Foods Inc.

710

12/31

6

5,350

Johnsonville Sausage LLC

700

12/31

6

1,400

House of Raeford Farms Inc.

700 (est)

5/10

7

6,000

Coleman Natural Foods LLC

672.7 (est)

12/31

17

2,300

670 (est)

9/10

3

4,400

Massillon, Ohio Neil Genshaft, Chairman/CEO Siloam Springs, Ark. Mark Simmons, Chairman Sheboygan Falls, Wis. Ralph Stayer, CEO/Owner

Raefods, N.C. Robert C. Johnson, Vice Chairman/CEO Golden, Colo. Mark McKay, CEO

Fieldale Farms Corp. Baldwin, Ga. Tom Hensley, President

fiscal year end

MODEL KDCMA AUTOMATIC DOUBLE CLIPPER

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

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS
































The mobile KDCMA automatic double

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

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

46

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011





Ross S Series

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

Ross Inpack A10 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.

The National Provisioner’s

>> TOP 100 Name of Company

35 2010: 37 36 2010: 34 37 2010: 38 38T 2010: 35 38T 2010: 35 40 2010: 39 41 2010: 40 42 2010: 41 43 2010: 42 44 2010: 46 45 2010: 50 46 2010: 47 47 2010: 49 48 2010: 51 49 2010: 57 50 2010: 52 51 2010: 67 48

Location Chief Officer, Title

net sales (millions)

fiscal year end

No. of plants

Number of employees

Clemens Food Group Inc.

650

4/10

2

2,200

Kenosha Beef International Ltd.

615

12/31

4

750

West Liberty Foods LLC

610

5/1/11

4

1,800

Quantum Foods LLC

600

12/31

3

1,000+

600 (est)

12/10

5

550

Case Foods Inc.

578

10/30/10

4

2,500

Peco Foods Inc.

550 (est)

3/10

6

3,800

Bar-S Foods Co.

542 (est)

10/10

4

1,627

Lopez Foods

540 (est)

12/31

2

1,200

Sam Kane Beef Processors Inc.

525

12/31

1

800

Creekstone Farms Premium Beef

500

12/31

1

720

Omaha Steaks

450

12/31

3

1,800

HatÀeld, Pa. Doug Clemens, President

Kenosha, Wis. Dennis Vignieri, President/CEO West Liberty, Iowa Ed Garrett, President/CEO

Bolingbrook, Ill. Edward B. Bleka, President/CEO

AFA Foods

King of Prussia, Pa. Ron Allen, CEO Troutman, N.C. Thomas R. Shelton, Chairman/CEO Tuscaloosa, Ala. Mark Hickman, President/CEO Phoenix, Ariz. Timothy Day, Chairman/President/CEO Oklahoma City, Okla. Ed Sanchez, Chairman/CEO Corpus Christi, Texas Jerry Kane, President/CEO Arkansas City, Kan. Dennis Buhlke, CEO

Omaha, Neb. Bruce Simon, President/CEO

427 (est)

4/30

3

3,200

Plumrose USA

400 (est)

9/10

3

1,000

East Brunswick, N.J. John Arends, President

Caviness Beef Packers Ltd. Amarillo, Texas Terry Caviness, CEO

Harris Ranch Beef Co. Selma, Calif. Robert M. Kettle, CFO

Cooper Farms

Oakwood, Ohio Gary A. Cooper, COO



6/30/11

2











































































740 

363.43

6/30

1

828

360

1/31

2

1,465

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011







370







Allen Family Foods

Seaford, Del. Robert Turley, President/CEO

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS

















The National Provisioner’s

TOP 100 >> Name of Company

Location Chief Officer, Title

52 2010: 53 53 2010: 54 54T 2010: 56 54T 2010: 55 56 2010: 60 57 2010: 58

Bob Evans Farms Inc.

Columbus, Ohio Steven Davis, Chairman/CEO

Cagle’s Inc.

Atlanta, Ga. J. Doug Cagle, President/CEO

Gold’n Plump Poultry St. Cloud, Minn. Mike Helgeson, CEO

Superior Farms

Davis, Calif. Lee Oesterreich, CEO

L&H Packing/Surlean Foods San Antonio, Texas Neal Leonard, CEO

Dietz & Watson Inc. Philadelphia, Pa. Louis Eni, CEO

net sales (millions)

fiscal year end

No. of plants

Number of employees

315.7 (a)

4/30/10

7

52,000

312

4/2/11

2

1,900

300 (c)

12/11

3

1,500

300

11/10

3

410

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS











12/10

2

585

260.5 (est)

12/31

2

600













290



















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MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

49

The National Provisioner’s

>> TOP 100 Name of Company

Location Chief Officer, Title

58 2010: 59 59T 2010: 80

Mar-Jac Poultry Inc.

Gainesville, Ga. Pete Martin, VP Poultry Operations

Natural Food Holdings

(formerly Sioux-Preme Packing Co,) Sioux Center, Iowa Jeff Swain, CEO

Stampede Meat Inc. 59T 2010: 61 FPL Food LLC 61 2010: NA Abbyland Foods Inc. 62 2010: 62 Carl Buddig & Co. 63 2010: 63 Agri Beef Co. 64 2010: 64 Overhill Farms Inc. 65 2010: 65 Fair Oaks Farms LLC 66 2010: 66 Land O’Frost 67 2010: 68 Pride Inc. 68 Farmer’s dba Bell & Evans

Bridgeview, Ill. Edward J. Ligas, President/CEO Augusta, Ga. Francois Leger, President/CEO Abbotsford, Wis. Harland Schraufnagel, President Homewood, Ill. Robert Buddig, Thomas Buddig, Co-CEOs Boise, Idaho Robert Rebholtz, President/CEO Vernon, Calif. James Rudis, Chairman/CEO Pleasant Prairie, Wis. Michael L. Thompson, President/CEO Lansing, Ill. Donna Van Eekeren, Chairman/CEO

2010: 69

Fredericksburg, Pa. J. Michael Good, CEO

69 2010: 70 70 2010: 75 71 2010: 71 72

Harrison Poultry Inc.

fiscal year end

No. of plants

Number of employees

260 (est)

4/30

1

1,200

250

3/31

2

350

250

9/20/11

2



240

12/31

3

8/27/11

2

10/10

4

220 (est)

12/31

1

1,100

209 (est)

9/10

1

1,000

205 (est)

12/31

2

283

195 (est)

12/31

3

1,000

192 (est)

12/31

1

1,100

12/31/11

3

300

Murry’s Inc.

170 (est)

5/26

1

1,100

Odom’s Tennessee Pride Sausage Inc.

166 (est)

3/10

2

700+

73T 2010: 78

Mountain States Rosen LLC Bronx, N.Y. Dennis StifÁer, CEO







12/11

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

2







125



















































165







177

Madison, Tenn. Larry Odom, Chairman/CEO



500+

900

Marlboro, Md. Ira Mendelson, President/CEO



650

1

Atlanta, Ga. Kirk W. Halpern, CEO







220 (est)



700 

225



820

12/11

Halperns’ Steak and Seafood Co.





183.3 (est)

Bethlehem, Ga. Mike Welch, CEO

2010: 72

50

net sales (millions)

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS


























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The National Provisioner’s

>> TOP 100 Name of Company

Location Chief Officer, Title

73T 2010: 73 75 2010: 74 76 2010: 81 77 2010: 76 78 2010: 77 79 2010: 79

net sales (millions)

fiscal year end

No. of plants

Number of employees

Dakota Provisions

165 (est)

12/31

1

700

Maple Leaf Farms Inc.

161 (est)

11/30

4

1,500

160

12/11

2

290

154 (est)

9/10

1

600

140

12/31

1

400

140 (est)

10/10

2

500

Huron, S.D. Kenneth D. Rutledge, President/CEO Milford, Ind. Terry Tucker, CEO

Custom Food Products LLC Carson, Calif. Jon Hickerson, President/COO

Rose Packing Co. Inc. Barrington, Ill. William R. Rose, CEO

John Soules Foods Inc. Tyler, Texas John Soules Jr., Co-CEO

Kayem Foods Inc. Chelsea, Mass. Ralph Smith, President

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS







































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Grote Company, Columbus, OH U.S.A. ‡ www.grotecompany.com | [email protected]

%RRWK

52

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011



Insist on the original “Genuine VR Apparel” – the only one made in the U.S.A. TM

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The National Provisioner’s

>> TOP 100 Name of Company

Location Chief Officer, Title

net sales (millions)

fiscal year end

80 2010: 90 81T 2010: 84 81T 2010: 83 81T 2010: 81 84 2010: 85 85 2010: 90 86 2010: 96 87 2010: 88 88 2010: 89 89 2010: 87 90

Lincoln Provision Inc.

134

J.H. Routh Packing Co. Strauss Brands Inc.

91T 2010: 90

2010: 90

91T 2010: 90

No. of plants

Number of employees

12/10

5

135

130

12/31/11

1

290

130

12/31/10

2

180

Stock Yards Packing Co.

130 (est)

NA

1

100+

Bridgford Foods Group

122.7 (est)

10/31

3

600

Marcho Farms/Provimi Foods

120

12/31

3

300

Chicago Meat Authority

110

12/31

2

330

Vienna Beef Ltd.

108 (est)

4/23/10

1

400

Holten Meat Inc.

107 (est)

9/10

1

220

Atlantic Premium Brands Ltd.

105

12/31

3

515

ALL Holding Co. Inc. (Alderfer/Leidy’s)

103

12/31

2

325

Peer Foods Group

100

12/31

1

210

100 (est)

12/10

1

350

Chicago, Ill. Jim Stevens, President

Sandusky, Ohio Thomas Routh, President/CEO Franklin, Wis. Randy Strauss, CEO

Chicago, Ill. Daniel Pollack, CEO

Anaheim, Calif. William L. Bridgford, Chairman Harleysville, Pa. Brian Friesen, President

Chicago, Ill. Jordan Dorfman, President/CEO Chicago, Ill. James Bodman, Chairman/CEO Sauget, Ill. Jim Holten, CEO

Northbrook, Ill. Thomas Dalton, President/CEO

JTM Provisions Co. Inc. dba JTM Food Group

Collingswood, N.J. Anthony Catelli Jr., CEO

MifÁintown, Pa. Robert Van Naarden, President/CEO Philadelphia, Pa. Guy Giordano, President/CEO

54





















100 (est)

12/31

3

225

99.8 (est)

1/31

1

1,000

84

12/31

2

90





THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011



















































































Harrison, Ohio Tony Maas, President/CEO

Fontelli Food Group 91T 2010: 96 Empire Kosher Poultry Inc. 94 2010: 95 Vincent Giordano Corp. 95 2010: 100





Harleysville, Pa. Jim Van Stone, President/CEO Chicago, Ill. Larry O’Connell, President

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS







The National Provisioner’s

TOP 100 >> Name of Company

Location Chief Officer, Title

96 2010: 99

Charlie’s Pride Meats

Vernon, Calif. Robert Dickman, Charles Dickman, Co-Presidents

Barber Foods 97 2010: 98 Farmington Foods Inc. 98 2010: NA

Portland, Maine Bruce Wagner, President/CEO Forest Park, Ill. Anthony M. DiJohn, President

99 2010: NA

Rocky Mountain Natural Meats Inc.

net sales (millions)

fiscal year end

No. of plants

Number of employees

82

12/11

2

145 

79.9 (est)

12/31

60

12/29

1



730 

2

140 

56

12/31

1



48

12/31

2









80

Denver, Colo. Bob Dineen, President

Godshall’s Quality Meats Inc. 100 2010: NA

Beef Slaughter Boxed Beef Beef Further Processing Ground Beef Pork Slaughter Fresh Pork Fresh Sausage Cured Sausage Ham Bacon Poultry Slaughter Poultry Further Processing Veal Lamb Seafood Rendering Case-Ready Frozen Prepared Foods Portion Control Prepared Meals Export

OPERATIONS







219

   Telford, Pa. Mark Godshall, President/CEO (a) informational gathered from company reports. (b) according to Forbes magazine, www.forbes.com. (c) company-provided estimate



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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MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

55

The National Provisioner’s

>> TOP 100 BEEF Segment Sales 1,100 525 500 370 345.3 261 240 187.5 109.7 104

Company Greater Omaha Packing Co. Inc. Sam Kane Beef Processors Inc. Creekstone Farms Premium Beef Caviness Beef Packers Ltd. Harris Ranch Beef Co. L&H Packing/Surlean Foods FPL Food LLC Stampede Meat Inc. Halperns’ Steak and Seafood Co. Custom Food Products LLC

Total Sales 1,100 525 500 370 363.4 290 240 250 177 160

Segment Sales 1,900 1,540 1,303 710 312 300 90.9 70 55.7 30

Total Sales 1,900 2,200 1,303 710 312 300 610 140 796 100

Top 100 Rank 17 14 21 30 53 54 37 78 29 91

56

Company SmithÀeld Foods Inc. Seaboard Foods Indiana Packers Corp. Fresh Mark Inc. Clemens Food Group Inc. Natural Food Holdings J.H. Routh Packing Co. West Liberty Foods LLC Abbyland Foods Inc. Cooper Farms

Segment Sales 3,584.8 1,388.3 1,000 716.4 637 197.5 130 114.0 101.3 90

Total Sales 11,202.6 1,388.3 1,000 796 650 250 130 610 225 360

Top 100 Rank 4 20 25 29 35 59 81 37 62 51

LAMB/VEAL

TURKEY Company Butterball LLC West Liberty Foods LLC Foster Poultry Farms Cooper Farms Godshall’s Quality Meats Inc. Peer Foods Group Stampede Meat Inc. Charlie’s Pride Meats Clemens Food Group Inc. Custom Food Products LLC

2011

PORK

CHICKEN Company Sanderson Farms Inc. Foster Poultry Farms Mountaire Farms Inc. Simmons Foods Inc. Cagle’s Inc. Gold’n Plump Poultry West Liberty Foods LLC John Soules Foods Inc. Fresh Mark Inc. Peer Foods Group

Top 100 Rank 24 44 45 49 50 56 61 59 70 76

Segment Sales 1,200 339.2 330 180 28.8 15 12.5 8.2 3.3 3.2

Total Sales 1,200 610 2,200 360 48 100 250 82 650 160

Top 100 Rank 22 37 14 51 100 91 59 96 35 76

TH THE H NA NATIONAL ATIO T NAL NA A PROVI PROVISIONER OV SIO S NER | PR SI PROVISIONERONLINE.COM ROVI O SIO ONER N ONLINE INE NE.COM | MAY N AY Y 2011 11 1

Company Mountain States Rosen LLC Marcho Farms/Provimi Foods Halperns’ Steak and Seafood Co. Natural Food Holdings

Segment Sales 156.8 120 26.6 2.5

Total Sales 165 120 177 250

Top 100 Rank 73 85 70 59

* Sales Àgures are in millions of dollars. Market segment reports are based solely on information provided by the processors themselves. Those processors that did not respond or declined to participate were not included. To be included in next year’s report, email gazdziaks@bnpmedia. com or [email protected]

The National Provisioner’s

TOP 100 >>

Market Segment Reports *

PREPARED FOODS Company SmithÀeld Foods Inc. (Packaged Meats) Foster Poultry Farms Abbyland Foods Inc. Cooper Farms Natural Food Holdings Harris Ranch Beef Co. Atlantic Premium Brands Ltd. Lincoln Provision Inc. Charlie’s Pride Meats

Segment Sales 4,369.0 330 105.8 90 25 18.2 15.8 6.7 4.1

Total Sales 11,202.6 2,200 225 360 250 363.4 105 134 82

Segment Sales Sanderson Farms Inc. 1,900 Foster Poultry Farms 990 Greater Omaha Packing Co. Inc. 275 Creekstone Farms Premium Beef 105 Natural Food Holdings 87.5 Rocky Mountain Natural Meats Inc. 47.6 Sam Kane Beef Processors Inc. 26.3 Peer Foods Group 25 Farmington Foods Inc. 18 Mountain States Rosen LLC 16.5

Total Sales 1,900 2,200 1,100 500 250 56 525 100 60 165

More If you want to share this information with colleagues or view it on-the-go, remember to check out

ProvisionerOnline. com. You’ll Ànd the digital edition as well as up-to-the-minute updates.

EXPORTED FOODS

NATURAL/ORGANIC FOODS Company

Top 100 rank 4 14 62 51 59 50 89 80 96

Top 100 Rank 17 14 24 45 59 99 44 91 98 73

Company Sanderson Farms Inc. Greater Omaha Packing Co. Inc. Hormel Foods Corp. Mountaire Farms Inc. Butterball LLC Simmons Foods Inc. Sam Kane Beef Processors Inc. Creekstone Farms Premium Beef Natural Food Holdings Case Foods Inc.

Segment Sales 361 275 266.4 195.5 144 106.5 78.8 70 62.5 57.8

Total Sales 1,900 1,100 7,200 1,303 1,200 710 525 500 250 578

Top 100 Rank 17 24 5 21 22 30 44 45 59 40

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Reiser – focused on customers When you walk down the long hallway that leads to its new Customer Center in the Canton, Mass., headquarters, you are struck by the proud history of Reiser. There are the framed accomplishments of 51 years of providing the highest levels of serving customers. As Roger Reiser puts it, “At Reiser our focus is on the customer, and our goal is to build relationships with those customers, gain their trust, learn their business, provide equipment solutions… and have them enjoy doing business with us – that’s us in a nutshell.” Reiser is a family-owned and operated company, run by brothers Roger and George Reiser. They continue the original vision of the company as a selling and servicing company. In its Canton headquarters, as well in Burlington, Canada and in the UK, Reiser’s 245 employees sell brands by having “people selling to people.” As Reiser’s Mission Statement says: “Robert Reiser & Co. will serve the food industry and other selected markets by selling and supporting equipment that provides solutions to customer needs.” When speaking with Roger Reiser, there is no doubt that he has structured his business around his Mission Statement. Reiser sells great equipment and develops creative solutions that help make customers more efÀcient, productive and proÀtable. Reiser supports it all with state-of-the-art customer support and service. Its Customer Support operation includes: O

O

O

O

Dedicated Technical Help Desk team with after-hours on-call service

Reiser continues to be the exclusive North American agent for:

Extensive network of Àeld service techs stationed all over the country

Vemag: Stuffers, in-line grinders, formers, Àllers, portioners, depositors, extruders, coextruders and dough dividers

Comprehensive spare parts inventory with same day shipping for orders received by 7 p.m.

Holac: Dicers, slicers and cutting equipment

The same service people serving the same customers

The 6,600-sq.-ft. Customer Center opened in late 2009 and provides the “highest level” of customer service with a fully staffed R & D department and food technologists for customers to test and develop new products and processes, along with conference rooms for on-site training. An example of its dedication to working with customers to solve their toughest challenges is the Vemag FM250. Hamburger sales were in the doldrums because patties were squashed, Áat and too chewy. Consumers wanted a homemade, tender burger which processors struggled to produce. In response, Reiser and Vemag developed the hugely successful FM250, which produces high-quality, gourmet patties at high rates of production.

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According to Reiser, “Suppliers are critical to us. We are all charged with strengthening our suppliers’ partnerships.” To that end, Reiser meets with its suppliers to discuss and develop new technology based on feedback from customers. It works closely with suppliers to help engineer equipment to meet the ever-changing needs of food processors. In addition, at company headquarters, Reiser constantly looks at ways to better serve customer’s needs by adapting and integrating existing equipment.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

AMFEC: Mixers, blenders, tumblers, massagers and macerators Seydelmann: Bowl cutters and choppers, mixers, grinders, mixing grinders Fomaco: Injectors, tenderizers, brine mixers and tanks Ross: Tray sealers for case-ready and modiÀed-atmosphere packaging Supervac: Automatic vacuum chamber packaging machines Repak: Horizontal form/Àll/seal packaging machines At the end of the day, Reiser helps its customers make a better product – today and tomorrow – and helps them make it more proÀtably.

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SpecialReport

SPARE PARTS MAINTENANCE

The missing O link

EfÀciency of an operation requires maintenance and preservation not only of operational assets, but on spare parts as well. By Phillip Slater, contributing writer

h no, not again! This the perennial cry of the maintenance and reliability professional. We all know this situation: A part or component, recently repaired, has now failed again. Not only is this annoying and frustrating, it also means costly and unnecessary downtime. In this situation we are usually quick to blame the technician, technique or design. But none of these may be at fault; the cause of the breakdown could be a poorly maintained spare part. This might be a hard idea to swallow, but many self-induced and premature failures are more likely the result of poor material-handling and storage methods for spare parts than any other cause. For many maintenance and reliability practitioners, understanding the impact of materials management is the missing link in achieving reliability.

Storage of spare parts and reliability

Photo courtesy of Phillip Slater,

This photo, shows spare parts stored in anything but an acceptable manner. Slater says processors must care for stored spare parts as diligently as they care for in-operation parts.

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Is it any wonder that many early life failures can and do result from poor preservation of the spare parts? The accompanying photo shows a cupboard in a workshop where the bearings are being stored in anything but an acceptable manner. Did the people that set this up really expect to get the full life from this arrangement? Ask yourself now if you have one of these cupboards

in your spare-parts storage system. The key issues for equipment maintenance are the dynamic effects of being in operation and exposure to the environment. This includes the effects of wear, heat and vibration. For the spare parts that we have in storage, the issues are similar. We still need to deal with the effect of exposure to the environment, but we also need to deal with the effect of not being in operation, that is, the effect of being stationary.

Exposure to the environment The key things to consider when dealing with exposure to the environment are where and how the parts are stored. For example, sometimes we are very careful to protect the operating equipment with environmental controls such as air-conditioning or dustproofing but then keep the spares in a storeroom without either of these. Even items kept in suitable storage or undercover are exposed to the environment and exhibit failure modes

from exposure, such as: ORust OOxidation of rubber components in seals, belts, and other parts OBuild up of dust (especially important in electrical, rotating and reciprocating equipment) OLubrication failure (through contamination, migration and evaporation) OVibration from the operating facility — slight vibration over a period of time can degrade many spare parts, from bearings to electronic components

Effect of being stationary It is easy to assume that because a part is not in operation and is environmentally protected, it will be OK. But for items that are stationary, the enemy of reliability is gravity, and gravity is always with us! The two main influences of gravity are: OFlat spots that result from a constant weight on one section in seals, shafts and bearings. OLubricants ‘flowing’ to the lower areas, leaving upper areas without lubrication.

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SpecialReport Passive and active controls Exposure can be controlled, but gravity must be managed (that is, the effects of gravity). Therefore environmental control is likely to be passive (in that we provide infrastructure which provides control) whereas managing the effect of gravity will need to be active (we need to perform tasks regularly in order to ensure the integrity of the part). To demonstrate this visually, Figure 1 shows the relationship between parts in operation and parts in storage, and Figure 2 shows, for parts in storage, the crossover between active and passive issues. In Figure 1, we see that whether a part is in storage or in operation, we must still manage the effects of rust, dust, lack of lubrication and other environmental impacts. This diagram alone indicates that for reliable plant operation we must maintain our parts because they are subject to many of the same issues as the items in operation. In Figure 2, we see that those same core issues of rust, dust and lubrication require active involvement if we are to ensure that a part will operate as required when needed. This is in addition to actions that we take in order to counter the effects of gravity and other environmental protection.

Transform storeroom function By viewing spare-parts management in this way, we can see that the real function of the storeroom is not just to store and control access to parts. It also serves to maintain them in a condition so that they are fit for use when required. This means ensuring an appropriate care and maintenance routine as well as providing environmental protection. Neatness and organization of spare parts only helps ensure storeroom efficiency — it does not guarantee spare-part integrity. Some basic storeroom practices that impact reliability include: OProper storage — safe from the en62

Figure 1: Influences on Stored Parts vs. Parts in Operation

Parts in Storage

Gravity

Rust Dust Lubrication Environment Vibration

Operating Parts

Wear Heat Corrosion

Figure 2: Active and Passive Issues for Parts in Storage

Active

Gravity

Rust Dust Lubrication

vironmental effects of dust, water, vibration and light OPreservation of parts — appropriate lubrication and management of the effects of gravity ORigorous rotation of parts, that is, using the oldest parts first OProper labeling of parts to ensure selection of the correct part OProper access and equipment for lifting devices in order to avoid mechanical damage to parts when storing or retrieving them

Establishing a maintenance program Establishing a spares maintenance program is really similar to establishing the rest of your maintenance/

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

Passive

Environment

reliability program. Whereas maintenance/reliability programs typically address kinetic effects — or reliability issues that arise through the physical operation of the asset — a spares maintenance program will address static effects — issues that arise through non-operation of the asset. Both programs, of course need to address environmental effects. Therefore, establishing a spare-parts maintenance program only really requires a change in mindset for your failure mode and effects analysis (FMEA). You now need to consider how the item will fail through not operating rather than how it will fail through operating. The rest of the program development is the same as with any other

maintenance/reliability program: You need to identify the what, why, when, how, who and where of your spares maintenance program. This is an opportunity to expand your maintenance process and procedures to the personnel in the storeroom. A world-class spares maintenance program is likely to not require any more personnel than you currently have. It is an opportunity to transform the perception of your storeroom personnel from a simple receiving, issuing, and counting role to a role integral to the reliability of the facility. A written, detailed program could add the structure and professionalism to transform your storeroom and your storeroom personnel.

A world-class spares maintenance program is likely to not require any more personnel than you currently have.

Boost profits with uniform cooking.

The missing link

Heat and Control ovens end wasteful

Maintenance and reliability professionals, charged with the responsibility of ensuring the preservation of the equipment in their care, often overlook one of the single greatest causes of equipment failure and subsequent downtime: poor spare-parts management. For many, this is the missing link in their reliability program. Poor spare-parts management results from systemic issues with the way that reliability data is collected, inappropriate techniques for storage, a misalignment of responsibilities, poor training, and a lack of formal policy and procedures in this area. Empirically we know all this to be true and so, equally, we know from experience that correction of these issues can have a significant impact on the outcomes from any maintenance and reliability program.

overcooking. Our AirForce impingement, spiral,

Phillip Slater is an international materials and spare-parts management specialist. He is a qualified engineer, an experienced operations and maintenance manager, a seasoned management consultant, and the author of four operations management books. For access to more information on spare parts management visit his Web site, www.PhillipSlater.com, or contact him at [email protected].

and MPO ovens always cook poultry, meat, and many other prepared foods uniformly. Increase production output, reduce product waste, and ensure every product reaches the same safe core temperature. See how our ovens, fryers, flame searers, branders, and batter-breaders can boost profits with a demonstration today!

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TechProcessing SOFTWARE SYSTEMS

Total recall

Sophisticated software systems are automating product grades, logistics and traceability. By Megan Pellegrini, contributing writer

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VIDEO IMAGE ANALYSIS SYSTEMS, robots and live animal tracking tags are coming to a plant near you, if they haven’t already. Software systems are enabling meat- and poultry-processing operations to largely automate their inventory management, logistics and product traceability today. Although some technologies may not be new — they are simply improvements upon existing software — today’s software systems are certainly streamlining paperwork and reducing physical labor at protein-processing plants. “A lot of companies are trying to extract more value out of everything that goes through their plants, whether it’s individual worker yields or tracking carcasses,” says Marcine Moldenhauer, president and owner, Meat-Link Management LLC, based in Wichita, Kan. “They need to understand what’s going on at the plant at every step of the way.” Perhaps the biggest hot-button technology today is the use of video image analysis systems to grade carcasses by applying the U.S. Department of Agriculture’s (USDA) traditional standards. “Sophisticated software allows companies to use images to assess the visible lean from fat meat, and determine the product’s marbling score and yield characteristics, therefore predicting the approximate yield value of the carcass,” says Dale Woerner, Ph.D., assistant professor, Department of Animal Sciences, Colorado State University, based in Fort Collins, Colo.

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

By taking the images and data and putting them into a mathematical or statistical model, this software develops an algorithm that will predict yield and cut-ability, making predictions on the types of cuts best-suited to each unique carcass, says Woerner. He notes that the pork industry has been more innovative than the beef industry with using instrumentation to determine fat and color quality. Asian markets, for example, prefer a darker product color, and carcasses can be sorted by color during the processing system to meet this demand. “Pork facilities harvest three to five times more product than beef plants, so they’ve increased their efficiency to grade product far beyond what human inspectors could do,” he says. The lamb industry, says Woerner, is also moving forward with the USDA on using vision systems to determine product quality.

analyze customer orders, in order to optimize their carcass purchases, says Moldenhauer. A smaller processing plant, Wasatch Meats uses software systems to track its custom orders since each customer’s cut and price can be different, says Scott Rich, vice president, Wasatch Meats Inc., based in Salt Lake City. “The entire order can be printed out for production before heading over to the cutters,” he says. “Based on the data, the computer can tell us if the weights are out of spec on the invoice.” Employees still handwrite the product weights on the order, but the company is in the process of automating that aspect, as well, notes Rich.

Automating efficiency Nearly every processing facility today uses software for logistics purposes to manage inventory, to the extent that if it were to malfunction, the plant would be temporarily shut down, says Woerner. “Automated inventory systems, however, increase efficiency and reduce the size of the plant,” he says. Production or operation software is more directed to the orders process and tracks systems on the harvest floor to begin data collection on every shift and plant for each day, says Moldenhauer. “The ability to sort, store and retrieve custom and short orders through robotics and electronic order tracking via bar-coding systems has been a major benefit to both our team members and our customers,” says Worth Sparkman, manager public relations, Tyson Foods Inc., based in Springdale, Ark. When it makes economic and logistical sense, he says, robots also do a lot of the heavy lifting in many of Tyson’s plants. “This has many safety and ergonomic benefits because team members are not experiencing as much strain,” he says. Plants are also using software to

“The software prevents us from using incorrect weights, which provides cost reductions, improved customer service and better efficiencies,” he says. “However, because of our company size, we always have to ask ourselves if we’re getting the right return on our investment.” Typically, most poultry-processing plants today have software for sales, automated inventory systems and a count of how many birds are in the house. Where software systems are making new inroads is with preventative equipment maintenance, says Gary McMurray, chief, Georgia Tech Research Institute’s Food Processing Technology Division, based in Atlanta. “The software evaluates why a piece of equipment may be having problems, so there aren’t breakdowns which close down lines for the day,” he says. He notes that it would be helpful for cutting machines’ software to dynamically assess the true size of the bird, since product weights don’t reflect possible differences in birds’ abdo-

men length and shoulder width.

Tracking animals from ranch to plate The meat and poultry industry was spared from the recent Food Safety Modernization Act’s traceability and inspection provisions, largely because it is already closely regulated by the USDA. However, some processors are finding it to their regulatory — and marketing — advantage to continue installing high-tech source verification, arrival tracking and live-animal tracking systems. Different types of software exist that can electronically identify an animal from the ranch (its date and time of birth, mother and location are stored on ear tags) to plate, which is vitally important during a food recall. “We can trace everything with our computer system,” says Rich. Since animal data is entered manually by employees when it arrives, Wasatch Meats is reviewing whether to invest in handheld scanners for this stage and to provide an easier trace backward in the event of a recall, he adds. Regardless, when the USDA Food Safety and Inspection Service (FSIS) was once investigating a possible recall (ultimately not associated with Wasatch Meats) the company was able to provide all animal records within two hours under the current system, he says. Woerner notes that traceability data is also useful for marketing claims involving source and age verification, humane living conditions, non-hormone raised and natural. Furthermore, he says, software systems can always be improved to maximize efficiency and the bottom line. Often times, employees (and companies) can be resistant to change and won’t allow these technologies to prove themselves, says Moldenhauer. The software is also exposed to a rough physical environment, so it may not have a long shelf life. “However, as our industry is faced with more regulations and demands — and [higher] expectations of consumers — we have to embrace more technology,” she says.

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FoodSafety SANITIZERS

A helping hand

How different sanitizers work Sanitizers play a part in maintaining sanitary operations, but they are not a “silver bullet” solution. By John Butts, contributing writer THE APPLICATION AND USE OF SANITIZERS IN OUR INDUSTRY IS WIDESPREAD, and it goes beyond the traditional application during the normal cleanup and sanitation process. Sanitizers are now used as an agent in process control to reduce risk and provide a greater level of consumer protection from pathogen contamination. The war on pathogens has changed the focus of sanitizer usage from shelf-life control to pathogen control. Sanitizer usage as a process-control agent in a zero-tolerance landscape presents many challenges. Let’s start by examining the difference between a disinfectant and a sanitizer. Both types are regulated by the Environmental Protection 66

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

By Brendan Murphy, contributing writer THERE ARE MANY FACTORS THAT COME INTO PLAY WHEN SELECTING THE BEST SANITIZER TO USE FOR A GIVEN APPLICATION. How a sanitizer attacks its target can affect its suitability (or otherwise!) depending on the conditions of that application. There are a number of ways sanitizers affect microorganisms, the mode of action of some commonly encountered sanitizers is summarized below.

Alcohols: Although several alcohols have been shown to be effective antimicrobials, ethyl alcohol and isopropyl alcohol are the most common and are widely used as skin antiseptics and hand sanitizers. Curiously, alcohols work best when diluted with water to concentrations of 60% to 90%. Little is known about the specific mode of action of alcohols, but based on their increased efficacy Continues on Page 68

Agency (EPA). The EPA rules include testing, claims and direction for use. 1

Disinfectant A disinfectant must completely eliminate all the organisms listed on its label and may include viruses and fungi.

Sanitizer Sanitizers do not need to eliminate one hundred percent of all organisms to be effective. Fungi or viruses are not included in a sanitizing claim. For food contact surfaces, a sanitizer must reduce the bacterial count by 99.999%.

Conditions of Use Disinfectants and sanitizers are intended to be used on hard, non-porous, environmental surfaces such as walls, floors and equipment. A disinfectant can be used on a food contact surface, but the surface needs to be rinsed with potable water after being disinfected. A food contact sanitizer should not be rinsed after sanitizing a food contact surface. A food contact sanitizer is designed to function as the final rinse on food contact surfaces. Sanitizers are defined as incidental food additives under the Federal Food, Drug, and Cosmetic Act, (21 U.S.C. 201), and require establishment of a food additive tolerance. Chlorine-bearing chemicals must be validated with the AOAC Available Chlorine Germicidal Equivalent Concentration Method. The requirements are for one test on each of 3 samples, from 3 different batches, one of which is at least 60 days old. The test organism is S. typhi. Test results must show chlorine concentrations of 50, 100, and 200 ppm of available chlorine. Efficacy testing of quaternary ammonium compounds (quats) is similarly conducted by the AOAC Germicidal and Detergent Sanitizers Method. The test organisms are E. coli and S. aureus. The minimum concentration of the product which provides a 99.999% reduction in the number of microorganisms within 30 seconds is the minimum effective concentration. The above examples describe the application of sanitizers on clean, hard, impervious surfaces. In many processcontrol applications, the surface to be

treated is not always clean. Likewise, the operational application of sanitizers to contact and non-contact surfaces as well as product is not required nor technically expected to have a 99.999% or 5 log kill (Figure 1).

Figure 1 % of Bacteria Killed 99% 99.9% 99.99% 99.999% 99.9999% 99.99999%

Log Kill value 2 3 4 5 6 7

This is why validation tests need to be conducted to determine effectiveness of the application. Figure 2 is an example to help define and describe some of the terms used in measuring the effectiveness of sanitizers. If a sanitizer applied to a process has a reported log kill value of Log 3 (It kills 99.9% of the bacteria present)

these are the results. Let’s assume 1,000 CFU/sq. in. and the surface area to be treated is 100 sq. in. This means there are 100,000 CFU/100 sq. in. If the sanitizer treatment has a 3 log reduction potential measured by a validation test, then 100 CFU/100 sq. in. would remain. This is equivalent to 1 CFU/sq. in. So out of 100 sq. in., each square inch would theoretically have 1 bacteria present. To effectively remove the contaminating organisms, the initial count must be lower or the sanitizer reduction potential must be higher. The use of sanitizers as an in-process control factor is best defined as a hurdle in the process-control system. Sanitizers, when used as an in-process control hurdle, do not always exert absolute control over the process as a HACCP critical control point (CCP) is intended. Hurdles reduce risk and exert some control. The level of control attained is measured with a validation study. Many in-process applications of

A future of safer food. Our expertise helps you focus on what you do best. Meat, seafood, and poultry processors around the world trust Diversey to meet their food safety and hygiene needs. Our cleaning programs and products are designed to improve worker safety, increase operational efficiency and support your brand integrity. When you work with Diversey, you get leading expertise in the food industry. For more information please visit www.diversey.com or contact us at 800-668-7171.

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FoodSafety sanitizers are designed to prevent or minimize the movement of the organism as it travels from transfer point to transfer point on floors, equipment, material, people and unfortunately products. Everything that moves or is moved inside the plant is a potential

transfer agent for a microbiological hitchhiker. Chemical sanitizers act as hurdles in these microbial pathways or transfer vectors. In many situations requiring control, or when one is forced with a zero tolerance, multiple hurdles are often required to exert the level of

in the presence of water, it is generally believed that they denature the hydrated protein of the cell’s surface, with subsequent membrane damage and cell lysis.

Halogens: Compounds like chlorine and iodine have long been used for general disinfection and as sanitizers in the food industry. The actual mechanism of halogens is not fully known but they are highly active oxidizing agents that react very quickly with all kinds of organic matter, including proteins. This non-specific attack destroys the cell’s proteins, stopping the activity of cellular enzymes and the cell dies.

Peracetic acid (PAA): Peroxy acids are also highly active oxidizing agents that denature the cell’s proteins and enzyme systems, but they are less affected by organic material than halogens. They also increase cell wall permeability by disrupting sulfhydryl and sulfur bonds, causing the cell to leak its contents and subsequently die.

Quaternary Ammonium Compounds (QACs or quats): QACs are positively charged surfactants that are attracted to the negative charge of the bacterial cell wall. It has been known for many years that QACs are membrane active agents with a target site predominantly at the cytoplasmic membrane in bacteria. The sequence of events in the destruction of the bacterial cell are (i) adsorption and penetration of the QAC into the cell wall (ii) reaction with the cytoplasmic membrane (iii) leakage of intracellular material (iv) cell wall lysis and death QACs also act to dissolve the lipid coat on enveloped viruses which inactivates the virus and it can no longer replicate.

Acid Anionics: Acid anionic surfactants are negatively charged surfactants that kill bacteria in a manner very similar to QACs. In spite of having a negative charge they are able to overcome the electrostatic repulsion of the cell surface because they are formulated in a manner to provide a pH low enough to cause the cell wall’s charge to reverse and become positive. If the pH is raised then the cell’s normal negative charge is restored and the acid anionic sanitizer becomes completely ineffective. Brendan Murphy is a senior field microbiologist for Diversey Inc. For more information, he can be reached at (800) 824-7171, or [email protected].

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control desired. The following link defines applications of sanitizers for indirect usage (21CFR178.1010): http://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfcfr/ CFRSearch.cfm?fr=178.1010 The sanitizers cited are approved for the uses stated by FSIS. The usage level or upper concentration limit is defined. The process-control factors for sanitizer usage include: • Contact time • Concentration • pH • Temperature • Water hardness • Cleanliness of surface (presence of organic matter) Product sanitizer concentration is regulated when used on contact surfaces that touch or may touch product. For specific information related to specific compounds there are several sources of information. Among them are FSIS Directive 7120.1; 21 CFR 178.1010; 21 CFR Part 173 — and be sure to read the suppliers label. Most sanitizers have a limited scope of organisms they affect. Rotating sanitizers can prevent a buildup of spoilage organisms. Also sanitizer effects on equipment are different. For instance, chlorine containing compounds are corrosive and do remove by oxidation in organic buildup on equipment, somewhat similar to an acid treatment. To prevent excessive corrosion, the rotation of chlorine and quaternary ammonia sanitizer keeps the surfaces bright and provides a broader spectrum of effectiveness.

Developing an effective system In the plant environment, microorganisms have many modes of protection as they make their way from their growth niche (Listeria) or primary source (E. coli on the hide of the animal) to the finished product. These modes or layers of protection are barriers that prevent direct physical exposure of the organism to the chemical sanitizer. Sanitizer effectiveness requires direct contact with between the sanitizer and the organisms at the molecular level. Harmful organisms are commonly embedded in a

bio-film or other organic matter. Figure 2 The sanitizer must penetrate the Number of Bacteria (CFU) per square inch protective material to be effecContaminating the Surface No. bacteria tive. For instance, a very thin layer of microscopic fat may prevent Log Log 3 Remaining per contact of a water-soluble saniCount value Kill % Killed square inch tizer. This is why cleaning always 1 100 99.9% 0.999 0.001 precedes sanitization. Spraying 10 101 99.9% 9.99 0.01 200 ppm chlorine on a dirty floor 100 102 99.9% 99.9 0.1 or on the hide of a carcass will only have a minimal effect on the 1,000 103 99.9% 999 1 overall microbial population. 10,000 104 99.9% 9,990 10 Microbiological control 100,000 105 99.9% 99,900 100 would be very easy if, by sim1,000,000 106 99.9% 999,000 1,000 ply spraying a weak chlorine solution on a contaminated 10,000,000 107 99.9% 9,990,000 10,000 surface, all of the contaminating 100,000,000 108 99.9% 99,900,000 100,000 organisms would be eliminated. A sanitizer solution can be used to penetrate some level of organic matter. Therefore when designing or evaluating a process-control system, pay Obviously, this varies with sanitizer, con- treat intact packages between a chilling medium and final packaging to “mantact time, concentration, etc. Disassemparticular attention to those factors that age” lot sizes when chilling media is bly, cleaning and sanitization to expose present interference to direct contact held over for extended periods of time. equipment growth niches is required to at the molecular level. The material or For this application the treatment must assure pathogen control. debris that protects often becomes the be validated with challenge studies to John Weisgerber, owner of Weisvehicle that is motorized from transfer support the efficacy of the treatment. gerber Consulting LLC, offers a few point to transfer point in the transfer For situations where environmenexamples of “hurdles in the processvectors. tal contamination is severe and there control system.” Sanitizers do have varied ability to

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FoodSafety

The war on pathogens has changed the

seems to be no real source other than the immediate facility structure, progress at controlling microbial contamination can be achieved with application of extremely high levels of sanitizer by both flood and fogging applications. While this can be effective, it should be considered the option of last choice if the high concentrations can have a deleterious effect on the facility infrastructure exposed to this treatment. One common application is the use of sanitizer baths or dip stations to store hand tools (knives, spatulas etc.) for the RTE process during operations. While this may have some impact at maintaining a sanitary condition, it is thought to be a less optimal solution to maintaining a dry environment and using periodic heat treatment or COP tanks to clean hand tools during the normal sanitation cycle. It is common to use sanitizer-dampened single-use towels to enhance the

control to pathogen control.

focus of sanitizer usage from shelf-life

sanitary condition of product contact surfaces in RTE packaging operations throughout a day. When used at breaks and lunch, shelf life is often improved. Jordan Woodbury, Director of Food Safety and Quality Assurance for Dakota Provisions describes the three-step hurdle system his company uses. “Dakota Provisions utilizes an antimicrobial mist consisting of anolyte part of the electrolyzed water on all fully cooked racks of product in impervious casings before they are either shipped to the customer or stripped out of the casing and sent to the slice room,” he says. According to Woodbury, the next hurdles used by Dakota are misting of Acidified Sodium Chlorite on the total surface (top and bottom) of exposed RTE deli meats after taking off the cas-

ings as they enter the room, and application of Acidified Sodium Chlorite mist to both sides of the slice blade. “This three-part hurdle addresses any incidental post-lethality contamination that could have occurred while the logs were en route after chill, during storage and as they traveled to the casing stripping area prior to slicing,” Woodbury explains. The second hurdle, misting the logs with Acidified Sodium Chlorite, places the sanitizer on exposed surfaces that potentially could have been contaminated during the casing removal and log transfer process. The third hurdle is at the slicer blade. This step is designed to reduce or eliminate the potential of any contamination occurring after product is exposed, when it comes into contact with equip-

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.

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THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

ment upon delivery to the slicer, at the slicer and as it is being sliced. The application to both sides of the blade assures exposure of each slice face. Dakota Provisions’ hurdle system highlights a classic example of how science can be used to design in-process hurdles to reduce risk. Woodbury uses multiple sanitizers to increase spectrum of coverage and makes applications before and after each exposure. As you are now well aware there are many novel approaches to the use of sanitizers to improve microbial control in meat-processing applications. Each appropriate application must be thoroughly studied and validated to be effective. Take, for example, the realities connected to the following “myths”: MYTH #1: Fogging is an effective method to sanitize a piece of equipment or a room. RESPONSE: Not necessarily. Fogging sanitizer will apply droplets of sanitizer on surfaces that will collect the droplets as they fall. Exposed surface coverage

is limited, and fogging does not provide for penetration of protected surfaces. Exposed surface coverage with a sanitizer does not substitute for disassembly to expose growth niches and cleaning of surfaces before sanitizer application. A gaseous vapor of sanitizer will not penetrate a hollow roller. It will only coat the surface where the seepage may occur. Thus the surface around the seepage area may be instantly treated, but not be effective hours later when the seepage occurs. MYTH #2: Sanitizer alone will maintain an asset in a sanitary condition. RESPONSE: Not true. Without appropriate use of detergent and physical scouring to remove soils, sanitizer will never, by itself, be effective. MYTH #3: Sanitizer rotation is required to prevent organisms from developing resistance to a particular sanitizer. RESPONSE: Not true. Some pathogenic microorganisms have developed resistance to antibiotics, i.e. staph. Microorganisms do not develop resistance to

chemical sanitizers at common usage levels. The reason to switch or rotate sanitizers is to increase the spectrum of organisms affected by the sanitizer application. In summary, the operational or inprocess use of sanitizer solutions is not a “silver bullet” that can keep our operations running in a sanitary manner. Sanitizers have their part to play in maintaining sanitary operations and improving process controls but they must be used appropriately, and the use validated. Sanitizer usage as a process-control agent in a zero-tolerance landscape presents many challenges. John Butts is vice president of research at Land O’Frost and may be reached at john. [email protected]. John Weisgerber is the owner of Weisgerber Consulting. John may be contacted at [email protected]. Jordan Woodbury is the director of food safety and quality assurance for Dakota Provisions. Jordan may be contacted at [email protected]. http://www.epa.gov/oppad001/dis_tss_docs/dis-04.htm

1

Alt-2 for RTE and Fresh Meats ®

with AutoJet Antimicrobial Spray Systems

Antimicrobial applied to each slice face during slicing and into each package for complete product coverage.

Precise application of antimicrobials onto each product or into each package with our automated spray system can help lower costs while ensuring food safety. Other benefits include: • Typical costs: $0.01/lb. for RTE, $0.003/lb. for fresh meats • Cleaner product labels • 2 - 3 log reductions typical for Listeria, E. coli O157:H7, Salmonella, etc. • Suitable for use with fresh and RTE whole muscle, roll stock and sliced products • USDA validated technology • Dozens of systems in use by NAMP and AMI members

For more information, visit www.spray.com/foodsafety or call 1-800-95-SPRAY.

Experts in Spray Technology Spray Nozzles

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71

I have a seat at the Exchange

Ed Bick Senior Vice President Pork Operations JBS Swift & Company

SM

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

“The focused productivity during MPX has saved us months in the development of projects and has contributed significantly to our bottom line.” Contact Becky Simon-Burton to reserve your seat [email protected] - 952-736-9361

TechShowcase Sanitizer

Saw

Spartan Chemical’s Sani-T-10 Plus is now available in 2-liters for use in Spartan’s Clean on the Go dispensing systems. Sani-T-10 Plus is a fourthgeneration quat-based, food contact sanitizer for use in food handling and process areas, federally inspected meat and poultry plants, fruit and vegetable processors, wineries, restaurants, bars and institutional kitchens. Ideal to sanitize Àlling equipment, food processing equipment, meat and poultry or fruit and vegetable conveyors dishes, glasses, cooking utensils, and eating utensils.

Hollymatic is marketing the Hi-Yield 16-5000 Saw for fresh and frozen meat, poultry, Àsh, and vegetable products. The 16-5000 is a competitively priced, highspeed, high-yield saw that offers signiÀcant safety features, including a Quick Stop Brake that stops the blade within 1 second of shut-off or opening of doors to dramatically reduce risk of injury, as well as safety interlocked doors and double Áanged wheels. Stateof-the-art controls optimize energy usage.

Spartan Chemical Co. Inc.: (800) 537-8990 or visit www.spartanchemical.com

Continuous Processing The Handtmenn ConPro Therm and ConPro LINK systems raise the co-extrusion process to new levels of speed and efÀciency for sizes from 10mm to 32mm by offering the industry’s Àrst “natural look” closed-end continuous process casing. This process delivers all the beneÀts of a continuous process using the Vega (vegetable casing) resulting in the look and feel of premium natural casing and the efÀciency of near automation. Handtmann Inc.: (847) 808-1100 or visit www.handtmann.com

Get the free mobile app at

http:/ / gettag.mobi

Hollymatic: 708-579-3700 or visit www.hiyield16.info

Form-Fill-Seal Ossid offers a horizontal form-Àll-seal machine rated at 10 to 15 cycles per minute (CPM), is scheduled to meet USDA meat, poultry, dairy, and 3-A Sanitary Standards, complies with Pack ML, and may be customized for customer speciÀc applications. The Integrity machine will be available in web widths of 320, 355, 420, and 459 mm respectively and indexes of up to 600 mm. The base unit comes with servo-driven clip chain drive and pneumatic presses. Ossid: (800) 334-8369 or visit www.ossid.com

Thermoformer Multivac is launching a commercially available, ultra compact model of its “e-concept” thermoformer – a system with electric lifts requiring no compressed air or cooling water. The Multivac R 095 thermoformer is just under 7 feet long and is ideal for users who have limited space and are new to automated thermoform Àll-seal packaging. Eliminating the need for cooling water in the machine also represents a substantial logistical and cost advantage for users. Multivac Inc.: (816) 891-0555 or visit www.multivac.com

Searer JBT’s Double D Searer/Grill Marker produces a seared or grill-marked effect on products to enhance taste and appearance. Designed and manufactured in the UK, the system can be custom built with any number of burners, and has the ability to sear on both sides of the product simultaneously, leading to signiÀcant savings in time and costs. The Double D Searer/Grill Marker can be stand alone, or as part of JBT FoodTech’s multi-phase cooking systems. JBT FoodTech: (419) 626-0304 or visit www.jbtfoodtech.com MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

73

TechShowcase

FPSA elects board members, sets dates for future Process Expo shows The Food Processing Suppliers Association held its annual conference March 9-12 at the J.W. Marriott Desert Springs, Palm Desert, Calif. In his message Scott Scriven, FPSA Chairman to the members, FPSA Chairman Scott Scriven announced that the association is on strong Ànancial footing, and that PROCESS EXPO sales are incredibly strong, up over 75% from the 2010 show and growing daily. Along with general sessions on economic trends and building better trade shows, the FPSA elected its board members for the next year. FPSA nominated the following board members to the Executive Committee: Scott Scriven, Weber Inc., Chairman; Jeff Dahl, JBT Food Tech., Vice Chairman; Gene Teeter, Meyer Industries, Treasurer; Barry Shoulders, Oystar North America, Immediate Past Chairman; and David Camp, Key Technologies, At Large Director. The following members will make up the 2011-2012 FPSA Board of Directors: John Atanasio, Alfa Laval Inc.; John Campbell, Separators Inc.; Bob Grote, Grote Co.; Steve Hughes, Lyco Mfg.; Tony Bayat, CFS NA; Ivo Cozzini, PrimEDGE; Ed Fay, CMC America; Tim O’Brien, Urschel Laboratories; Goran Olsson, Tetra Pak Inc.; Chad Sprinkman, W.M. Sprinkman; and Gil Williams, Poly-clip System. The Board also thanked the following members for their service to the board: Viggo Nielsen, Mettler Toledo Safeline; John Rooney, Evergreen Packaging Inc.; Ken Hagedorn, Naegele Inc.; and Lou Beaudette, Admix Inc. The FPSA also announced that it has reached an agreement with Chicago’s Convention and Tourism Bureau that will keep the association’s trade show, PROCESS EXPO, in Chicago for the foreseeable future. In 2013 the show will be held October 14-17, while the 2015 show dates will be October 6-9. “With PROCESS EXPO 2011 rapidly approaching the 200,000 square foot mark, it is important to show our exhibitors, attendees, and partners that we remain Àrmly committed to a two-year show cycle, in the fall, in Chicago” said Scriven. “The response and the commitment from our membership and the entire industry has been remarkable, and to honor that commitment it is important that FPSA show, that without question, PROCESS EXPO is here to stay,” noted David Seckman, President and CEO of FPSA. 74

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MARCH 2011

Vaccine Lohmann Animal Health’s AviPro IBD Xtreme provides effective protection against highly virulent infectious bursal disease viruses. AviPro IBD Xtreme is designed for the protection of commercial layers, breeders and broilers against infectious bursal disease. AviPro IBD Xtreme is classiÀed as an intermediate plus IBD vaccine. The IBD virus can break through the maternal antibodies which protect the chick in their Àrst few days, resulting in an early infection and a severe case of the disease. Lohmann Animal Health International: (800) 655-1342 or visit www.lahinternational.com

Packaging FreshCase packaging from Curwood delivers superior Áavor, quality and extended shelf life of vacuum packaging; the fresh red color consumers prefer; and cost advantages that help processors and retailers maintain critical proÀt margins. FreshCase packaging is an FDA- and USDA-approved technology engineered to maintain fresh red color in a vacuum package. For the consumer, the attractive, leak-proof packages are easy to open; freezer-ready; and can be stored in the refrigerator, readyto-cook, until the Use-By date. Curwood: (800) 544-4672 or visit www.curwood.com

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Cryovac introduces QuickRip packaging, the next-generation bag for boneless fresh red meat applications. This innovative, high performance packaging was designed speciÀcally to improve efÀciencies and safety in the retail backroom and foodservice back-of house. The bag features improved performance in comparison with B620 & BH620 bags, an option for an easy-open tab, improved abuse resistance, enhanced shrink and optics and in-line one color print. Sealed Air, Cryovac: (800) 391-5645 or visit www.cryovacquickrip.com

Loma Systems’ new LCW line of checkweighers features a fully welded frame that lives up to Loma’s “Designed to Survive” tagline. The frame is now completely welded for strength, rigidity, and durability. The load cell is mounted to a rigid piece of 1/2-inch steel plate, giving it tremendous accuracy and resistance to outside noise and vibrations. The optional Washdown Package makes the LCW IP66 rated and adds in many sanitary features. Loma Systems: (800) USA-LOMA or visit www.loma.com

Supplier News Visit www.nutecmfg.com to view NuTEC’s recently re-designed company website. Vibrant colors, vivid graphics, and valuable information on the company’s full line of food formers and portioning depositors is contained on this easy-to-navigate site. Five simple buttons at the top of every page lead visitors Home, to Food Formers, Portioning Depositors, Trade Show Information, and a Contact Us page. The dynamic design of NuTEC’s new website features several ways to access information on individual machines. Photos, features, speciÀcations, and literature are easy to pull up. Attractive food photography is used throughout to demonstrate the different products that can be manufactured on NuTEC equipment. MAY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

75

TechShowcase Provisur Technologies Inc. has appointed Tom Van Doorn to sales manager, Slicing North America. With more than 25 years of food industry experience, Van Doorn brings an impressive record of accomplishments to Provisur characterized by business growth, Van Doorn world-class customer service and team building, the company says. “We are fortunate to have a professional like Tom at Provisur as his talents and skills are the perfect Àt with our long range plans for continued growth and expansion,” said Kevin Howard, vice president sales and service for The Americas at Provisur Technologies. “Tom has demonstrated success in building and leading high performance teams in the pursuit of higher productivity and lower cost solutions for our customers. Our Formax and Cashin slicing brands, represented by the PowerMax and CashinEDGE product lines, clearly provide a solid foundation for Tom and his team to build upon.”

Foran Spice says that for nearly 60 years, it has taken pride in forming real partnerships with a wide variety of food industry companies to create unique spice and seasoning blends. The company has recently updated its website, www.foranspice.com, with the goal of making its expertise, creativity and customer-oriented philosophy more accessible than ever. 76

Curwood announced that its LiquiÁex Advance Àlm—an ultra-tough, sustainable new option for packaging pumpable bulk foodservice products—won gold in the 2011 FPA Achievement Awards Competition. Used to make bulk pouches for liquids and semi-liquids such as soups, sauces, condiments and meat slurry, the award-winning new Àlm replaces metal foodservice cans or traditional bulk liquid Àlms, generating 96% less waste than cans and up to 30% less waste than conventional Àlms. “We’re honored that LiquiÁex Advance Àlm was recognized with an FPA Gold Award,” says Jon Pietsch, market manager for Liquid Flexibles, “the Àlm is a big leap forward for the bulk foodservice packaging industry, and it is part of a total Àlm and equipment solution that raises the bar for performance, efÀciency and ease of use.” The American Meat Science Association (AMSA) has announced that Craig Bacon of Tyson Foods, Inc., Rosalind Zils of Cargill and Kevin Nanke of Lopez Foods will be the speakers in the Reciprocal Meat Conference Product Development Concurrent Session sponsored by ADM on Monday, June 20. They will discuss three critical stages in new product development. Bacon will focus on the discovery and exploration of new ideas, the processes to evaluate them and how to turn them into the gold standards that can become successful new products. He will also explore how large food service accounts develop new products - all with the consumer in mind. Zils will explore food safety risks as they relate to supplier systems, and performance- and risk-based approaches to supply-side management. She will also discuss the importance of developing supplier relationships to enhance understanding and reduce risk. Nanke will explore how assuring a safe food supply chain is a complex, multi-faceted activity that involves the interaction of different disciplines across the entire supply chain. He will elaborate on standards that must be put in place throughout the entire supply chain, including the distribution channel, point-of-sale, and how the product will be consumed to ensure food safety. The AMSA 64th Reciprocal Meat Conference (RMC) will be held June 19-22, 2011 at Kansas State University in Manhattan, Kan. For more information, visit www.meatscience. org/rmc or contact Deidrea Mabry at (800) 517-AMSA ext. 12 or [email protected].

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | MAY 2011

@

Read More TECH SHOWCASE

CSB-System, a provider of software solutions for the protein industry, has hired Patrick Pilz to a newly created position of industry principal, CPG. Pilz has over 20 years of experience in relation to high-tech software solutions for the food industry. John W. Chlopek, CEO, CSB-System International Inc., stated, “We are thrilled to add Patrick to our team. We Pilz are continually incorporating enhancements to our solutions; Patrick will assist with the ongoing design, creation and delivery of effective solutions for the most critical requirements within the industry such as Yield Management, Traceability and Food Safety.” Multisorb Technologies announced the appointment of Brizman Packaging Business Development Ltd. as exclusive sales representation for Israel. Brizman Ltd. is led by company founder Udi Brizman. Based north of Tel Aviv, Brizman will oversee the development of the local market via the communication of Multisorb’s Calculations through OperationsSM program to manufacturers and packagers in the healthcare, food/beverage, electronics, and transportation industries.“The appointBrizman ment of Brizman Ltd. is a part of our continuing drive to provide leadership in the global active packaging market,” said James V. Renda, president of Multisorb. “Their appointment reÁects our dedication to offer the local support that customers have come to expect from Multisorb.”

Registration and housing for PACK EXPO Las Vegas 2011 (September 26–28, Las Vegas Convention Center) are open at Packexpo.com. PMMI projections for the September trade show stand at more than 1,200 exhibitors; 25,000 attendees; and nearly 600,000 net square feet of exhibit space. “PACK EXPO Las Vegas will easily be the largest processing and packaging trade show in North America this year,” says Charles D. Yuska, president & CEO of show producer PMMI. “Our initial estimate was 500,000 square feet, but we had to add space to respond to exhibitor demand. Attendees at PACK EXPO can see technology in action, meet face-to-face with suppliers and engage experts in one-on-one conversations. It really is the best place in North America for Ànding total systems solutions.” The September event will introduce processing technologies — and The Processing Zone — to the PACK EXPO Las Vegas show Áoor. “PACK EXPO attendees are seeking out processing and packaging solutions. We know that from our research and the success of the Processing Zone at the PACK EXPO show in Chicago. Bringing Processing to the Las Vegas show Áoor was a clear choice,” Yuska says.

Proper hand hygiene protects not only your employees, it also protects your reputation! Reduce the risk of Contact us today food-borne illness and product contamination with for your FREE hand washing, hand drying and hand sanitizing hand hygiene products from Nelson-Jameson. products catalog.

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

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

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WANTED Motivated Individuals or Agency to Sell our Equipment Line. If interested, please contact: Larry Wilson 662- 328-2750 [email protected]

BUSINESS FOR SALE

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

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© 2011 Thermo Fisher Scientific Inc. All rights reserved. Copyrights in and to the Piggy Bank photograph is owned by a third party and licensed for limited use only to Thermo Fisher Scientific by Punchstock.

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“Our new Vemag stuffer performs exactly as promised.” “At Maglio Sausage Company, we make a variety of sausage products – each with a very distinct look, bite and taste that our customers have enjoyed since 1947. When it was time to upgrade and automate our production line, we decided to look at Reiser and Vemag. We knew Reiser was well-respected throughout the industry and found them to be a company built on integrity. We were pleasantly surprised at the performance of the Vemag Stuffer during our tests. The Vemag was the only system that could consistently replicate the same look, bite and taste of our existing products. “With the Vemag stuffer, inline grinder, linker and link cutter, we now have the flexibility and reliability we need from our equipment. We’ve also discovered Reiser’s service and support to be second to none. For Maglio Sausage, partnering with Reiser has been a very pleasant experience.” Anthony L. Maglio Maglio Sausage Company, Philadelphia, PA

Product photography courtesy of Perretti Photography.

Maglio Fresh Foods is a third generation company, with two generations shown (left to right): Gerald McNelis, Anthony L. Maglio and Anthony J. Maglio Jr.

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.


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