Maple Leaf Foods’ renaissance Also Inside THE 2011 DELI REPORT Our annual look at trends in the industry
COOKING / CHILLING SYSTEMS A special pull-out supplement Vol. 225 • Issue 7 • July 2011
PICTURED: Steve Dowbiggin (left to right), Sharon K.K. Beals and Randy Huffman, Maple Leaf Foods
CUTTING OUR COMPETITION We reached a milestone in clip technology! The FCA 160 offers unrivalled versatility in an automatic clipper. The automatic self-monitoring process combined with RFID technology help avoid incorrect machine settings and ensure maximum productivity. Standard centralized lubrication is included for maximum reliability and service life.
FCA 160
38 – 160mm caliber range at speeds up to 160 cycles per minute. Poly-clip System 1000 Tower Road, Mundelein, IL 60060 • Phone (847) 949-2800 • Fax (847) 949-2815 Email:
[email protected] • 1-800-usa-clip (800)872-2547 Visit our website: www.polyclip.com
ing Chill ing / k o o C tems Sys
» 2011 JULY
SPECIAL SUPPLEMENT
Cooking / Chilling Systems
22
COVER STORY
Cook-in-bag technology is quickly gaining popularity for its contamination elimination.
Food safety renaissance Maple Leaf Foods’ commitment to ensuring safe products has become the bedrock of its business.
SPECIAL REPORT
2011 Deli Report
12 | Fight for Food Safety: Wash your hands of foodborne illness outbreaks 10 | Regulations & Legislation: Healthy People 2010 goal met on E. coli
Visit the new ProvisionerOnline.com
32 | Economical and healthy options spurring sales
Departments Editor’s Journal ............ 8 New Products ................ 16 Tech Showcase.................52 Classifieds ........................58 Ad Index...........................66
Business Strategies Podcast! Charlie Arnot tells processors how to build and develop consumer trust in our newest podcast. 4
Read Us Online The National Provisioner is online in an easy-to-navigate, easy-to-read digital format at www.ProvisionerOnline.com.
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Contact Us PHONE (847) 405-4000 FAX
(847) 405-4100
MAIL
155 N. PÀngsten Suite 205 DeerÀeld, IL 60015
“After months of research, we decided only Reiser would supply the ideal packaging machine.” “At Ideal Meat, we supply the food service industry and broadline distributors with high-quality products. We needed a new form/fill/seal packaging machine for our expanding line – a significant expense for our company. We couldn’t afford to buy the wrong packaging machine, so we researched all the manufacturers. We chose the Repak RE20 from Reiser because of the value it represented to us. The machine meets all of our needs, from flexibility and seal integrity to machine design and ease of sanitation. It allows us to easily produce both vacuum and gas flush packages for a variety of products and package sizes. Plus, Reiser’s local service and support can’t be beat. Working together, Reiser and Ideal Meat produced the ideal solution.” Larry Vad, President, Ideal Meat & Provisions
Larry Vad President
Joe Azzaro General Manager
David Villarreal VP of Operations
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.
July 2011
Tech
Volume 225 Issue 7
Editorial Board
eb
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
FOOD SAFETY |44
Traceability
John E. Johnson
How federal traceability legislation may impact the food supply chain.
JBS
Huston Keith Keymark Associates
CONTRIBUTING THIS MONTH INGREDIENTS & FORMULATION
PROCESSING TECH
PACKAGING TECH
Lynn Knipe
40 | When adopting
42 | Form/fill/seal tech-
Ohio State University
18 | Donna Berry
forming technology, processors need to consider the impact it will have on their operations.
nology offers processors options for packaging their products while taking advantage of industry trends.
discusses tingredients that assist in keeping food, and consumers, safe.
Gary McMurray Georgia Tech Research Institute
Mark Reed Border Management Strategies
THE NATIONAL PROVISIONER (ISSN 0027-996X) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: THE NATIONAL PROVISIONER, P.O. Box 1080, Skokie, IL 60076. CANADA POST: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. CHANGE OF ADDRESS: Send old address label along with new address to THE NATIONAL PROVISIONER, P.O. Box 1080, Skokie, IL 60076. FOR SINGLE COPIES OR BACK ISSUES: contact Ann Kalb at (248) 244-6499 or
[email protected]
6
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Steve Valesko Butterball LLC
Kurt Vogel University of Wisconsin - River Falls
(*( ()*$#*)
$)* ' (* )&%* * "&%)#* #) &)($&"" "'&)(!*& '%!*)(* ' "! $# &* "'&"* "(&!( * $%* ''!* '(##$%* &%! '$))(!*)'*' * &%* '* )(* ' "!#* "(&!$% &%!#* ("* '%* #* !&$"* )'* (()* ( &)$% #)&%!& !#* (* $%(#)* $%* )(* "&)(#)* &"$) # &%(* #&%$)&)$'%* &!$)$%* &%!* ''! #&()* )(%'"'$(#* )'* $(* '* )( '%$!(%(*
)&)
)'*)(*""(#)*( )(%)*'##$"(
$#'( *&""*)&)**&%*!'*' *'
**************************************
''
' &*""$%'$#
Editor’sJournal
Only a matter of trust
I
t seems that the word of the month around The National Provisioner, as well as around my own business travels, is “trust.” Our cover story this month tells the story of Maple Leaf Foods’ threeyear rebound and internal renaissance in the realm of food safety — a transformation the company had to make in order to eventually restore Canadian consumer trust in their brands after the deadly August 2008 listeriosis outbreak that was linked to their products. Maple Leaf, in my opinion, handled the situation correctly from the start — with president and CEO Michael McCain announcing that the company would accept responsibility for the tragedy, commit to changing their approach accordingly and then keep the public informed as to how they were preventing tragedy from occurring again. On ProvisionerOnline.com, we just posted a new episode in our Business Strategies series by Charlie Arnot, CEO of the Center for Food Integrity and president of CMA, titled, “Building and protecting your most valuable asset: Trust.” Furthermore, Arnot and Janet Riley, senior vice president, Public Affairs and Member Services for AMI, presented sessions on building consumer trust and consumer perception, respectively, at the American Meat Science Association’s (AMSA) Reciprocal Meat Conference at Kansas State University in Manhattan, Kan., this past month. We in the media are no strangers to the importance of trust — however, in trade publishing, we’re not trying to build trust among the general public. In order to bring the best information, analysis and news to the protein-processing industry and other interested parties, it is up to our editors to earn the trust and respect of processors, academics, suppliers, consultants, etc. Our goals may be different than those of the meat industry — but the vehicles by which we earn that trust are not all that dissimilar. We strive to be honest, fair, straightforward and, most importantly, great listeners and learners. Protein processors need to do the same with their consumers. Engage them, but then listen and learn from them what they want in their products, what they want from you and how you can get that to them in a satisfactory way. The more you do that, the more trust you build — and the more trust you earn, the more loyal those individuals become. Maple Leaf Foods had to work hard to restore its image, but in the three short years after the outbreak, the company has seen support from consumers build over time, as those consumers slowly regain their trust in Maple Leaf’s efforts to keep them safe. Would your consumers have been as trusting in the event of a similar tragedy? As loyal? If not, it’s time to begin building that foundation.
ANDY HANACEK
[email protected]
8
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Our
Family
of Products 2011 Sourcebook e for Processors A Buyer’s Guid
ALSO INSIDE Separators ng Interleaving/Stacki
Rapid Testing y Mixing Technolog
H24+.FNEE 1.TFFI 557' THE FORMULA
FOR THE PERFECT
BURGER.
Independent Processor A supplement to The National Provisioner, publishing every two months.
Provisioner Prime Weekly eNewsletter
provisioneronline.com The industry’s only BPA-audited website offers a digital edition as well as updated industry news that you can read anywhere.
Twitter Follow us at www.twitter.com/ natprovisioner.
Facebook Check out our Facebook page at www.facebook.com/ NationalProvisioner.
There are times when cheap, immitation parts just won’t cut it.
Genuine Busch replacement parts are often imitated, but never duplicated. For example, consider the exhaust filters in our R 5 series vacuum pumps. Busch exhaust filters are engineered to help optimize pump performance, efficiency and operation, and are developed specifically for separation of the oil mist from the exhaust air for oil-lubricated rotary vane vacuum pumps. In addition, the proprietary filter media we use is not affected by water or water vapor that is common to most food packaging and processing applications. Most importantly, each and every filter we supply is 100% performance tested to ensure that the filter you purchase is both fit for operation and provides the longest service life possible. Can the cheap, knock-off suppliers say the same thing?
For more on the benefits of genuine Busch parts, visit our website and search “genuine.” Expect the best when you specify Busch.
1-800-USA-PUMP
www.buschusa.com
www.ProvisionerOnline.com Publisher/Midwest Sales > Dave Lurie
[email protected] • (248) 593-0337
editorial
Editor-In-Chief > Andy Hanacek
[email protected] Editor > Sam Gazdziak This month’s contributors > Donna Berry, Elizabeth Fuhrman, Dennis Johnson, Derek Rickard, Shawn Stevens Art Director > Mary Ann Lawrence
print, event & web marketing Sales (Southeast/East Coast) > Rick Parsons
[email protected] • (407) 302-7952 Sales (Great Plains/West Coast) > Wayne Wiggins
[email protected] • (415) 387-7784 Sales (Business Development) > Vito Laudati
[email protected] • (630) 962-0094 Advertising/Production Manager > Brian Biddle
[email protected] • (847) 405-4104 ClassiÄed Sales > Diana Rotman
[email protected] • (847) 405-4116
MeatProcessingXchange event Nick Sattler
[email protected] • (952) 224-8541 Fax - (952) 736-9362
Food Safety Summit
Emily Patten
[email protected] • (847) 405-4030
reprints
Jill L. DeVries
[email protected] • (248) 244-1726
custom media
Christopher Wilson
[email protected] • (248) 244-8264
audience development Audience Development Coordinator Teresa Owens •
[email protected] Corporate FulÄllment Manager Alison Illes Audience Audit Coordinator Carolyn M. Alexander
For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected] www.provisioneronline.com
list rental For postal information: Contact Rob Liska at 800-223-2194 x726
[email protected] For email information: Contact Shawn Kingston at 800-409-4443 x828
[email protected]
BNP Corporate Directors
Co-CEO Taggart E. Henderson Harper T. Henderson Mitchell L. Henderson Publishing Timothy A. Fausch Publishing John R. Schrei Corporate Strategy Rita M. Foumia Information Technology Scott Kesler Production Vincent M. Miconi Finance Lisa L. Paulus Creative Michael T. Powell Marketing Holly Banks Directories Nikki Smith Human Resources Marlene J. Witthoft Clear Seas Research Beth A. Surowiec Events & Conferences Emily Patten BNP Media Helps People Succeed in Business with Superior Information
10
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
)*)"#)(*$%*(
$(*'#)*(& * *!& (%*%(#&()$"&!!*!'"&() ' *()*'#!* $%*&*!'&! !)&)#* $ * ''* #'")%%$ * & * "'$(()* (' )$ *'#* )) ('*&)*&* )*#'"(*"' ")(*&*#)&!$(** &%* ()* %!* "&$ * & * ''* #'")%%$ %%()%* $ * !&")* ('* (&)* '#* $)&%* #' "' ")(*('*()*)(!&")** (**)*)!$) ) (&(* $%*&(*%)(%*%*&(*$%*"'!!&'#&($' *"#)&()% )"$($ *%$ )%%*%'!($' %*
$%"' )#*&!!*(&(**"& *'*'#*'
**************************************#'"'
#'#&*!!$ '
%$ Regulations&Legislation
We did it By Dennis Johnson
L
ike the proverbial lineman whose number is only called when he commits a penalty, industry seldom gets any accolades for its efforts to produce safe food. Last month, industry finally got some recognition for its efforts to control E. coli O157:H7. CDC issued its final Healthy People 2010 Report. The goal of Healthy People 2010 was to reduce by 50% the incidence of foodborne illnesses caused by certain pathogens. This was only met for one pathogen, E. coli O157:H7. The 2010 goal was met overall, and in 2004, 2009 and 2010. CDC included industry efforts as contributing factors in this reduction: “cleaner slaughter methods, microbial testing and better inspections in ground-beef processing plants.”
The entire report is at: http://1.usa.gov/mTqovy. So to each and every person in the beef industry, I wish to extend my sincere congratulations and thanks. It truly took a team effort to have achieved this reduction on a raw product. Now it seems we must prove ourselves all over again. CDC set the Healthy People 2020 goal for E. coli O157:H7 at 0.6 illnesses per 100,000 — 40% less than the 2010 goal of 1.0 illnesses. In addition, CDC flagged Salmonella as a pathogen of special concern: “Less progress has been made with most other infections, especially Salmonella.” The question is, how do we achieve a 40% reduction in E. coli O157:H7 and reduce Salmonella? There are a few low-hanging fruits. Q Some gains can be made through improved implementation (one emerging “technology” is videomonitoring systems at slaughter to improve employee line performance). Q More (if not all) slaughter establishments conducting 100% testing using a robust sampling/laboratory method to provide feedback for the system. A true N-60 is still the gold standard. Q Aggressive “event” policies to deal with those infrequent situations when the incoming load exceeds the capability of the system or when there is a system failure. All that said, to meet the Healthy People 2020 goals, we need to focus on the live side. We have to minimize the presence of E. coli O157:H7 and Salmonella on the animals that come to the slaughter plant. That is going to require more stakeholders than simply FSIS and the beef-slaughter/processing industry. Ranchers, veterinar-
12
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
ians, FDA, ARS, APHIS and who knows who else has to be involved. Other industries need to be engaged as well. Neither of these pathogens is limited to beef. It will not be easy, but if we don’t start now, it will be hard to achieve the goal we need to meet in 2020. Dennis R. Johnson is a principal with Olsson Frank Weeda Terman Bode Matz PC in Washington, D.C. Johnson has 30 years experience in food-safety law and regulation, representing large and small meat and poultry companies.
FightforFood Safety
Wash your hands of foodborne illness outbreaks By Shawn K. Stevens
E
scherichia coli comes in many different forms — far too many, in fact, to list here. Most are completely harmless. E. coli occurs naturally in human beings and is known to aid our digestive system. The most dangerous strains, those that cause the well-known symptomatology (including bloody diarrhea and kidney failure) in humans, produce Shiga toxins. These are referred to as Enterohemorrhagic Escherichia Coli (EHECs). The recent, devastating outbreak of a virulent strain of E. coli O104:H4 (STEC O104:H4) in Europe has resulted in widespread fear and unfounded accusations against an assortment of food product manufacturers. At the time of this writing, the outbreak had sickened more than 3,000 people and was one of the worst foodborne illness outbreaks in history. It has been learned, however, that the Hamburg strain most likely resulted from a genetic recombination of two distinct types of E. coli (one of which only occurs in humans). This recombination (or mutation) resulted in a highly pathogenic strain never before seen. In turn, the most likely source was an ill employee at a facility in Germany where sprouts were produced. While this can be viewed, in many ways, as a frightening development, it is, in some sense, good news. It means that food companies can take immediate measures at the processing level to avoid such an outbreak from originating from their own establishments. Ultimately, the emergence of this new pathogenic strain demonstrates the need to be constantly vigilant for the curveballs Mother Nature may throw when we least expect it. The recent industry-wide decrease in foodborne illnesses generally remains is a great testament to the work industry has done. But we can never let our guard down. The Hamburg Outbreak should serve as notice for all companies to re-evaluate their sanitation measures. This sort of disaster can be avoided — or at least substantially mitigated — by refining and enforcing stricter sanitation standards.
14
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Indeed, STEC O104:H4 is not the first outbreak associated with human-to-product transmission. In fact, many foodborne illnesses are caused by human contamination. This is perhaps most common in homes and restaurants, but it can also occur in processing facilities. Increasing the number of hand-washing stations is a simple and relatively inexpensive way to immediately decrease the likelihood of human-to-product illness transmission. We live in a microbe-rich world, and unfortunately, the food industry is the place where humans and pathogens are most likely to come into contact. Maintaining effective sanitation practices is not only relatively straightforward and simple, but also the best way to avoid getting your hands dirty with outbreaks and recalls. 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.
THOUGHT-LEADER WEBINAR SERIES: PRESENTED BY:
www.hixson-inc.com
Anticipating the Next Generation Thursday, September 29, 2011 2:00-3:00 p.m. EDT Exclusively for thought-leaders in food and beverage processing facility management, Food Plant of the Future webinars are presented by Hixson, a leading design and engineering firm of food processing facilities in North America. Anticipating the Next Generation continues the dialogue about issues and advancements that will define how tomorrow’s food plants are built and operated. Can’t attend live? Register and watch anytime.
Register for free at webinars.provisioneronline.com
NewProducts Tyson Fresh Meats launches vacuum-packed, pre-seasoned beef line The new Backyard Flavors™ line of vacuum-packaged, pre-seasoned beef products features ready-to-cook beef sirloin tri-tips that offer a “just off the grill” taste for casual at-home dining in three Áavor varieties: Steakhouse, Peppercorn and Santa Maria Seasoning. The new line is being launched by Tyson Fresh Meats Inc., the beef and pork business unit of Tyson Foods. In addition to easy preparation and multiple Áavor options, Backyard Flavors gives consumers the beneÀt of leakproof and clear packaging, which also includes basic cooking instructions and a cutting guide to give consumers the best eating experience possible. Backyard Flavors products are part of the company’s ibp Trusted Excellence® Specialty Cut Meats program, which specializes in creating beef and pork products to meet diverse customer needs. www.tysonfoods.com
16
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Saffron Road offers antibioticfree frozen foods at Whole Foods Saffron Road™, the packaged food brand of American Halal Co., recently began shipping eight additional All Natural, Antibiotic-Free, Hormone-Free, Halal CertiÀed frozen foods to Whole Foods Market stores nationally. The eight new products slated for distribution include entrees: Lemongrass Basil Chicken, Moroccan Lamb Stew, Lamb Koftis and Chicken Pad Thai, as well as frozen chicken options: Chicken Nuggets, Chicken Bites, Chicken Tenders and Tandoori Seasoned Chicken Nuggets. These new, convenient meal options are ideal for shoppers looking for products CertiÀed Humane®, Halal, All Natural, 100 percent vegetarian fed and raised without antibiotics. The new products are certiÀed gluten-free as well. www.saffronroadfood.com
King’s Command introduces CAB sliders, meatball platter King’s Command Foods, of Kent, Wash., aims to help retailers deliver take-home convenience with new meatball party platters and meatloaf sliders on pretzel buns. Made with the known quality of the CertiÀed Angus Beef® (CAB) brand, the premium products are made with CAB chucks and blended with onions, green peppers and breadcrumbs for homemade Áavor and texture. Ten strict standards ensure the brand is a cut above USDA Prime, Choice and Select. No MSG, binders or Àllers are used. The precooked meatballs are available in a 2.75-lb. (44 oz.) microwavable tray. Each tray includes two 16-oz. packages of half-ounce CAB meatballs and both Sweet Chili (6 oz.) and BBQ (6 oz.) sauce packets. The meatloaf slider on a pretzel bun are frozen for optimum stocking ease and come 80 sandwiches per case. www.kingscommand.com
West Liberty Foods adds peel-andreseal option for private label West Liberty Foods is pleased to announce the introduction of its Peel & Reseal packaging system for their private-label customers. This consumerfriendly packaging option can be opened and closed multiple times while maintaining its seal, and uses 33.7% less plastic than the leading grocery retail tray package and tubs. It will be available in a rectangle conÀguration with or without hang tab for Áuffed deli meats or individually quick-frozen products. It will also be available in D-shaped conÀgurations allowing for easy removal of meat slices without tearing. Packages can hold from 7 to 16 ounces of product including turkey, chicken, ham, roast beef, breakfast sausage, chicken strips and beef strips. The packaging can accommodate four-color print labeling in either horizontal or vertical orientation, providing retailers with an unmatched brand impact opportunity. www.wlfoods.com
Quickdraft knocks problems out of the park! Like a powerful cleanup hitter, Quickdraft Engineered Solutions and Venturi Technology come through for you, blowing both exhaust and conveying problems out of your plant.
Venturi V enturii Powered P d Solutions: S l i Increase Incr In c ea cr ease se Productivity Pro rodu duct ctiiv ivity ivit itty an and nd Reduce Redu Re duce ce Maintenance Mai aint nten enan nce e for Both Exhaust and Conveying Systems.
Exhaust
Conveying
0 hhKdQ in Air Stream
0`mhAhh9IA 0hhdKA
0 NK`KdAhhIhm Grease Buildup
855-VENTURI
(330) 477-4574
[email protected] quickdraft.com
1h1]mh0Amq[B7kk0AQ0hhYgkk 1hh1Amh0hqk[O7kk0YK1Qh0hhYgkL
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
17
Ingredients&Formulations
Do your part to ensure safety By Donna Berry
t’s that time of year when consumers typically experience increased media attention to food safety, as most foodborne pathogens grow fastest at summertime temperatures and high humidity. Further, improper outdoor cooking practices, such as undercooking of meat, exposing raw meat to the elements and crosscontamination, increase the likelihood that harmful microorganisms will proliferate. Indeed, given the right circumstances, harmful bacteria can quickly multiply in food, going undetected by the human eye. Consuming large numbers of these microorganisms can result in food poisoning, and depending upon the severity, the malady can be fatal.
I
According to the 1,000 American adults surveyed during a two and a halfweek period in March and April for the 2011 Food & Health Survey: Consumer Attitudes Toward Food Safety, Nutrition & Health, consumers recognize that food safety is a shared responsibility among all parties involved in the supply chain, from farm to table. However, according to the survey, which was commissioned by the International Food Information Council (IFIC) Foundation,Washington, D.C., twothirds (67%) of those surveyed believe that food manufacturers are responsible for ensuring that their products are safe. This can be quite challenging for animal protein manufacturers, as many of the traditional ingredients associated with providing an extra safety net do not complement today’s trend towards allnatural and clean labeling. A good example is the use of nitrites in many sausages. Nitrites not only contribute flavor and color, but also prevent the growth of Clostridium botulinum. However, nitrites are perceived by many consumers as negative. In fact, national retailer Whole Foods Market has nitrites on its list of unacceptable ingredients. The pathogen that is likely the greatest concern for ready-to-eat animal-protein
18
manufacturers is Listeria monocytogenes, which, if consumed, can cause the human illness listeriosis. In fact, according to a risk assessment of Listeria carried out by federal agencies less than a decade ago, deli meats were identified as a very high risk food. This is because even though cooking kills Listeria, many processed meat
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
products — in particular those sold cut-to-order in the deli department — are susceptible to contamination, as Listeria is present everywhere. Every time a loaf of luncheon meat is sliced and wrapped, it is exposed to the elements and can become contaminated without the proper foodsafety measures in place. Unlike most other pathogens, Listeria multiplies at refrigeration temperatures, and invisibly, until it is too late. The good news is that protein processors can choose from an array of ingredients to assist in ensuring safety. Many recent introductions complement the clean and green trend that today’s labelreading consumer prefers. Many of these ingredients focus on reducing the pH of meat, as an acidic environment prevents the growth of many microorganisms. For example, this past April, at the American Meat Institute (AMI) Expo in Chicago, one company showcased a new concept for U.S. fermented meat manufacturers: lactic acid in powdered form. Fermentation is one of the oldest forms of food preservation used to ensure safety and shelf life. Until now, manufacturers of sausage, jerky and other fermented meats either used traditional fermentation with
Balance food safety and shelf life with clean labels
Meat manufacturers are under increasing pressure to deliver safe products while satisfying consumers’ desires for foods that taste great, have improved shelf life and label-friendly ingredients. The PuraQ® Verdad family of ingredients fights pathogenic and spoilage organisms in a wide variety of meat and poultry products ensuring shelf life and safety while maintaining the clean label sought by consumers. Purac is your proven partner, developing innovative products and providing technical support for almost 80 years. For more information, please visit www.purac.com/meatandpoultry. Purac, 111 Barclay Boulevard, Ste. 100 • Lincolnshire, IL 60069 • 888 899 8014
Ingredients&Formulations lactic acid bacteria or coated citric acid powder. Of course, bacterial fermentation is the most natural process, but can also be very lengthy, tedious and inconsistent. Coated citric acid does the job, but sometimes product quality suffers because of the taste of citric acid and the coating. Further, the encapsulating agent, which is often palm oil, must be declared on the ingredient statement and contributes unnecessary solids to the product formulation. Lactic acid is naturally a liquid, but a proprietary process produces a powder. Once added to the formulation, the powdered form releases acid slowly, in a manner equivalent to a traditional bacterial fermentation process. This inhibits spoilage and pathogenic microbial growth, thus contributing to the safety of the meat, as well as flavor and tactile attributes. It does all this while being declared on ingredient legends as lactic acid. Another supplier introduced a concentrated, dry vinegar product that can be added to seasoning blends for application
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.
in fresh and cured meat products. Application flexibility allows use in brines for injection, surface application and direct addition. It is declared on ingredient legends as simply “dried vinegar,” and at levels as low as 0.8% has been shown to inhibit the growth of Listeria. Applications range from fresh marinated chicken breasts to pork loin chops and beef hot dogs to cured ham. A third supplier showcased an array of protective ingredients. For example, a lauric arginate-based surface treatment not only can destroy Listeria, but is also effective against Salmonella enterica and E. coli O157:H7, two other common pathogenic microorganisms.
When used on the surface of raw meat, the ingredient functions by acting on the cytoplasmic membrane of the pathogens, disrupting the metabolic process. In this application it is considered a processing aid and does not require declaration on the ingredient statement. A derivative of naturally occurring substances, when used in some cooked meats, it is simply labeled lauric alginate. The same company has also developed a line of antimicrobials based on corn or cane sugar that have been fermented by specific cultures. The ingredients inhibit a wide range of pathogens and have application in fresh, enhanced meat and poultry, fresh sausages, and cured and uncured processed meats and hot dogs. Ingredient declaration is often something as simple as “cultured sugar and vinegar.” These are just some of the options available to protein manufacturers to do their part in food safety … after all, at least two-thirds of the country is counting on you!
Automatic Vacuum Packaging Equipment
Purchase Factory Direct! Simple and reliable machines that offer the lowest cost of ownership in h/f/f/s packaging. Tremendous Values & Quick Delivery Model No. RA200 RI200 RZ200
Length 111⁄ 2 ft. 16 ft. 18 ft.
Description Starter Machine Standard Machine Zipper Machine
*1 year or 1 million cycle warranty on all machines
888-314-2152 Made in the USA
1728 N. Topping Avenue • Kansas City, MO 64120 816-455-8055 • Fax 816-455-8469
Stainless Steel Trucks & Screens
Beacon Can Customize Its Standard Designs For Your Processing Needs.
You can trust a Beacon expert to design a unit that will provide the maximum amount of efficiency at the lowest possible cost. Our Trucks & Screens are built to hold your weight requirements. We don’t over design resulting in added costs or under design resulting in a unit that will not last or hold the weight load needed. Call us with your dimensions and Beacon will engineer Trucks & Screens that fit your requirements.
Stainless Steel Trucks • Nesting Trucks • Cages, Racks & Trees • Bacon Trucks & Trees • Rib Racks • Four Post Designs Stainless Steel Screens • Mesh Screens • Wires One-Way Jerky Screens • V-Screens • Rib Screens
For more information visit our web site at: www.beaconmetals.com or call toll free 800-445-4203.
CoverStory
Steve Dowbiggin (left to right), senior vice president of manufacturing; Sharon K.K. Beals, senior vice president of food safety & quality assurance; and Randy Huffman, chief food safety ofÀcer, Maple Leaf Foods.
22
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Food safety
renaissance Nearly three years after Maple Leaf Foods began to overhaul its food-safety culture, the company’s commitment to ensuring safe products has become the bedrock of its business. By Andy Hanacek, editor-in-chief Photos by Brian Summers, Summers Photography
I
n world history, the Renaissance was a cultural revolution that brought the human race out of the Middle or Dark Ages via enlightenment of the arts, religion, politics and science. The Renaissance brought humanity into the Modern Age and was a true transformation of the way of life. In the modern business world, three centuries is a bit much to ask — three years, however, is a more realistic timeframe, during which a company might undergo a total transformation — a period of enlightenment that takes that company to the next level. For Toronto-based Maple Leaf Foods, Canada’s largest protein processor, the past three years have brought just that — a renaissance of increased awareness, self-improvement and forward-thinking around food safety that has brought the company back from its own dark days of late 2008, when a listeriosis outbreak that killed 23 people and sickened others in Canada was traced back to its product.
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
23
CoverStory Restoring trust The 2008 listeriosis outbreak put Maple Leaf Foods squarely in the crosshairs of consumers, who demanded that the company prove itself as a producer of safe, wholesome foods once again — even as Maple Leaf took accountability for its role in the tragedy. Company president and CEO Michael McCain has been very visible and very open about Maple Leaf Foods’ role in re-establishing this trust, and Maple Leaf has communicated its goals openly with consumers — for example, creating a Food Safety section on its Web site, where visitors can read about the company’s commitment to food safety or ask Randy Huffman, chief food safety officer, a foodsafety question. One tenet of the Maple Leaf’s stated food-safety pledge reflects the mentality of the company: “We commit to building a strong culture of food safety, with high performance teams, through continuous training, education and communicating results. Our people are encouraged and expected to act on any food safety concern they may have to improve our food safety practices.” Even with this pledge now being front and center for consumers to view on the Web site, Huffman stresses that the outbreak didn’t change Maple Leaf’s core values. “These values had been in place [for more than a decade], and only had a slight rewording a couple years ago,” he says. “But essentially, the values are the same, and that served us well in responding to this issue.” Nor did the outbreak change the company’s thoughts about food safety. It always was a high priority — in fact, Huffman adds, it wasn’t the strategy or even the execution of the food-safety program that led to the recall and outbreak. “At that time, Maple Leaf had proactively designed a Listeria testing program that was based on what the company believed at the time to be best-practice,” he explains.“And in fact, they were using 24
During the brief minutes in which other employees are changing labels further down the line, a Maple Leaf Foods employee takes initiative to quickly clean the surfaces on one of the slicing/ packaging lines at the Bartor Road facility in Toronto, Ontario.
spreadsheets developed by the AMI Listeria workshop team to collect that data, so the data was being collected above and beyond the requirements. “It was a documented program that told them what to do when they got a positive,” Huffman continues,“and if the manufacturing leader asked if they’d followed the program, the answer would have been,‘Yes, we have the program and followed it.’” Steve Dowbiggin, senior vice president of manufacturing, says a lack of “data interrogation” was the primary cause of the incident. “The function of verification of the Listeria control program was very much a QA function, and the awareness or knowledge of the repercussions weren’t entrenched in the organization — in manufacturing specifically,” he says.“We had a protocol we felt we were doing right,
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
but … were we asking the third and fourth questions? Not having deep enrichment understanding of what we were really seeing was an issue.” Once the awareness and understanding was present, the food-safety renaissance at Maple Leaf Foods unfolded. “We are an organization that, once we become aware of something, we are great ralliers around it,” Dowbiggin says.“The understanding of what we’re measuring from top to bottom is where the journey has started, and we’ve gotten it to where employees are super-engaged in it.”
Creating a foundation of understanding Motivating Maple Leaf Foods employees to embrace the new level of foodsafety understanding is not a difficult task, says Huffman. “Every one of our customers knows
THE FORMULA FOR THE PERFECT BURGER.
Some things just add up perfectly. To craft the perfect burger you need the superior grinding and mixing of Weiler®, the efficient separating of Beehive® and the precise portion control of Formax® Forming. Each is part of the Provisur® family of superior food processing brands, with industry-leading solutions and uncompromising productivity. They deliver the highest standards in performance and the lowest cost of ownership. Weiler,® Beehive® and Formax.® They’re not just the formula for a perfect burger, but your formula for a successful production line.
To learn how the Provisur® family delivers breakthrough line performance and efficiency,
visit perfectburgerformula.com. Nothing stacks up to the perfect formula of Weiler®, Beehive® and Formax®.
USA: 9150 191st Street, Mokena, IL 60448 708-479-3500 E-mail:
[email protected] ©2011 Provisur® Technologies, Inc.
BEEHIVE®
CASHIN®
FORMAX®
WEILER®
THE PROVISUR® FAMILY OF PROVEN BRANDS
CoverStory about [the outbreak], so the awareness is extremely high,” he says.“We live with it every day — that’s the one thing that motivates us every day, and there’s not really anything else.” Dowbiggin agrees passionately with Huffman’s assessment of the motivating factors involved in the transformation of the mentality at Maple Leaf Foods. “We are very overt to ourselves that we killed 23 people,” Dowbiggin explains. “We took personal accountability for that, and it’s tough, but our people are engaged in solving that, and not letting it happen again.” One way in which employees are engaged are the Food Safety Foundations courses that Maple Leaf Foods hosts in conjunction with the University of Guelph — an education and training program that creates a common language around food safety within the organization. “At the heart of it, it’s people and culture, and having these values to lean on as
26
Sharon K.K. Beals (left), senior vice president of food safety & quality assurance for Maple Leaf Foods, and Kelly Cresswell (right), plant manager at the Courtneypark facility, discuss with Andy Hanacek, editor-in-chief of The National Provisioner, the different production capabilities the Courtneypark facility features.
an organization, as well as having the support to do what we want to do,” Huffman says.“Everybody understands the values, they live by them and support everything related to food safety in my mind.”
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
With the support of McCain, whom Huffman calls “unique” among top executives in terms of his food-safety knowledge, Maple Leaf Foods uses the Food Safety Foundations to reinforce the values
and help all understand and become engaged in the food-safety processes and the ramifications of being lax in committing to food safety. Huffman relays that the company has more than 600 senior leaders at the company — from all departments and all facilities — who have participated or will participate in the three-day Foundations course.The course powerfully reminds employees of Maple Leaf’s own incident, and then proceeds to walk them through risk-assessment, risk-management, and risk-communication.The course uses reallife case-studies with Maple Leaf products to communicate the systems, protocols and verification-testing that the company uses. Senior leaders who attend the Foundations course return to their facilities and are expected to host their own course for their local salaried staff members. Finally, Huffman says, Maple Leaf plans to train hourly employees via Alchemy’s SISTEM training program. Training of new hires and re-training/ refresher courses are expected to keep the courses active in the future.
Rallying the troops When Dowbiggin says Maple Leaf employees rally around an initiative, it stands to reason that buy-in would come quickly and easily for the senior management team. Sharon K.K. Beals, senior vice president of food safety & quality assurance, got a glimpse of the culture and buy-in during the job interview for her current position — stating that the human-resources department was very open and up front with her about the deadly 2008 outbreak. During The National Provisioner’s visit to Maple Leaf Foods’ Bartor Road and Courtneypark processing plants in early June 2011, employees were seen taking individual initiative in following sanitation protocols — for instance, line workers wiping down equipment surfaces during downtime, such as during label changeovers (see photo on page 24), or designated sanitation employees removing waste product from floors (as opposed to line workers). Huffman tells a story of when he realized that employees were absorbing the information and buying into the
food-safety program. A few years ago, Huffman toured one of Maple Leaf’s larger processing facilities, and while on the tour, he was curious about the ingredients in a high-moisture pepperoni product the facility was manufacturing. Huffman says he picked up a label from the stack at the back end of the packaging line, read the ingredients list and put the label back on the stack when his curiosity was satisfied. “Shortly thereafter, the woman who was loading the packaging machine tracked me down and basically read me the riot act, saying,‘You came into my product zone and did not follow the SOP.You took that label and then put it back on the stack with your bare hands,’” Huffman explains.“It was impressive that she actually took time out of her break to come find us on our tour, and [tell me] I shouldn’t have done that. “That’s when I realized,‘People are paying close attention to all this, and that’s really good.’” In Huffman’s view, getting buy-in is nothing groundbreaking at Maple Leaf — just another example of everyone at the company, from top to bottom, being involved. “It’s a team sport, as [Beals] has
said before, and that really is what has driven the change,” he says. “I don’t think anybody feels as though they’re on their own, and everybody’s pulling in the same direction. That’s made it successful.” Beals believes employees embraced the new approach based on town halltype visits by executive leadership to each facility. It showed commitment from the top down. “It was the fact that the mountain came to Mohammed, as opposed to us sitting here in the ivory tower,” she explains. “When the corporate guys take it out and really look for the input and feedback, it works.We had some really good insight from some of the folks in those town halls.” Moving forward, Dowbiggin concludes, Maple Leaf Foods expects its topto-bottom awareness and commitment to make it a global leader in food safety. He says it’s terrible that the company’s wakeup call had to come in the form of a deadly outbreak, but it’s a consequence that now carries tremendous weight within the walls of the organization. “[We’re] very aware of it. Every day. And people don’t want it to happen — ever again.”
Maple Leaf Foods employees hand-portion and fold the ingredients into Maple Leaf Foods Prime Chicken Scaloppini Folds products at the Courtneypark processing plant during The National Provisioner’s visit. JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
27
CoverStory
Safety steps
Employees at Maple Leaf Foods’ Bartor Road plant in Toronto, Ontario, transfer sliced product into packages on one of the slice lines.
28
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Although Maple Leaf Foods has always been committed to food safety, the deadly 2008 listeriosis outbreak traced back to some of its products forced the company to adopt more rigorous food-safety processes. Andy Hanacek, editor-in-chief of The National Provisioner, discussed some of the new processes and strategies with Steve Dowbiggin, senior vice president of manufacturing, Sharon K.K. Beals, senior vice president of food safety & quality assurance, and Randy Huffman, chief food safety officer, during his visit to Maple Leaf Foods in early June 2011.What follows are their comments on a few of those processes.
W H E N
I T
C O M E S
T O
increasing M A R I N AT I O N Y I E L DS, WE’D LIKE TO SHARE A FEW POINTS. With the smartest engineering in the industry, the Fomaco Injector not only provides the highest performance, it also raises marination yields to new highs. From its FM80 self-cleaning filter to its unique pump-to-pipe brine transport system to its individual stripper feet, every detail has been optimized to ensure injection accuracy and consistency. The result is a new level of product uniformity with unrivaled yields. Fomaco Injectors are available with 1, 2 or 3 needle bridges for all types of bone-in or boneless product.
The self-cleaning FM80 Filter is always clean, eliminating brine flow restrictions and pressure drops, as well as clogged needles and declining yields. At the end of the day, you’ll realize higher yields and a more consistent product.
Individual stripper feet conform to the shape of the product and hold it in position for accurate injection and improved product quality. Brine flows only when the stripper feet are in contact with the product. This allows uniform injection, even with irregular product or partially loaded belts.
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
A unique pump-to-pipe system ensures uniform brine flow and distribution to each needle. Constant pressure is maintained as the brine flows from the pump to the needles through pipes with continuously decreasing diameters. The system is rounded to eliminate particle traps. The design allows easy cleaning without elaborate, time-consuming disassembly found in manifold systems.
Leading the food industry in processing and packaging solutions.
CoverStory Steam-tenting Huffman: While we didn’t originate the idea — others had been talking about it and doing it — we put the documentation and rigor around how to do it well, in our plants, with our equipment. Frankly, that’s the big contribution we’ve made [to food safety as a non-competitive issue], because others have wanted to borrow that documentation. One of Maple Leaf Foods’ lines at the Bartor Road facility in Toronto, Ontario, pumps out a natural sliced lunchmeat product during The National Provisioner’s tour of the plant.
Beals: It encompasses not just the food-safety elements, but the workersafety elements as well. That is critical, given the use of the steam. Our lessonslearned document is in place. Dowbiggin: We have plants on regular 30-day rotations to plants that do it more in a predictive fashion, in response to swabbing certain areas and being predictive. … We have a project specifically to confirm the predictability of our new methodology. … But if you have five or more slicers in the plant, you’re doing a minimum of one every week.
NY[mmeLmeZdaf_Aehjgn]k LYkl]NYdm]
D]egfH]hh]j :mll]j?Yjda[
D]egf:mll]j @glKha[q
AlYdaYf L]jaqYca
E]kimal] :YjZ][m]
;Ybmf :m^^YdgOaf_
0G976
0G976
0G976 0G976
7KH%LUR0DQXIDFWXULQJ&RPSDQ\ 0DUEOHKHDG2+86$ )D[
ZZZELURVDZFRP5% 30
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Beals:We also do spot-steaming, we have portable steamers to get to a hollowframed leg that you can’t get anything else to.We boil parts, we put forklifts in smokehouses. But that whole thing about wet heat, to make sure you get a good penetration and you get good kill, that’s what is key.
Deeper disassembly and rigorous environmental testing Dowbiggin: We have gone to the extreme on some machines — when we’ve not been able to get it clean from a numbers perspective — of disassembling it down to every bolt and bar taken apart. We believe there is a frame to a machine that we try to keep in one piece, but getting down to that point is critical to us. Huffman: Finding solutions on a line-by-line basis is really in the hands of the plant employees. They’re the ones who are going to solve the issues. Each individual finding that is generated through our environmental testing program stimulates a lot of activity at the plant level. … Once they identify a cause or learn something
new, it’s fed back through the entire network and to the other plants. Dowbiggin: During the initial stages [of the rigorous testing program], if plants couldn’t come up with a logical hypothesis that was reasonable, … they begged for forgiveness in the sense that they weren’t starting the line up.There were plenty of times where they’d come on the [companywide conference] call and say,‘We don’t know what it is, and because of that, the line’s not starting up.We’re either tearing it down further or continuing to investigate, and until we have a hypothesis we believe in, we’re not starting that line.’ … They’d keep tearing it down, even to nuts and bolts, and didn’t give up until they found the cause. But they had the support of the organization to do that.They had the authority and right to do it, and nobody pushed them. … Our values speak for themselves, and no matter where you are in the hierarchy, if you see something, you step forward and say something.
Conversion to Alternative 2 Huffman: We made the decision to convert all ready-to-eat products from Alternative 3 category status to Alternative 2. … Basically it’s like a belt-and-suspenders approach, in that we’ve got great sanitation programs and we have data to prove it, but in addition to that, we’ve taken a step to reduce the risk of outgrowth of Listeria if it happens to be there.We’ve done that through formulation changes, which was a major, major change. Dowbiggin: The only options available, freezing was not applicable, HPP was basically just coming on the market — it’s
only now that deli meats are getting exposed to that.We were trying to push the envelope for approvals for Listeria growth inhibitors then, but we weren’t making much progress. I don’t mean to blame the government, but we were not making great progress, and as soon as the recall event happened, they approved the use of growth inhibitors. Huffman: We had to reformulate the recipes for more than 1,300 SKUs. It was all hands on deck. Beals: We made a conscious effort that every ready-to-eat product would be Alternative 2 or better by the end of last year, and we made that goal. Huffman: It was a huge change effort, with a lot of work by our product-development and sales & marketing teams, as well as at every plant. And it was a big investment, both one-time and ongoing.
“I Stand Behind All Our Patty Paper and Interleaving Products.” Larry Czaszwicz Jr.
President/Owner
s 'REAT SELECTION
CUSTOM SIZES s /RDERS MATCHED TO YOUR NEEDS s ,OW MINIMUMS
s 7ORLD CLASS CUSTOMER SERVICE s v3UPERIORv '-0 CERTIlCATION
3224 Butler Avenue South Chicago Heights, IL 60411 0 F
[email protected] www.framarx.com
Interleaving the worlds of meat, poultry, dairy, baking, and specialty products
4OLL &REE #ALL TODAY AND EXPERIENCE THE Framarx/Waxstar DIFFERENCE
framarx ® waxstar ™
”Our goal is to astonish you with great service. Let me know how we’re doing.” - Larry
Interleaving The World
We’re proud to be part of your quality products
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
31
SpecialReport THE NATIONAL PROVISIONER’S
2011DELIREPORT
HOT
A
SPOT
Economical and healthy options, as well as product quality and taste, allow the supermarket deli to remain an attractive destination for shoppers. By Elizabeth Fuhrman Consumers’ enhanced appreciation for fresh foods and convenience at a reasonable value has kept supermarket delis a top destination for protein purchases. In 2010, deli meats recorded sales of around $4.5 billion in the food channel, excluding Walmart, reports the Perishables Group, Chicago. Last year, deli meat, including pre-sliced meats, posted dollar sales up 4 percent and volume that was relatively flat with a 0.4 percent increase, the research firm says. Pre-sliced meat grew 9 percent in both dollar sales and volume last year, which is where a substantial amount of the gains were derived, says Jonna Parker, Perishables Group’s account services director. In terms of pre-sliced meat versus bulk meat sales in the deli food channel, excluding Walmart, 88 percent of all dollars sold in 32
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Non-Sliced Lunchmeat, Top 20 Brands Rank Brand 1 Private Label 2 Boar’s Head 3 Oscar Mayer 4 Hebrew National 5 John Morrell 6 Jennie-O Turkey Store 7 Cloverdale 8 Higueral 9 Neese’s 10 Kahn’s 11 Jones 12 Bridgford 13 Usinger 14 Farmer John 15 Schweigert 16 Kretschmar 17 Hillshire Farm 18 Induveca 19 Klement’s 20 Jenkins Total Non-Sliced Lunchmeat Total Luncheon Meats Category
Dollar Sales $14,669,810 $10,346,010 $8,449,634 $8,339,841 $7,322,134 $6,676,006 $3,852,030 $3,723,039 $3,582,114 $3,472,503 $3,122,498 $3,010,979 $2,957,150 $2,768,588 $2,442,637 $2,394,851 $1,976,916 $1,876,003 $1,693,128 $1,591,916 $147,090,200 $3,577,847,000
% Chg YAgo 10.34 1.42 (2.70) (6.73) 12.58 59.23 (2.58) 6.85 3.22 (10.55) (1.38) (19.82) 4.24 (10.17) (2.45) 2.95 7.30 (1.09) (16.54) 12.58 2.24 3.34
Dollar Share 9.97 7.03 5.74 5.67 4.98 4.54 2.62 2.53 2.44 2.36 2.12 2.05 2.01 1.88 1.66 1.63 1.34 1.28 1.15 1.08 100.00
Unit Sales 4,283,763 1,588,658 2,826,046 1,459,007 2,476,073 1,115,669 596,088 481,067 1,581,042 1,082,808 1,196,211 706,565 604,608 1,364,124 886,004 803,572 455,153 281,654 483,111 928,842 38,320,290 1,238,914,000
% Chg YAgo 8.42 0.92 (5.84) (8.30) 7.74 48.96 (7.71) 3.09 (2.74) (13.26) (4.67) (18.96) (0.64) (8.12) (5.58) (1.56) 4.55 (0.77) (13.83) 13.11 (1.27) (1.12)
Avg Price Per Unit $3.42 $6.51 $2.99 $5.72 $2.96 $5.98 $6.46 $7.74 $2.27 $3.21 $2.61 $4.26 $4.89 $2.03 $2.76 $2.98 $4.34 $6.66 $3.50 $1.71 $3.84 $2.89
Sliced Lunchmeat, Top 20 Brands Rank 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Brand Oscar Mayer Private Label Oscar Mayer Deli Fresh Hillshire Farm Deli Select Land O’Frost Premium Bar-S Buddig Sara Lee Fresh Ideas Hormel Natural Choice Louis Rich Oscar Mayer Carolina Pride Land O’Frost DeliShaved Buddig Deli Cuts Foster Farms Butterball Hillshire Farm Deli Select 16 Hearty Slices 17 Eckrich 18 Oscar Mayer Carving Board 19 Plumrose 20 Healthy Ones Total Sliced Lunchmeat Total Luncheon Meats Category
Dollar Sales $673,495,400 $593,969,500 $436,450,000 $343,818,300 $130,697,900 $108,426,500 $69,432,850 $61,632,000 $57,935,870 $47,447,180 $43,696,350 $42,739,580 $42,685,240 $42,327,490 $41,579,780
% Chg YAgo (4.70) 6.37 12.36 7.66 16.11 0.85 (2.85) 2.91 22.43 (11.03) 1.47 6.90 (2.71) 1.52 (3.20)
Dollar Share 19.63 17.31 12.72 10.02 3.81 3.16 2.02 1.80 1.69 1.38 1.27 1.25 1.24 1.23 1.21
Unit Sales 209,595,500 223,841,200 119,954,600 93,813,260 32,151,330 59,791,700 73,367,430 11,996,410 18,438,500 17,010,070 33,318,160 17,131,270 14,310,290 13,814,180 14,528,700
% Chg YAgo (6.48) 0.29 8.37 0.48 11.61 (1.03) (2.81) 3.20 25.86 (11.20) (0.30) 4.22 (1.63) 1.28 (2.11)
Avg Price Per Unit $3.21 $2.65 $3.64 $3.66 $4.07 $1.81 $0.95 $5.14 $3.14 $2.79 $1.31 $2.49 $2.98 $3.06 $2.86
$38,200,080
(19.27)
1.11
10,441,210
(20.58)
$3.66
$31,397,050 $31,318,490 $28,996,890 $28,917,580 $3,430,757,000 $3,577,847,000
(0.07) N/A (0.06) (24.02) 3.39 3.34
0.92 0.91 0.85 0.84 100.00
17,012,010 7,998,114 9,834,797 10,658,320 1,200,593,000 1,238,914,000
1.70 N/A (1.44) (23.44) (1.11) (1.12)
$1.85 $3.92 $2.95 $2.71 $2.86 $2.89
Source: Infoscan Reviews, SymphonyIRI Group. Latest 52 Weeks Ending May 15, 2011. TOTAL U.S. - F/D/Mx (Supermarkets, Drugstores, and Mass Merchandise Outlets (excluding Walmart). EDITOR’S NOTE: The rankings of top brands are not totaled brand listings (e.g. all UPCs or brand extensions rolled up into a single Àgure, such as Total Crest Toothpaste), but are rather individual brand listings.
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
33
SpecialReport Deli Lunchmeat
Deli Prepared Foods
Top reasons given for purchasing deli lunchmeat
Top reasons given for purchasing deli-prepared foods
1
I buy it regularly
2
For lunch(es) at school or work
3
For easy meal at home
4
Was a good price
5
Had a craving for it
Ranked on percent of purchases Source: Port Washington, N.Y.-based NPD Group DeliTrack year ending December 2010
the deli come from bulk, the Perishables Group reports. Bulk meat’s dollar share is down slightly, 0.3 percent, which was gained by deli pre-sliced meat. Supermarket delis are gaining share of the food channel’s perishables sales, driven by deli prepared foods, the Perishables Group reports. In 2010, the supermarket deli led all fresh departments, including produce and bakery departments, in sales growth, increasing both dollar and volume sales by 4.5 percent. According to the research group’s Deli Department Drivers report, 94 percent of consumers purchased from supermarket delis last year and nearly one-third of those purchases contained multiple deli items. This rate of multiple purchases was higher than any other fresh department except produce, the Perishables Group says. Deli entrees and deli-prepared chicken both increased dollar and volume sales by double-digits, the research firm says. The report also attributes a portion of the supermarket deli’s success to the growing assortment that better meets the needs of a diverse consumer base. For example, new ethnic and spicy flavors drove gains in deli meat. In addition, the number of low-sodium deli meat items grew by 22 percent in the past year, catering to a more health-conscious demographic, Perishables Group says. Of the whole supermarket deli, meat holds about 26.5 percent of weekly sales and about 22.9 percent of adjusted gross profit, according to Barrington, 34
1 2 3 4 5 6
Hot For dinner that night For easy meal at home To eat right away I buy it regularly Didn’t want to cook Had a craving for it
Cold I buy it regularly Had a craving for it For easy meal at home For dinner that night To eat right away For lunch(es) at school or work
Ranked on percent of purchases Source: Port Washington, N.Y.-based NPD Group DeliTrack year ending December 2010
Ill.-based market research firm Willard Bishop’s Total Store SuperStudy data. By comparison, prepared foods represent about 31.8 percent of weekly deli sales and about 15.3 percent of adjusted gross profit. Through the deli, supermarkets are selling approximately $10,164 each week of meat and about $12,192 each week of prepared foods,Willard Bishop data shows. While supermarket deli lunchmeat grew by 2.1 percent between 2009 and 2010, it showed 6 percent gains between 2007 and 2010, indicating that consumers are willing to pay more for perceived higher quality and freshness even in an economic recession, according to Chicago-based Mintel International’s May 2011 Lunch Meat report. Mintel forecasts that the segment will post consistent annual growth between 2011 and 2015, with potential to push the segment past the $5 billion mark in 2015.
A fresh appeal The deli can help fulfill a number of people’s different dining needs.Yet, in the supermarket deli, turkey breast and ham are still the top two sellers and make up about one-third of deli sales, the Perishables Group reports. “In our market insights data, both ham and turkey have heavy penetration, and some shoppers might even switch in between ham and turkey depending what’s on sale,” Parker says.“It’s about flavor and about brand variety.” Following next in sales is beef, which
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
posted better numbers after years of decline, Parker says. While chicken is a small market compared to ham and turkey, the protein is growing in doubledigits, she says. International Dairy-Deli-Bakery Association (IDDBA) research has shown that shoppers find the deli appealing because they see it as fresh and convenient. Research in Mintel’s May 2011 Lunch Meat report, confirms consumers’ desires for freshness. More than two-thirds of respondents to Mintel’s consumer survey of people who eat lunchmeat indicate that deli counter lunchmeat is fresher and claim they can tell a difference in taste between deli counter and prepackaged lunchmeat. “It’s the freshness and the difference in taste that I think is what is attracting them,” says Carla Chastain, a senior food analyst at Mintel.“Additionally to that, about half of respondents are willing to pay more for a product that they consider premium.” On the whole, the deli has some very strong equities with consumers in terms of product quality and freshness. “The grab-and-go items, whether hot or cold, provide quick, convenient meal solutions,” says Worth Sparkman, manager of public relations at Tyson Foods Inc.“One benefit that a deli convenience meal has over, say, a visit to a quickservice restaurant, is that it becomes the centerpiece of a fill-in shopping trip where the shopper picks up other items that they need without making an ad-
ditional stop.” Customization also is essential for many shoppers, says Kari Lindell, director of retail marketing at Butterball LLC. “Consumers shop the deli for fresh, high-quality meat options that will be sliced upon ordering,” she explains. “Slicing at the point of ordering ensures meat is as fresh as possible, plus it enables customization of slice thickness based on the customer’s usage or preference. “Furthermore, the deli offers a vast variety of flavors,” she continues. “Again, this is a great way to customize meals to individuals in your family. Children tend to prefer mainstream flavors such as Oven Roasted or Honey, whereas adults may have a palette that seeks more intense flavors such as Cajun, Deep Fried Buffalo or Lemon Pepper — all of which are delicious for sandwiches or recipes.” The prepackaged deli case also offers consumers freshness and convenience with no standing in line, says Tom Lopez, director of marketing at Kraft Foods for Oscar Mayer. “In addition, it offers consumers variety in meats, flavors and package size,” he says. Overall, consumers continue to look for foods they like to eat and feel good about serving. Paula Shikany, director of Sara Lee Deli, says it’s important to deliver foods that provide a balance of quality, taste and nutrition, which adds to the appeal of the deli case. “Additionally, consumers consider sliced-to-order meats to be of the highest quality and freshest options available, which continues to drive its appeal,” she says.
Nearly two-thirds of consumers surveyed for IDDBA’s Consumers in the Deli 2010 research admit to monitoring their purchases more closely, and 65 percent are buying fewer items on impulse — down from 75 percent in 2009. Sixty-four percent of consumers said they’re paying extra attention to advertised prices, down from 73 percent in 2009. Sixty-three percent say they stick to a shopping list, and 54 percent are using coupons more often. Forty-five percent of consumers said they bought the same amount from their supermarket deli in 2010 compared to 2008, IDDBA’s report found. But the percentage who said they bought less has increased significantly since 2004 — from 23 percent to 34 percent, the association says. Delis are bridging the gap between dining out and dining in as time-strapped shoppers stay away from higher restaurant prices but still want high-quality, easy-to-assemble meals. Forty percent of shoppers said they eat sliced-to-order deli meats once or more a week, indicating that they’re packing more sand-
wiches for lunch to minimize food costs, according to IDDBA’s Consumers in the Deli 2010. In addition, the deli prepared food category’s share has grown to more than 50 percent in the last five years, while deli meat shares have gradually declined to around 24 percent, IDDBA says.Versatile rotisserie meats such as chicken have been flying out of the deli as part of the dining-in trend, the association says. These meats can be eaten as they are, as well as in leftovers, sandwiches, salads and soups — a benefit to time-stressed consumers. Pricing concerns in the deli are the same trends affecting purchasing of most food items in the store. “Everybody is concerned about the effects of food price inflation,” says Jim Hertel, managing partner at Willard Bishop. In turn, most shoppers are trading to the deli from other channels, he says. But in other efforts to save money, some consumers may trade down to purchasing deli items less frequently or trading to a store without a service deli.
Cost is key The biggest factor that would make shoppers purchase more from the deli is price, says Alan Hiebert, IDDBA’s education information specialist. “Price still trumps freshness, convenience and even taste,” he says. “A few deli shoppers would like to see more variety in the departments they shop, but it’s a significantly smaller group than the shoppers who’d like to see lower prices or more sales and specials.”
Tyson Foods Inc. JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
35
SpecialReport “Sharp retailers are going to be thinking in terms of highlighting what the value offerings are, maybe thinking about delivering equivalent quality and look for ways that they can save as a retailer and pass those savings on to shoppers,” Hertel says. “… The challenge that they are going to face over the rest of the year is what happens to costs, their costs, and how can they leverage the deli strengths in terms of maintaining shopper loyalty without making an incremental shopper investment. Managing costs and maintaining shopper loyalty in a very challenging economic environment is going to be the name of the game.” In 2010, deli suppliers were able to keep price increases relatively minor and flat for the majority of the year, especially in deli meat and cheese, the Perishables Group’s Parker says. But toward the end of last year and beginning of 2011, costs began to be passed along to the consumer. For example, deli bulk meat is up an average retail price of about 5 percent for the 52 weeks ending April 30, 2011, verses being flat in 2010, she says. “A lot of that increase is happening right here, now in the most recent weeks of 2011,” Parker says.“A lot of [it comes] in a lower percent discount when on promotion. We’re still seeing the same frequency of promotion, but we are seeing less of a discount being offered to that consumer.” Private-label deli meats, the largest portion of deli bulk meat sales nationally, are flat when it comes to pounds sold and up slightly in dollar sales for the year ending April 30, Perishables Group reports. “The average retail price on privatelabel deli meats is actually a little bit higher on average on a national perspective,” Parker says.“But what happened with private label over the last five years, even in the last three or so since the recession, is that retailers are coming out with a two-tiered or multi-tiered privatelabel pricing program in deli meat and deli cheese, so offering a premium-type, exclusive corporate brand product in addition to more of that generic-type product in private label.While there 36
is price increase and it’s a little more market in private label, some of that is still the switch to having a higher-quality private-label item.”
Healthier shoppers While no typical deli shopper exists, respondents to IDDBA surveys tend to be worried about their health and how their diets affect their health. “A majority of respondents said they or someone in their households were making serious efforts to decrease fat, calories, trans-fat, sugar, sodium or carbohydrates,” Hiebert says. From 21 to 29 percent of people who eat deli and prepackaged lunchmeat indicated, in a Mintel consumer survey, that they seek out some type of health claim for their meat purchases at least some of the time. About half of consumers surveyed agree that they have purchased in the past three months low-sodium or sodium-free deli and prepackaged lunchmeat all, most or some of the time. About 56 percent of consumers polled also agreed to selecting natural deli and prepackaged lunchmeat all, most or some of the time in the past three months. Nearly half of consumers also reported buying low-calorie deli and prepackaged lunchmeat all or most of the time in the past three months, Mintel says. Low-fat purchases also were popular with about 55 percent of consumers saying they select this option of deli and prepackaged lunchmeat all, most or some of the time in the past three
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
months. About 35 percent of respondents indicated purchasing American Heart Association endorsed deli and prepackaged lunchmeat all, most or some of the time in the past three months. “There’s a lot of talk right now about healthy eating,” Tyson’s Sparkman says. “Different areas of the deli are shopped by different consumer segments, and health claims are typically more important in the cold service case and the cold self-serve case.” The biggest trend the Perishables Group’s Parker sees in deli meat sales is the rise in low-sodium products. Most retailers are now carrying a low-sodium line and expanding their low-sodium bulk and pre-sliced offerings as just part of their everyday deli case offerings. “We’re seeing brands reinvented because of low sodium, like Sara Lee, that have really performed very well in the last year or two with their low-sodium line,” Parker says.“… Low sodium is also a product that has allowed people to feel better about their deli meat purchases, and maybe even sodium was always the scary thing of deli meats. People were afraid of how much sodium it had in it. Now with low-sodium offerings, it allows them to keep eating deli meats and not be as worried.” “Anything that a deli product overall, especially meats and cheeses, can do to make the consumer feel good about the ingredients and a limited number of ingredients going in is a good thing,” Parker adds.
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
“WEBER MADE ME FEEL LIKE ONE OF THE BIG BOYS – THEN HELPED ME PERFORM LIKE ONE.” – David Terry, Owner, Terry Packing, “For me, there is no other slicer. My 305 – and Weber partnership – is incredible.” “Instant credibility with new prospects came along with the delivery of my Weber 305,” says David Terry who recently upgraded the slicing capabilities of his start-up co-packing company. Come see Weber at PROCESS EXPO ‘11 Nov. 1-4, 2011 Booth #5231 Chicago, IL
“Weber was my best decision. It cut our shrink in half, delivered perfect portions of much thinner slices and provides capacity for years of growth,” David believes. “Plus sanitation is easier, faster and verifiable.” “Just as important is my relationship with Weber,” David believes. “From sales to set-up and thorough
Scan to view video. Get the free app at http//:gettag.mobi
training, they’ve made me feel as important as if I’d been Sara Lee herself.” “Here’s proof. When I chipped a blade and the chip damaged my interleaver on a Friday, Weber cheerfully agreed to work on Saturday to fix it. Instead, Weber’s technician picked me up at Kansas City airport and worked all Friday night. I was back on a plane at 7:30 am Saturday, in time to process a critical weekend delivery. That doesn’t happen for little guys like me. “ Learn how a Weber Slicing System can help your business grow. Call today or use the video TAG below to watch the 305 in action.
1-800-505-9591
SpecialReport THE NATIONAL PROVISIONER’S
2011DELIREPORT
What’s
up
with
what’s new By Elizabeth Fuhrman
Two reasons supermarket delis were successful last year were because they were able to keep price increases manageable and they were able to innovate, says Jonna Parker, account services director at the Perishables Group, Chicago. For example, more retailers began offering bundling and combo options to create convenience. In addition to more new low-sodium offerings, Parker also has seen a rise of bold flavors, such as buffalo. New flavors and brands are a way the deli case tries to stay relevant to consumers, she says. “We’re seen a lot of innovation in the deli and you’re seeing that be the place where the supermarket tries to change typical perception for a shopper,” Parker says.
38
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
As the United States slowly climbs out of the economic doldrums, Alan Hiebert, IDDBA’s education information specialist, believes the industry will see the success of more new products. “Data we’ve seen showed a significant drop in new product introductions in 2010,” he says.“2011 should show some recovery, though I’m not sure we’ll see levels where they were a few years ago.” However, innovation has not disappeared, it has seemingly adapted. IDDBA has seen a huge new bacon trend. “One menu survey I saw recently indicated that bacon was used more often than turkey in sandwiches,” Hiebert says. Many deli-meat suppliers have launched new products and recorded success during the past year. For example, the Sara Lee
Fresh Ideas Lower Sodium sliced-to-order varieties have performed well over the course of the past year, says Paula Shikany, director of Sara Lee Deli. “The lower-sodium varieties deliver against what consumers are looking for — great tasting, more nutritious options that help nourish families simply and easily,” she says. In order to maintain growth and address consumers’ desire for bolder and more differentiated flavors from the deli, Sara Lee Deli will launch a Sara Lee Fresh Ideas Herbed and Seasoned line at the end of September. The line will include Sara Lee Fresh Ideas Herbed and Seasoned Rosemary and Sage Turkey Breast, Herbed and Seasoned Basil Pesto Chicken Breast, and Herbed and Seasoned Peppercorn Premium Roast Beef. “The new product line provides a key protein ingredient for consumers to easily create restaurant-inspired meals at home,” Shikany says. The most significant successful new item from Tyson Foods in the past year has been its Crispy Glazed chicken wings, says Worth Sparkman, manager of public relations at Tyson Foods Inc. “The wing category in deli is driven by repurchase, and repurchase is driven by the consumer’s eating experience,” he says.“Crispy Glazed wings deliver a superior taste and crunch with gross margin benefits to the retailer. These wings have been very successful with retailers,
achieving significant volume increases and displacing established competitive product.” In 2010,Butterball introduced a Deep Fried Deli product line,including Deep FriedTurkey in Original andThanksgiving Style along with Deep Fried Buffalo Chicken. “These are full-flavored products that provide consumers the taste of deep-fried turkey without the expense and mess of frying their own turkey,” says Kari Lindell, director of retail marketing at Butterball LLC. “The best news is that these products are 99 percent fat-free and carry the American Heart Association (AHA) certification.” This year, Butterball is continuing to help consumers eat healthy by reducing the sodium content by an average of 10 percent of its top selling SKUs, which are also AHA certified. These will be available in market late summer, Lindell says. In addition, Butterball is introducing a new flavor, Butterball Original Naturally Roasted Gold Turkey Breast, which also carries AHA certification and will be available late summer. Trial on Kraft Foods’ Oscar Mayer Carving Board Meats, launched earlier this year, is ahead of expectations, says Tom Lopez, the company’s director of marketing.The line includes Oven Roasted Turkey Breast, Rotisserie Seasoned Chicken Breast, Slow Cooked Ham and Slow Roasted Roast Beef. The company attributes the line’s success to its “carved-off-the-roast” taste and unique cut, he says. “As they carry more sandwiches, con-
sumers seek quality and variety,” Lopez says.“They are looking for high-quality cuts and flavor cues such as ‘slow oven roasted.’ More are seeking a carved-off-the roast taste.” Sadler’s Smokehouse Ltd. aimed to make meals easier for consumers with its new Dinner for Two options. The portioned controlled meals for two are based on barbecue favorites, Pulled Pork in a savory barbecue sauce with baked beans and Shredded Beef Brisket in a savory barbecue sauce with macaroni and cheese, says Greg Klein, executive vice president of marketing at Sadler’s.The company’s new Mini Briskets also offer smaller and more convenient portions for smaller households, he says. The deli-oriented focus of Canadian processing giant Maple Leaf Foods Inc. has been on the introduction of Natural Selections, a line of natural deli meats introduced a year ago, made from cuts of meat and other ingredients consumers can actually pronounce, the company says. Moms are embracing the line and driving growth for Maple Leaf Foods. In one year since the product line was launched, Maple Leaf’s share of the Canadian deli market has grown by 35 percent, the company has 30 of the top 600 selling SKUs, Natural Selections is now the topselling sliced meat product in Canada, and Natural Selections won the 2010 Product of the Year in the Fresh Deli category as voted by a survey of 5,900 Canadian consumers.
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
39
TechProcessing
Forming a plan By Andy Hanacek, editor-in-chief FOLLOWING A SPRING 2011 VISIT TO ADVANCEPIERRE FOODS’ Cincinnati processing plant, where the processor was pumping out a wide variety of formed protein products, The National Provisioner queried Tom Burroughs, director, Protein Research and Development for AdvancePierre, on some of the challenges and considerations through which processors need to work when developing and incorporating forming technology. NP: Discuss the main challenges when developing a product that is to be formed (as opposed to other further processes) — what are the top one or two factors you must take into account when creating this product/process? Burroughs: The first challenge and objective is to clearly define what the customer really wants. Since current forming technology can produce a wide range of products with a wide range of attributes, we seek to ask as many questions as possible in the first stage of a project to help direct our development plan. Cost is also a consideration for our customers and an objective we must keep in mind. Oftentimes, a formed product is able to meet a client’s need while also solving the issues of size and shape variation that is common in whole muscle products. NP: AdvancePierre Foods has formed products across all species — describe the differences that come into play when handling these different proteins during the forming process? Burroughs: Beef, pork and poultry all respond differently during the forming process; in fact, even poultry items like chicken and turkey respond differently from each other when being formed. Beef and pork tend to tolerate a wider range of forming temperatures. Poultry is Iess tolerant of temperature variation and usually requires colder forming temperatures, which generates another set of challenges, such as damage to the protein structure, which we need to consider and solve. AdvancePierre Foods’ commitment to careful process design and control in manufacturing allows us to achieve very good consistency and product character. NP: What are some of the more significant technological advancements you’ve seen over the last couple years when it comes to the forming process? Burroughs: The ability to form at lower pressure has improved product quality, especially for poultry products.
Photo by Ross Van Pelt, RVP Photography
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.
Lower pressure minimizes damage to the protein structure, which results in a more natural product. Also, the move to digital control systems has significantly improved the level of operator control and reduced product variation. NP: What challenges remain? In other words, in your dream scenario, what would your forming lines be able to do that they maybe struggle with today? Burroughs: An ideal forming line would be able to create products that are indistinguishable from whole-muscle cuts such as chicken breasts, pork chops and steaks. In the Protein Research and Development department at AdvancePierre Foods, we are committed to providing the best product for our customers — both through innovation and improvement in technology. For example, our sandwich product has textural character very much like whole muscle and performs better in microwave heating and holding than the similar whole-muscle item. NP: Do you believe that processors such as AdvancePierre Foods have taken full advantage of the technology as it stands, or is there plenty of room for your company to expand in the realm of formed products? Burroughs: While we are utilizing the best available forming technologies at AdvancePierre Foods, we recognize that there is always room for new developments and innovation in the marketplace.Whether that innovation is through the creation of a new product, a better product — including better flavor, texture and nutritional value — or a more cost-effective product for our customers, our research and development team strategizes and develops new ideas every day.We anticipate that the demand for formed products will continue to grow. As protein costs increase, customers will seek to deliver formed products that can be formulated to use less expensive raw materials.
TechPackaging
FORM/FILL/SEAL
Opportunity knocks Form/Àll/seal technology offers processors plenty of options for packaging their products while taking advantage of current industry trends. today’s environment package sustainability and recyclability are considerations.
By Chip Bolton, J.H. Bolton Communications LLC
Q:
Are the challenges mentioned above easy to solve? Either way, what types of technological advancements are needed to bring solutions into the industry? There’s not much left to do that can significantly drive down packaging costs. The shift is toward more sustainable packaging, but without raising costs, [as well as] any packaging options that can help promote improved food safety and improved shelf-life for products.
ASKED CHIP BOLTON, principal at J.H. Bolton Communications LLC, to detail the latest challenges and trends in the realm of form/fill/seal technology for this month’s Packaging Technology story.What follows is a Q&A between Bolton and an independent product and package development consultant to the food industry who has more than 30 years experience in the food packaging industry.
Q:
What primary area of use (i.e. frozen, what species, what type/ style of product, etc.) does form/Àll/ seal technology Àt best into in the protein-processing industry? The more precise question may be,“What primary form/fill/seal package is best for protein overall?” The answer is thermo-form. It’s more versatile using the same equipment system because you can produce small format and larger format packages by just changing dies.
Q:
Describe some of the challenges processors must be aware of when adopting form/Àll/ seal technology into their processes. Seal contamination, because processors are forming and loading the package themselves. Loading — meaning bringing product to the equipment — may lend itself to more manual loading because there isn’t the variety of loader options to choose from as there is with bags. Equipment options — there are many options to choose from: thermo-form, flow-wrap, vertical, horizontal, gas-flush, vacuum. Also retail or foodservice package, printed package or no print, and registered print 42
Q:
How signiÀcant has been the effect of exact-weight/netweight products on the form/
Àll/seal arena? Form/fill/seal gives more packaging options to take advantage of exact-weight products. or random print [pose challenges].
Q:
What about on the materials side? Are there considerations processors must make in regard to the actual packaging materials when it comes to form/Àll/seal technology? The short answer is, yes. Cost of materials is a primary concern. Does the processor have multiple supplier options? Does the material comply with the requirements of the application, i.e. cook-in? Is barrier required, gas-flush, vacuum, shrink, abuse resistance? If the package requires two webs then they must be compatible. If the package is printed then that will affect the material selection because it will need to be less stretchable for registered print. In
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Q:
Do you believe this technology has room to grow in the protein-processing industry, or has the industry tapped the full potential of the process to this point? There is incredible growth left, but most likely at the expense of bags. Form/fill/ seal gives greater packaging options and reduces overall packaging costs because there are more suppliers to choose from and more equipment systems options. Chip Bolton is a principal at J.H. Bolton Communications LLC, with more than 20 years experience in the food packaging industry. For more information, contact him at (864) 525-3494, or chpbolton@ gmail.com.
Raise Your Form Fill Seal Expectations
With Integrity. We asked the meat and poultry marketplace what they liked and didn't like about their existing horizontal form fill seal (HFFS) machines. Then we built our new Integrity line from the ground up to meet these needs. It features: • • • •
An American-made design and build Non-proprietary components and controls Tool-less accessibility to sealing chamber Intelligent interface with training, manuals and bilingual options built-in • Faster Return on Investment (ROI) It’s time for a new level of performance. It’s time for Integrity.
Go to www.OssidIntegrity.com or call 1-800-334-8369 to find out how Integrity can raise your HFFS expectations.
FoodSafety
OfÀcial White House Photo by Pete Souza
President Barack Obama signs H.R. 2751, the “FDA Food Safety Modernization Act,” in the Oval OfÀce, Jan. 4, 2011.
TRACEABILITY
Deep impact How federal traceability legislation may impact the food supply chain. By Derek Rickard, RMT Robotics EARLIER THIS YEAR, U.S. PRESIDENT BARACK OBAMA SIGNED the FDA Food Safety Modernization Act (FSMA) (P.L. 111-353), a law that will overhaul U.S. food safety for the first time since the Great Depression. The legislation passed in response to a growing public concern about the integrity of both local and imported food supplies and the inability of officials to trace the sources of many tainted foods. As those involved in the food chain begin to examine the impact of FSMA, one requirement in particular is striking: “The Secretary [is required] to establish a product tracing system to track and trace food that is in the United States or offered for import into the United States.” (FSMA d 204 (c)) Although FSMA focuses on products under the jurisdiction 44
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
of the U.S. Food and Drug Administration (FDA), its provisions reflect a larger push for traceability across the entire food supply chain, including the meat and poultry under the purview of the U.S. Department of Agriculture (USDA). The recent, deadly E. coli outbreak in Europe triggered a heightened sense of urgency and scrutiny among the public, media and lawmakers who have been pushing for more federal traceability requirements. The trend toward stringent track-and-trace requirements could have a significant impact on the meat and poultry industry, as fresh products and the cold-chain supply industry pose special challenges to traceability. According to Dr. Don Ratliff, Regents and UPS Professor and Research Director at Georgia Tech’s Integrated Food Chain Center, any orga-
The recent, deadly E. coli outbreak in Europe triggered a heightened sense of urgency and scrutiny among the public, media and lawmakers who have been pushing for more federal traceability requirements.
nization involved in the importation, manufacturing, production, storage, transportation and sale of food needs to understand the consequences, requirements and cost of compliance associated with FSMA and similar legislation that targets meat and poultry producers.
Traceability in black and white The new U.S. food-safety law will most likely mean an increased burden on the bar code. Every shipment will likely carry a bar-code label that tracks at the case level where a product is
produced and who produced it, as well as a unique lot number and content description. Ratliff believes that a logistically viable solution is a dynamic tracking scenario. When product is received, information regarding product type, lot number and the name of the companies shipping and transporting the case can be captured with a bar-code scanner. Similarly, upon shipment, information regarding product type, lot number, dispatch details and the name of the transportation supplier must be captured and recorded. This information
is vital, Ratliff says, for meeting the new requirement of tracing the product “one forward and one back” in each point of the supply chain. In addition, manufacturers, distributors and importers will need to record processing, handling, storage and transportation details for internal recordkeeping. Products will only require straightforward traceback methods because the supply chain is reasonably linear, but food processors and cold-chain operations will need more complex traceback methods.
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
Spray Control
Spray Analysis
Spray Fabrication
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
45
FoodSafety
WE PROTECT PRODUCTS & REPUTATIONS
The U.S. Food and Drug Administration
An FDA scientist scans a bar code into a tracking database in the mobile laboratory’s command center. Bar codes correspond to samples collected for testing. Replacing the paper system with bar codes streamlines the operation of entering data, tracking samples, and sharing test results.
Global standards
Innovators in Food Safety & Marination { Let us show you how to } r*OIJCJUQBUIPHFOPVUHSPXUI r&YUFOEQSPEVDUTIFMGMJGF r3FEVDFTPEJVNDPOUFOU r&OIBODFQSPEVDUóBWPS r*ODSFBTFZJFMET
Call us at 877-221-8558 Or visit www.wtiinc.com
46
From cans of soup to strawberries, to meat to bottled fruit drinks, every food product is different in terms of origin, ingredients, storage, transport and shelf life. Moreover, these products are referenced differently as they pass language, culture and brand barriers. The success of a track-and-trace system, however, relies on a standardization of these diverse product descriptions that can be translated into associated database codes. Now is the time to confront and find a solution to standardize product labeling, says Ratliff. Without a global set of standards, the challenge of developing and maintaining a centralized traceability database may well become insurmountable.
Tracing food using real-time data capture and automation The most practical way to handle the required volume of transactions is to automate the capture and upload of tracking data to an online database. This would be especially helpful in the meat and poultry industry with fresh products and temperature requirements. A Web-based system would allow officials
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
to manage recalls more efficiently while storing data securely. However, such a database does not currently exist, and there are many issues regarding who would be responsible for storage and management of the data, pricing, etc. that need to be resolved. As new track and trace legislation moves into the global food supply chain, manufacturers and distributors need traceability solutions now to meet compliance challenges. Material-handling automation is the key to effectively managing the workload and accuracy requirements, and solutions that address these requirements are available through suppliers in the industry. Of course there are many benefits to material-handling automation that help justify the cost of a new system. Labor is much more efficient as demand, risk of injury and turnover decrease and efficiency increases. Food is moved more quickly and with less risk of spoiling. An article in the June 9, 2011, Automation Skills newsletter published by Automation World magazine states: “Given the critical importance of food safety and food defense to producers, both need to be viewed not as expenses but as an important capital investment
ADVERTISER PROFILE /E͘ tKZ>d,EK>K'z/E'Z/Ed^
Let WTI’s decades of experience in food safety maintain the quality and trust of your company’s products
W
olfgang Ludwig founded WTI in 1978. Wolf started his profession at the age of 14 as an apprentice under a German master of meat processing in a small Black Forest town near Baden-Baden, Germany. By the age of 23 Wolf was driven by his passion and took his dreams to America. He used his knowledge and intense interest in meat processing to begin his journey into the unknown US market. The company has grown rapidly by remaining true to Wolf’s work ethic and vision, a strong desire to succeed and an old world background as a highly skilled food artisan. Whatever our size, WTI will always maintain our heritage as a familyowned and operated company, dedicated to developing deep and personal relationships with our customers, who have come to view us as true partners in achieving their business goals. As a leading provider of clean label and specialty ingredients designed to enhance food safety and quality, WTI is JVTTP[[LK[V\WOVSKPUNÄ]LJVYL]HS\LZPU[OL^H`^LKV business:
$6FLHQWLÀFDQG5HVHDUFK'ULYHQ$SSURDFK The backbone of WTI is our food scientists. Not only were they trained at some of the best schools in the country but they posses years of industry expertise. We also maintain SVUNZ[HUKPUNHUKT\[\HSS`ILULÄJPHSYLZLHYJOHUK[LHJOPUN relationships with many of the world’s leading food science and food safety programs, allowing us to develop and fully validate cutting edge ideas and new product formulations to meet our customers’ needs.
,QQRYDWLRQDQG&RQVWDQW,PSURYHPHQW 5L]LY ZH[PZÄLK ^P[O [OL Z[H[\ZX\V >;0 OHZ H Z[YVUN track record of leading the way for the industry in terms of developing unique solutions to some of its most pressing issues.
$)RFXVRQ5HODWLRQVKLSV5DWKHU7KDQ6DOHV Because we’ve never lost sight of our family-owned company heritage, we believe in creating customers for life, rather than making a quick sale. Our customers will never be an order number or a quota to us and will always receive superior personalized service.
0DUNHWGULYHQ&RQVXPHUUHOHYDQW 7HFKQRORJLHV WTI’s commitment to customers goes beyond just keeping pace with consumer demands. Our focus is on anticipating these ever-changing demands and creating products and solutions to help our customers meet them. We do this by leading the way in areas such as nutriceuticals and clean label technologies.
&XVWRPL]HG&OLHQW6ROXWLRQV'HVLJQHGWR (QVXUH7KHLU6XFFHVV Each customer has his or her own unique set of challenges and issues, so we never take a cookie cutter approach. While many of our products address a wide range of food safety and quality issues, our food scientists will work with `V\[VKL]LSVWJ\Z[VTPaLKZVS\[PVUZ[VTLL[`V\YZWLJPÄJ goals and challenges.
FoodSafety
in the future of their businesses. The same return on investment (ROI) criteria should be used, just as if a new production line or packaging machine is being considered. Take, for example, the fact that an average recall costs $10 million, not counting hidden contingent costs. For a producer with $100 million in annual sales and 10 percent net margins, a recall’s cost of that size would wipe out bottom line profit for the year.”
A silver lining Dr. Ratliff also predicts that, while there may be a significant cost burden on the food chain in order to ensure compliance with new requirements, there are also potential benefits to both consumers as well as suppliers. For consumers, the visibility and accountability in the food chain should result in enhanced food quality and freshness with less risk of contamination. A recent survey conducted by Performance Food Group found that consumers were willing to pay $2 or $3 more for the same cut of meat if various “pleasers” were added — a higher meat quality, traceability, and improved animal handling and feeding. Supermar48
Manufacturers and distributors need traceability solutions now to meet new compliance challenges. kets, food retailers and food suppliers can all benefit from increased “sell” life of products, better order management, fewer rejected loads, less waste because of better handling, and a quicker and more efficient way to identify where failure points occur. In the meat and poultry industry, this implies higher customer satisfaction and less risk of recall as well as higher ROI for the industry as food moves more quickly and with less risk of spoilage. Ratliff emphasizes that, in order to receive the advantages of increased visibility, it is essential that the tracking
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
data be standardized at the case level and that it be shared across the entire supply chain. While many procedures are yet to be specified, FSMA provides for pilot studies to be undertaken by industry groups and organizations such as Georgia Tech’s Integrated Food Chain Center to evaluate potential tracking systems and make recommendations. Ratliff advises that food suppliers around the world should become proactive in determining how to get in front of the regulations by meeting best practices rather than waiting for mandates. Together, automation and standardization will make it easier for food and beverage suppliers worldwide to comply with new traceability requirements and benefit from all that comes from tighter control of inventory. For more information about FSMA and food-safety legislation under consideration in the 112th Congress, please visit http://thomas.loc.gov or http:// usda.gov. Derek Rickard is distributions systems manager for RMT Robotics, A Cimcorp Oy Company, www.rmtrobotics.com. Contact Rickard at
[email protected] or (905) 643-9700, ext. 223.
WebSpotlight
Biro Mfg. Co.
Beacon Inc.
Busch USA
The Biro Manufacturing Company designs, manufactures and markets safe, durable and reliable power-operated, stainless steel, food and meat processing machinery. Biro’s product line includes a broad selection of models and variations of Power Saws, Tenderizers/Knitters, Cubers, Strip Cutters, Poultry Cutters, Horizontal High Speed Meat Slicers, Meat Room/Deli Slicers, Grinders, Mixer/ Grinders, Marinating Vacuum Meat Tumblers, and Food Formers. (419) 798-4451 www.birosaw.com
Beacon Inc. has been supplying stainless steel processing screens to the meat industry for over 60 years. Our specialty is customizing the perfect screen for your processing requirements based on the type of product and weight load. For pricing please contact Beacon at (800) 445-4203. (800) 445-4203 www.beaconmetals.com
Busch Vacuum Pumps and Systems offers a comprehensive line of vacuum pumps, expertise in designing and building vacuum systems and an extensive service network, making it easy to provide comprehensive solutions to Àt your speciÀc needs. Expect the best when you specify Busch. (800) 872-7867 www.buschusa.com
framarx/waxstar
Handtmann Inc.
Hollymatic Corp.
framarx/waxstar is a family-run business manufacturing since 1966. We specialize in converting waxed and coated paper for meat, poultry, confectionery and baked products. We emphasize quality, stress customer service and are always willing to put in RUSH priority, customized printing, a unique size, or special packaging. We are conÀdent that we have what you are looking for in a paper source. (800) 336-3936 www.framarx.com
Handtmann equipment and process management technology enable traditional old world quality with new economy precision. Proprietary servo controls deliver industry leading weight and length accuracy. All Handtmann models offers simple, efÀcient productivity using less power and water, creating less residual meat, and reducing clean-up time and routine maintenance costs. (847) 808-1100 www.handtmann.com
Hollymatic has been a leading manufacturer of food processing equipment for 74 years. Best known for the inventions of the Hamburger Patty Machine and the Mixer/Grinder, Hollymatic continues to lead the industry with other innovative machines like its Saws, Tenderizers, Tumblers/Marinaters and other processing equipment as well as Patty Paper. (708) 579-3700 www.hollymatic.com
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
49
WebSpotlight
Ingredients Solutions Inc.
JBT FoodTech
Ingredients Solutions offers special Carrageenan systems to improve yield and reduce cook loss in caseready, rotisserie and other injected and/or tumbled marinated meat and poultry products. ISI’s Natural and Organic-Allowed carrageenans can restore texture and yield in reducedsalt/phosphate formulations. Call for samples and technical support. (800) 628-3166 www.ingredientssolutions.com
JBT FoodTech is recognized for its portioning, cooking, coating, frying and freezing technologies. It is also known for its Tech Center, customer training and 24/7 aftermarket services. If you are processing poultry, red meat, Àsh, ready meals or baked goods Ànd the most advanced solutions at jbtfoodtech.com. (800) 408-7788 www.jbtfoodtech.com
OSI Group LLC
Ossid LLC
For over 50 years, the OSI Group, LLC has been a global leader in supplying value added protein items and other food products to leading foodservice and retail brands. They are a privately held corporation with more than 40 facilities in 17 countries and specialize in creating custom products. (630) 851-6600 www.osigroup.com
Ossid manufactures stainless steel, highspeed, tray packaging, weigh/labeling, and form/Àll/seal machinery. Our patented solutions continually exceed industry expectations by delivering better looking, high performing packages at lower costs than our competitors. Visit us at Ossid.com or call 1-800-334-8369 for more information. (800) 334-8369 www.ossid.com
50
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Materials Transportation Co. For over 60 years, the experienced team of engineers, designers and manufacturers at Materials Transportation Company have set the standard in the food processing industry for quality, durability and increased productivity. MTC offers complete Food Processing Solutions from dumpers and cookers to augers and conveyors. Visit mtcworldwide.com today for additional information or call (800) 433-3110. (800) 433-3110 www.mtcworldwide.com
Packaging Progressions Inc. Packaging Progressions Inc. designs and manufactures interleavers and counter stackers to interface with your slicer, cutter or former. The PPI-200 places a programmed length of paper or Àlm under your product that can be automatically folded or wrapped around the product for ease of separation and sanitary handling. (610) 489-8601 www.pacproinc.com
Purac
Reiser
Remco Products
In your search for natural ingredients, turn to Purac a leading ingredient company that helps develop safe, nutritious and delicious meat and poultry products. Purac ingredients serve a wide range of functions such as natural preservation, food safety, Listeria control, shelf-life extension and sodium reduction. For more information, visit us at www.purac.com. (847) 634-6330 www.purac.com
Reiser offers a range of innovative processing and packaging equipment for the meat, poultry and seafood industries. Our variety of equipment helps processors produce a higher quality product while maximizing production efÀciency and proÀts. Our solutions combine specialized machines, custom applications and in-depth Reiser expertise to meet any customer challenge. (781) 821-1290 www.reiser.com
With today’s focus on hygiene and cross-contamination, Remco provides a broad range of color-coded cleaning and material handling tools including polypropylene shovels, scoops, scrapers, mixing paddles, kart tubs and metal detectable tools. Remco also offers the Vikan line of brooms, brushes, squeegees, pails, and handles. Contact us at (317) 876-9856 or visit www.remcoproducts.com. (317) 876-9856 www.remcoproducts.com
Rollstock Inc.
Spraying Systems Co.
Wolf-tec Inc.
The website for this manufacturer of Rollstock Vacuum Packaging Equipment lists full speciÀcations and details on its 2 different Rollstock Machines and its Zipper Machine. Coming soon to the website are details on Rollstock’s new Rotary Chamber Machine which is currently being introduced. To learn more, go to www.rollstock.com. (800) 295-2949 www.rollstock.com
AutoJet Antimicrobial Spray Systems help processors of ready-to-eat and fresh meats ensure product safety, increase productivity and reduce chemical use with precise application of antimicrobials onto each product or into each package, eliminating slower, more expensive post-pasteurization techniques. Typical costs: $0.01/lb. for RTE, $0.002/lb. for fresh meats. (630) 665-5000 www.spray.com/foodsafety
For more than 34 years, meat & poultry processors from around the world have relied on Wolf-tec to deliver better equipment and smarter solutions. Leading brands including Polar Massagers, Schroder IMAX injectors, Armor Inox automatic thermal processing systems and TVI portioning systems offer innovation, performance and reliability. We are changing the way you do business. (845) 340-9727 www.wolf-tec.com
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
51
TechShowcase
Slicing System PowerMax Slicing Systems from Formax were engineered with the latest designs and technologies for slicing luncheon meats with superior quality and performance. Both models – the PowerMax4000 and the mid-sized PowerMax3000 – provide a lower cost of ownership, due to a proprietary blade technology that increases yield by up to two percent, extends overall blade life and minimizes or eliminates crust freezing requirements. Formax’s exclusive independent drive technology allows for complete control over each log. Provisur Technologies | Formax: (708) 479-3500 or visit www.formaxinc.com
Data Management Software Mettler-Toledo has introduced ProdX – an advanced connectivity software program that allows centralized monitoring, control and data documentation for checkweighers, metal detectors and x-ray systems whether in one plant or multiple plants. ProdX boosts process productivity, improves product quality, and provides robust operational security and total clarity for your product inspection program. Multiple product inspection devices are integrated into a central monitoring system that can be monitored from multiple locations. Mettler-Toledo Product Inspection Group: (800) 447-4439 or visit www.mt.com/pi
52
Mixer/Grinder Hollymatic Mixer/Grinders for industrial plants feature removable stainless steel mixing arms that offer efÀcient mix and dispersion of product and are programmed with automatic forward-reverse mixing cycles. Powered by two independent gear reduction units, they deliver quiet, continuous, trouble-free operation. Robust stainless steel, seam welded construction provides rugged durability for increased reliability. Output rates range from 3,000 lbs/hr to up to 9,900 lbs/hr. Various horsepowers and options are available. Hollymatic Corp.: (708) 579-3700 or visit www.hollymatic.com
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Conveyor Heat and Control has developed a Progressive Pack Conveyor integrated with an Ishida weigher. The weigher deposits each product charge into a diverting timing hopper centered over the conveyor. The conveyor has two Áighted center belts to accept product charges and independent variable speed packing conveyors on each side. Operators remove a product charge from the center Áighted belt and arrange it in trays on the outer packing belts, which carry them to sealing equipment.
Anti-Bacterial Wipes Hypred announced that the EPA has approved its new AQTIVESan-97 antibacterial wipes for use on food-contact surfaces in dairies, institutional kitchens, food handling and processing areas. The anti-microbial, pre-moistened wipes are ready-to-use and do not require a post-sanitation rinse, making AQTIVESan-97 ideal for surface sanitation in production lines. The advanced formula of AQTIVESan-97 contains two active ingredients to sanitize food- and nonfood-contact surfaces: didecyl dimethyl ammonium chloride (0.024%) and alkyl dimethyl benzyl ammonium chlorides (0.016%).
Heat and Control Inc.: (800) 227-5980 or visit www.heatandcontrol.com
Hypred USA: (800) 225-3832 or visit www.hypredusa.com
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. CSB-System software provides resources for: Traceability and Recall Management Scale, Labelling and Scanning Solutions Yield Management and Product Costing Gross Margin Analysis Inventory Management Systems Batch Processing Management Livestock Solutions Enterprise Resource Planning CSB-System International, Inc. USA Contact us: (800) 852-9977
[email protected] www.csb-system.com
Take advantage of our expertise - contact us in order to learn more about our state-of-the-art software solutions for the protein industry.
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
53
TechShowcase
Conveyor Belt
Packaging FreshCase packaging from Curwood for case-ready meats delivers superior Áavor, quality and extended shelf life of vacuum packaging; fresh red color consumers prefer; and cost advantages that help processors and retailers maintain critical proÀt margins. The hermetic packaging offers a shelf life of more than 30 days for whole muscle beef and extends typical retail display life up to 28 days compared to 3-5 days for tray overwraps. Curwood: (800) 544-4672 or visit www.curwood.com
Premium belts from TB Wood’s have the highest power density of any V-belt, and stretch dramatically less than standard cross sections which makes them ideal for use on problem drives requiring high-impact strength and load-carrying power. Premium Banded belts can replace several belts with the strength of a single belt. Banded belts feature a multiple layer tie band that provides excellent lateral rigidity to prevent belts from turning over or from coming off the drive. TB Wood’s Inc.: (888) 829-6637 or visit www.tbwoods.com
See How We Stack Up! Whether you’re forming beef, poultry, vegetables or fish for jumbo ½ lb. patties or mini 2 oz. sliders, Hollymatic has the forming equipment you need. We offer 6 food formers, from tabletop models that portion 1200 patties/hour to our largest hydraulic machine that portions 7800 patties/hour. Check out our equipment, their features & benefits. You’ll find we really do stack up.
Beef
Turkey
Veggie
708-579-3700 www.hollymatic.com/np Fish
54
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
Checkweigher OCS Checkweighers offers the HC-M series. Designed for speeds up to 250 pieces/min, the HC-MEDIUM is the link between the basic EC-E (ESSENTIAL) model and the high-end HC-A (AVANTGARDE) checkweigher. The HC-M is operated by an industrial PC (IPC) and is characterized by its 10.4 inches mobile touch display. It features the same control concept of the high-end checkweigher HC-A making cross training between various controllers a thing of the past. OCS Checkweighers Inc.: (678) 344-8300 or visit www.ocs-cw.com/english/Home
BE HERE TO FIND
100% Food-Focused Technology
Sausage Compound Frutarom Savory Solutions has developed a compound for sausage from Àsh that allows manufacturers to present Àsh in a new form. It is available in several varieties containing different seasonings, and is mixed with minced Àsh, oil, ice and salt to form a homogeneous mass, which is then processed into sausage. The Àsh sausage compound has high temperature- and freeze-thaw stability and is particularly suitable for manufacturers of convenience and restaurant chain meals. Frutarom Savory Solutions GmbH: +49 4744 91 81 32 or visit www.frutarom.com THE GLOBAL FOOD EQUIPMENT AND TECHNOLOGY SHOW™
Former NuTEC Mfg. is offering free literature on its 710 Patty Forming Machine. The full-color brochure features illustrative technical drawings and detailed speciÀcations to describe unique features of the 710. NuTEC’s 710 machine can form up to 3600 patties per hour. USDA-approved, it provides excellent weight control and gentle product handling, operating with minimal wear and maintenance. A PDF of the literature can be downloaded from NuTEC’s website. NuTEC Mfg.: (815) 722-2800 or visit www.nutecmfg.com
NOVEMBER 1-4 2011 – CHICAGO
REGISTER TODAY at www.myprocessexpo.com
©2011 FPSA
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
55
TechShowcase Supplier News Foodmate US Inc., the North American distributor for Netherland-based Foodmate B.V., recently named Tim Morgan as an area sales manager. Morgan serves Foodmate clients in Georgia (North of Atlanta), North Carolina, South Carolina, Tennessee, Virginia, Kentucky, West Virginia and Delaware. With nearly 20 years in the poultry equipment industry experiMorgan ence, Morgan has a diverse background with 10 years in the packaging, three years in poultry processing, and six years in services and installation.
A new webinar presentation is available from Provisur Technologies, entitled “The Formula For The Perfect Burger.” Hosted by Tom Tonra, forming product manager at Provisur, the webinar uncovers the latest technologies and solutions for improving productivity, lowering the cost of ownership and elevating product quality to make the perfect burger. The discussion is based on a recent Executive BrieÀng Series White Paper that integrates grinding and mixing knowledge from Weiler, bone and hard tissue removal knowledge of Beehive and forming insights from Formax. Tonra covers the following topics: Proper Product Preparation, Raw Material Selection, Best Practice, Pre-Grind, Mixing, Final Grind, Bone and Hard Tissue Removal, Forming Process and Value-Added Options. The exclusive White Paper is available by contacting Tom Tonra at (708) 479-3572 or
[email protected]. “Information is essential to our industry, and the success of the webinar shows the importance of keeping everyone up to date about the technologies and methodologies employed around the world,” said Tonra. “Our live audience asked compelling questions about what
56
they hope to accomplish and what they can do to get their equipment working together seamlessly. The presentation shows how to get the most out of your raw materials, from selection to grinding, mixing, bone and hard tissue removal, and forming technologies for unprecedented productivity, superior texture, portion control and yields.” Hydrite Chemical Co. has purchased a new facility in Milwaukee, Wis., to help support its growth in chemical manufacturing. The facility, which was previously the home of Unilever Foodsolutions, will manufacture chemical solutions to the food industry. The facility, built in 1991, boasts 133,000 square feet of manufacturing space and 15,000 square feet of ofÀce space. “With the additional location and square footage of manufacturing space, we can be ready for the growth we’ve positioned ourselves for in the food industry,” said Joe Weishar, vice president of operations.
Sealed Air’s Cryovac brand now offers design and marketing services to customers with its Cryovac Graphics+ services. Cryovac Graphics+ is a convenient solution for customers’ marketing collateral and secondary packaging needs including design, art and pre-press customization. Previously, Sealed Air’s Cryovac Graphics+ Services offered design and color separations for bag or rollstock packaging. Now it extends these capabilities to provide fully integrated design and creative support for customers across packaging and communications materials. Cryovac Graphics+ designs logos, websites, brochures, pressure-sensitive labels, cartons, boxes, coupons, envelopes, trade show materials and 3D prototypes. “Our design experts offer graphics capabilities that provide customers with brand integrity and consistency throughout all of their marketing and packaging materials,” said Roxanne Baker, graphics business development manager for Sealed Air’s Cryovac packaging. “Cryovac Graphics+ enables customers to promote their businesses with professionally designed graphics developed by a trusted packaging partner.”
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
For more information about Cryovac Graphics+ services, call (800) 845-3456 or visit www.CryovacGraphicsPlus.com.
OSI Group LLC announced it will implement Arrowsight Inc.’s third-party 24/7/365 Remote Video Auditing (RVA) food defense services in its Àve U.S. processing plants. The RVA program will enhance the company’s existing efforts in the area of food defense to guard against the threat of agroterrorism. “OSI has been working with Arrowsight since 2005 to innovate new solutions using RVA services and is proud to continue to drive new standards in the critically important area of food defense,” said David McDonald, president and chief operating ofÀcer, OSI Group, LLC. “By measuring the performance of our employees and providing them with immediate feedback while they work, OSI will be able to continually measure and improve all of our plant operations in the U.S.”
Cantrell has reached an agreement with Tecnologia Empresarial S.A. to be Cantrell’s representative in Central America and the Caribbean. “Central America is a fast growing area for poultry processing,” Cantrell General Manager Sales/Service/Engineering Dane Woods said. “Having a representative in Central America has been a goal of ours. Tecnologia Empresarial S.A. will give Cantrell a strong presence in the region.” Based in Honduras, Tecnologia Empresarial S.A. will be the exclusive representative for Cantrell in the region and will be marketing all Cantrell equipment and parts. Led by founding partner and general manager Alejandro Cerna, Tecnologia Empresarial S.A. has a strong background in a poultry processing equipment industry. Solbar, Israel, announces the appointment of Todd R. Watson as president
of Solbar USA. The appointment is part of Solbar’s strategy to strengthen its position in the US market and comes as a direct enhancement to the acquisition of a new processing plant in Nebraska last year. Watson joins the Solbar Group following more than 25 years of managerial and commercial experience in the Watson food ingredients and commodity industry. He has extensive experience in sales and marketing, working for well-known multinational companies including Cargill. “Todd’s vast experience and capabilities will augment Solbar’s ability to work closely with our customers, and help sustain our mission to become the preferred partner in creating healthier products with our isolated soy protein ingredients,” says Shaul Shelach, CEO of Solbar.
According to Director of Logistics Todd Gooch, opening the new ofÀce was a crucial step in making JBS Carriers even more competitive. “Adding the logistics division allows us to be more competitive in today’s transportation marketplace,” said Gooch. “As we continue to expand our service lines, this brings us one step closer to becoming a nationally recognized provider of transportation services.” JBS Logistics will continue to contract with beef and pork producers from JBS and chicken producers from sister company Pilgrim’s, and it will now contract with outside shippers and manufacturers as well to match services, routes and products.
Sara Lee Corp.
Industry News Keystone Foods Chief Operating OfÀcer Larry S. McWilliams has assumed the company’s leadership role as President and CEO, succeeding Jerry Dean, who recently elected to retire after leading the company for 17 years. McWilliams joined Keystone Foods in April 2011, from the Campbell Soup Co. McWilliams where he was president of that company’s International Division.“I’m thrilled to have joined Keystone Foods at this exciting time. Now part of Marfrig Group, Keystone Foods is even better positioned to serve customers around the world,” he said. “I look forward to putting my own experience to work for Marfrig and continuing to leverage Keystone Foods’ strengths to create greater opportunities.” JBS Carriers has opened its new JBS Logistics Center in Gainesville, Ga. The new ofÀce will expand the company’s capacity and add revenue by allowing it to work with outside carriers to transport products across the 48 contiguous U.S. states. Logistics Manager Neil SatterÀeld will oversee the Gainesville operation, which will initially employ a staff of six. Gooch estimates that staff to double by the end of 2011.
Dr. R. Bruce Tompkin was named the recipient of the 2011 American Meat Science Association (AMSA) R. C. Pollock Award on Tuesday, June 21 at the 64th Annual Reciprocal Meat Conference. The R. C. Pollock Award is presented annually in honor of the Àrst general manager of the National Live Stock and Meat Board. The award, sponsored by the AMSA Educational Foundation, honors a dedicated AMSA member whose work through teaching, extension, research, or service represents an extraordinary and lasting contribution to the meat industry. Dr. Thomas Powell, executive director of AMSA, said, “Because of his sustained commitment to the application of science and the breadth of his contributions to the research community and the industry, Dr. R. Bruce Tompkin is a deserving recipient of AMSA’s highest award.” Tompkin has spent his 40-year career advancing and applying the science of food safety as a researcher and educator. He is internationally recognized as a top food microbiologist in fresh and processed meats and as one of the top HACCP experts in the world. He served on the International Commission on Microbiological SpeciÀcations for Food, providing him with the opportunity to assist in the development of the Hazard Analysis and Critical Control Point program, now accepted by the meat and food industry worldwide.
The company opened its state-ofthe-art sliced meats manufacturing facility in Kansas City, Kan. The facility, located at 4612 Speaker Road, represents an investment from Sara Lee of over $140 million and is a leader in processing technology. The facility will manufacture sliced deli meats for Sara Lee under the Hillshire Farm and Sara Lee Deli brands. “We are proud to celebrate our new Kansas City facility and showcase the state-of-the-art features that make it an industry leader in processing,” said CJ Fraleigh, chief executive ofÀcer, Sara Lee North America. “This investment underlines our commitment to our core protein category and provides us with the ability to deliver to our customers and consumers the safest, highest quality, most cost-effective product possible.” The Kansas City sliced meats facility utilizes robotic systems and allows “no touch” processing from the initial raw meat phase through the Ànished product. Due to engineering processes, the facility processing time is reduced by 50% compared to conventional manufacturing and requires half of the employees normally required to operate such a facility.
JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER
57
To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail:
[email protected] CAREER OPPORTUNITY
PROCUREMENT MANAGER
®
“Specialists in Distinctive Deli Products”
The Downs Food Group is seeking candidates for the position of Procurement Manager. We are a producer of frozen and canned chicken, pork, and beef proteins. The position would be located in our Mankato, MN corporate office. Please check out our web site to learn more about us. www.downsfoodgroup.com Some of the major responsibilities would include inventory management, cost control, forecasting, insuring material delivery to meet production needs, supplier audits, contract negotiation, and participating in planning meetings with sales and operations to develop short and long term production plans.
Charlie’s Pride Meats, a leader in Premium Deli Meats Since 1969, is looking for highly qualified direct Sales Representatives throughout the USA. The qualified candidates must have a minimum of ten years experience and are currently selling Roast Beef, Corned Beef and Pastrami Deli items.
Successful candidates must be able to develop strong supplier relationships that will provide cost effective high quality materials. They must also possess general computer skills and be comfortable working with word, spreadsheets, and presentation software. Understanding and the ability to use a materials requirements planning system is needed and at least two year’s experience as a procurement manager in a meat processing environment is required.
We offer a highly competitive salary and benefits package, and are recognized as providing exceptional Deli products at an excellent value from coast to coast.
Salary is commensurate with experience and qualifications. The benefit package includes a 401K plan, health insurance, life insurance, disability insurance and paid vacation and holidays. If you are positive, energetic, results driven individual please email your cover letter and resume to
[email protected] AA/EEO | Veteran Friendly Employer
Contact us at: Toll Free (877-866-0992) | www.cpmhotline.com Or send your resume to
[email protected]
TREIF USA, Inc. is a leader in manufacturing food cutting machines in meat, poultry and cheese. We are looking for a sales person(s) in capital investment goods for the USA. Qualifications: min. 5 years sales experience for processing equipment in the food industry. Highly motivated and professional sales drive. Excellent communication and customer service skills; who is willing to travel extensively.
Meat Career in Jax. Fl. Florida New Zealand Lamb and Meat Co., a subsidiary of Beaver Street Fisheries, Inc., Jacksonville, FL, seeks experienced protein product champion to expand market share and increase revenue domestically and/or in the Caribbean/Latin American markets. Ideal candidate will be an expert meat merchandiser with proven success in buying, selling, and trading proteins and in exploiting solid customer and procurement contacts to build new business and deepen existing customer and trading partner relationships. Candidate confidentiality respected. Send resume to jleafgreen@beaverfish.com or call James at (904) 634-6630.
Interested candidates should forward their resume and compensation requirements to
[email protected]. We are an equal opportunity employer
Kosher specialty shop in Hollywood, FL seeking
EUROPEAN TRAINED SAUSAGE MAKER with knowledge and training of Automated Linker. Must agree to formulate recipes for business. Salary & benefits. Steven Chase 561.632.7025/
[email protected]
58
We offer a position with an excellent opportunity for the right candidate possessing the following qualifications: · MS office (or similar) working knowledge · Experience in the food industry, smokehouse maintenance experience and / or smokehouse operation experience · Mechanical, pneumatic, electrical, and PLC hands-on experience · Willingness to travel extensively with short notice · Excellent communication skills within team environment and the ability to build customer relationships · Ability to understand and translate information from mechanical drawings and construct equipment to meet specifications
Interested? Please send your resume to:
[email protected]
TREIF USA is a growing sales and service company offering an excellent benefit compensation package. For more information please go to: www.treif.com
Regional Service Technician Amtrade Systems Inc., a Michigan based company, is looking for Service Technicians. We are a fast growing company serving the US food industry with Schroeter (German based manufacturer) smokehouses and equipment.
www.amtrade-systems.com
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
Please send resume to: ROBERT REISER & CO., INC Attn: HR Department 725 Dedham Street Canton, MA 02021 Fax (781) 821-1316 Email:
[email protected]
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
CONTINUING EDUCATION
HACCP Workshop October 27-29, 2011
Basic Sausage November 8-10, 2011
Cured Meat January 17-19, 2012
Dry & Semi-Dry Sausage April 10-12, 2012
Sausage & Processed Meat July 16-20, 2012
www.ans.iastate.edu/meatcourses
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 development of several projects and has contributed significantly to our bottom line.” Contact Becky Simon-Burton to reserve your seat
[email protected] - 952-736-9361
To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail:
[email protected] EQUIPMENT FOR SALE
RECRUITMENT
Night Mgr. (PC Steaks) .................................$65K Op.’s Mgr. (PC Steaks)..................................$75K Op.’s Mgr. (GB/Case Ready) ........................$65K Op.’s Mgr. (PC Steaks)..................................$75K QA Sup. (Bf. Sl/Fab).....................................$52K QA Mgr. (Sausage) .......................................$90K Asst. Mnt. Mgr (Bf Sl/Fab) ...........................$70K Safety Mgr.....................................................$85K PM (Food Processing).................................$100K
THE JUDGE GROUP Recruiting Excellence in the NP0711BillBraggs.indd 1
6/20/11 3:44 PM
Beverage/Food manufacturing industry for over 35 years!! We can take your company and or your career where you want to go!!
*Handling both Contingency and Retained Searches* National Openings available including but not limited to: • Plant Management • Operations Supervisors and Managers • Maintenance and Engineering • Quality Control Supervisors and Managers • Sanitation Supervisor and Managers • Warehouse Supervisor and Managers • Engineering Project/Process/Management • Positions available at various levels! To submit resumes or engage searches please contact: Kelly Meaney, Associate VP
Check out these and more ads at Provisioneronline.com
Judge Inc. Tel: 904-435-1302 • Fax: 904-435-1303
[email protected] www.judgeinc.com
BUSINESS FOR SALE
For Sale
Located in Central Indiana.
Retail butcher shop. Very profitable with sales exceeding $800,000. Owner retiring. Contact: Martin & Martin | 62 South 9th St. | Noblesville, IN 46060
Ready to OWN your OWN BIZ? Profitable custom butchering ser vice in Oklahoma for sale. State-inspected, custom e xempt, in busine ss for decade s. Enjoys unsurpassed reputation for qualit y and customer ser vice. $435,000. (417) 861-5401
60
FOR SALE
Property and Warehouse For Sale USDA and HACCP Compliant Est #1439 -15,000 square foot cement block building on 7.5 acres. (Room for expansion) -Apprx 12,000 square feet of storage and 3,000 square feet of office space -The 12,000 square feet is cooler and freezer storage -Located in PA 4 miles from NYS border -Buffalo 2 hrs—Erie 2 hrs—Cleveland 4 hrs— Pittsburgh 3 hrs—Rochester 2 hrs -City sewage and all utilities available -Indoor truck parking for 4 vehicles -Low taxes—approx $2500 per year -Excellently Maintained Replacement Value $1,200,000 | Appraised $425,000 Selling $350,000 Whitehawk Beef Company (O’Jacks, Inc) 45 Railroad Ave | McKean County | Eldred, Pa 16731 1-814-225-4755 | fax: 1-814-225-4908 cell: 1-716-498-0065 (Steven Slavin)
THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011
PLANT FOR SALE
PLANT FOR SALE Hog kill plant with processing facility for sale. The plant is located in the southeastern U.S. with several government incentives available to new owners. Call Scott 229-423-2093
To place your classified ad in The National Provisioner call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail:
[email protected] EQUIPMENT FOR SALE
MO FIKRY ENTERPRISES The World Local Supplier Jay - 323-972-5373 jay.mofi
[email protected]
Mo Fikry - 626-375-6291 mofi
[email protected]
www.grupoemex.com
www.vanzutphen.eu
Grupo Emex Mexico
Van Zutphen BV The Netherlands
www.havantec.eu
www.havantec.org
Havantec The Netherlands
Havantec Food Equipment Cairo, Egypt
Place an ad in The National Provisioner Classified Network
Need Grinder Parts? Want service after the sale? Meat Processing Equipment & Supplies Phone: 800-467-1201 • 402-597-5777
[email protected] www.mbasuppliers.com
Slaughter Equipment Cutting & Boning Equipment Rendering Equipment Processing & Packing Equipment Packaging Materials / Containers Miscellaneous & Safety Supplies Consultation Repair Services Plant Design Mesh Aprons, Processing Gloves & Sleeves Equipment Equipment Appraisal Specializing in QUALITY NEW-USED-RECONDITIONED-REBUILT equipment for the food industry
CALL US TODAY TO SAVE TIME AND MONEY!!!!!
www.rome-ltd.com
1-800-443-0557 PROVEN QUALITY & PERFORMANCE Denman DenmanEquipment EquipmentPartnership Partnership Equipment EquipmentLiquidator Liquidator&&Locator Locator EQUIPMENT EQUIPMENTFOR FORSALE SALE
4OLEDO 7ORKHORSE 7RAPPING 3YS s &ORMAX