The National Provisioner July 2011

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.

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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

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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

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“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

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July 2011

Tech

Volume 225 Issue 7

Editorial Board

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

H. Russell Cross Texas A&M University

Dan Emery Meaningful Solutions

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]

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Steve Valesko Butterball LLC

Kurt Vogel University of Wisconsin - River Falls

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Editor’sJournal

Only a matter of trust

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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]

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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

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We did it By Dennis Johnson

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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-

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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

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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.

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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.

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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

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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

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JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

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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!

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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

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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.

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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.

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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.

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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

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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.

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2011DELIREPORT

What’s

up

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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.

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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.

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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.

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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.

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FoodSafety

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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

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]

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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

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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

4OLEDO7ORKHORSE7RAPPING3YSs&ORMAX • Fatso 35 litre Bowl Kutter • Hobart 4356A M/G 'ROTE3LICERs3MITH-IXERs#60!6ACUUM • Cleveland 60 gal tilt kettle 901-755-7135 901-755-7135 Fax: Fax:901-754-0105 901-754-0105 e-mail: [email protected] [email protected] sswww www.denmanequipment.com .denmanequipment.com

JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

61

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

PARTIAL IN STOCK EQUIPMENT LIST * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

FOMACO MODEL 88-DW, TWIN HEAD INJECTOR WITH ROTARY BRINE FILTER ..................STOCK VMAG ROBOT 500 W/PORTION & POLYCLIP PDC 600 DOUBLE CLIPPER ..........................STOCK GROTE 613 VS MULTI SLICER ( NEVER USED ) SERIAL # 1135491 .................................STOCK RISCO 3000 BABY W/ PORTION & LINKER DRIVE ......................................................STOCK RISCO 5001 W/ PORTION,LINK & LIFT ...................................................................STOCK HANDTMANN VF20 W/ PORTION, LINK & LIFT .........................................................STOCK VMAG HP15S W/ PORTION & LINKER DRIVE ...........................................................STOCK HOLLYMATIC 865 MULTIFLO AND HOLLYMATIC 865 ROTOFLO PATTYMACHINES................STOCK CRYOVAC 8610-14E ROTARY VACUUM CHAMBER MACHINE ........................................STOCK REISER SUPERVAC GK 803 B ,NEW S.S 12” HOOD, NEW PLC, NEW BELT ........................STOCK ULTRAVAC 2000 & 2100 VACUUM DOUBLE CHAMBERS W/ 7.5 H.P. VAC.PUMPS ...............STOCK GLOBUS INJECTSTAR HSL 750 VAC.TUMBLER W/ PLC CONTROLS, 2 DRUMS/ LIDS ...........STOCK POLAR PM 4000 VACUUM COLD MASSAGER W/ GLYCOL REFRIGERATION .......................STOCK MTC 5000 # VACUUM RIBBON BLENDER W/ LOADCELLS & DIGITAL READOUT ..................STOCK KASEL BH20K CONTINOUS SLICE N TACT C/W 4 S.S. HARPSETS...................................STOCK SEVERAL BETTCHER BH 15 & 1- BETTCHER BH20 SLICE-N-TACTS .................................STOCK URSHEL 5600 COMUTROL .................................................................................STOCK URSCHEL 3640 COMUTROL ...............................................................................STOCK URSCHEL SLA DICER .......................................................................................STOCK 2- MULTIVAC 860 EPC ROLLSTOCKS .....................................................................STOCK DIXIE DP50 E & DP2000 ROLLSTOCKS ..................................................................STOCK GROEN INA 250 GALLON ,100 PSI STEAM JACKETED KETTLES W/ ADG.& SCRAPERS .........STOCK 2 JC PARDO 150 GALLON 70 PSI STEAM JACKETED KETTLES W/ ADG. & SCRAPE ..............STOCK MUELLER 1000 GALLON 90 PSI STEAM JACKETED PROCESSOR W/ADG. & SCRAPE ...........STOCK M TEK CORR-VAC GAS FLUSH MACHINE W/ 54” SEALBARS ........................................STOCK JACCARD SECTOMATIC SLICER ...........................................................................STOCK RYOWA RC 7800 SLICER ...................................................................................STOCK ROSS 950-3 SLICER .........................................................................................STOCK BIRO S.S. BANDSAWS MODELS 44, 55 & 4436 ........................................................STOCK AEW MODEL 350 & 400 BAND SAWS ....................................................................STOCK PACE S.S. 43’ TWIN 18 “ BELTS, 20 ADJUSTABLE WORK STATIONS ...............................STOCK KILIA 175 LITRE S.S. BOWL CHOPPER & SEYDELMANN K120 S.S. BOWL CHOPPER ...........STOCK WOLFKING 1000 # VACUUM PADDLES BLENDER W/ C02 SYSTEM & CONTROLS ................STOCK REITZ 2000 # TWIN S.S. SCREW BLENDER .............................................................STOCK MEPACO 5000# TWIN PADDLE MIXER ...................................................................STOCK HOLAC HO10,TRIEF DERBY & JACCARD DICERS ......................................................STOCK WEILER 1109 B GRINDER ..................................................................................STOCK SEYDELMANN CS 160 SELF FEEDING GRINDER .......................................................STOCK A-ONE WORKHORSE S.S. LIFT AND PIVOT- VAT DUMPER ...........................................STOCK

$$ VERY INTERESTED IN YOUR SURPLUS EQUIPMENT $$ APPROX. 45 MINUTES FROM NASHVILLE, TN AIRPORT, INSPECTIONS WELCOME

POLAR PM 4000 VACUUM COLD MASSAGER--STOCK

GROTE 613 VS MULTI SLICER (NEVER USED)--STOCK

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SPECIAL SERVICES SPECIAL SERVICES

62

3262 Hwy. 76, Cottontown, TN 37048 (phone) 615.323.9127 (fax) 615.323.9128 (cell) 615-289-3029 Email: [email protected] Website: www.mrlindle.com

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011

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

Wholesale Prices Used and Reconditioned Meat Dealers Welcome Processing Equipment from Europe

INJEKTOR 148 NEEDLES

KUTTER SEYDELMANN ALL SS 200 L loader unloader

011-52-722-213-6672 or 011-52-722-773-2337 | www.fleimatec.com | [email protected]

Bettcher 75 Dyna Form Meat Press complete with 1 in stock die (we currently have 50+ dies in stock). Completely refurbished with 30 day warranty.

SLAUGHTER www.barliant.com email: [email protected] Ph (630) 553-6992 Fax (630) 553-6908

Water Saving Washers

To advertise, call Diana Rotman at 847-405-4116

EPDM INFLATABLE DOOR SEALS,

Split Carcass Washers

Hide-on Carcass Washers

Head and Tongue Washers

Water Management Resources 800-552-5797 ~ www.watermr.com JULY 2011 | PROVISIONERONLINE.COM | THE NATIONAL PROVISIONER

63

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

Tenderizers New and Refurbished Machines Trades Accepted Original Super Blades in Clear Orange Top Tubes Solve Sanitation & Magnetic Testing Problems! Stainless Super Blades With “Stay On” Washer Standard & Hybrid Stainless Mag Sani-Heads w prices. Ross 24” Wide Poultry Tender-Press Tender King® by Staples Research Corp (703) 335-1301 [email protected]

64

THE NATIONAL PROVISIONER | PROVISIONERONLINE.COM | JULY 2011

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

FOOD SAFETY

BOILERS

Geor ge Lapsley Enterprises Food Safety Specialist www.getfoodhelp.net T: 267-221-2426 HACCP / SSOP / 3rd Party Audits E. coli, Lm, BSE Compliance Recall Technical Assistance USDA Assistance

Visit Us Each Morning For Your Daily Market News! Urner Barry Daily Price Report Daily, unbiased price quotations for the beef, turkey, chicken, pork and seafood markets. Urner Barry Market Report Video Updated every business day and provides the latest industry news, market production and price trends for the protein industries.

Urner Barry Daily Price Report

Urner Barry Market Report Video

www.ProvisionerOnline.com

AdIndex Company

Page

Armor Inox / Wolf-tec, Inc.

CCS2-CCS3

Beacon, Inc. Biro Manufacturing Company BrookÀeld Engineering Busch Vacuum Pumps and Systems CSB-System International, Inc. Formax/Provisur Technologies

21 30 10 9 53 25

Framarx / Waxstar Handtmann Inc. Henry & Sons Inc. Hixson

31 2 16 15

Hoegger Food Technology, Inc. Hollymatic Ingredients Solutions, Inc. James V. Hurson Associates Inc. JBT FoodTech Materials Transportation Company Meat Processing Xchange` NuTEC Manufacturing OSI OSSID Packaging Progressions, Inc. Poly-clip System Process Expo Purac Quickdraft Reiser Remco Products Rollstock Spraying Systems Co Weber Inc. West Liberty Foods World Technology Ingredients

CCS15 54 26 10 CCS7-CCS9 CCS13 59 40-41 7, 11 43 28 3 55 19 17 5, 29, 67 13 20 45 37 14 46-47, 68

Web site www.armorinox.com www.wolf-tec.com www.beaconmetals.com www.birosaw.com www.brookÀeldengineering.com www.buschusa.com www.csb-system.com www.formaxinc.com www.perfectburgerformula.com www.framarx.com www.handtmann.com www.dhenryandsons.com www.hixson-inc.com www.webinars.provisioneronline.com www.hoegger.com www.hollymatic.com/np www.IngredientsSolutions.com www.hurson.com www.jbtfoodtech.com www.mtcworldwide.com www.mp-xchange.com www.nutecmfg.com www.OSIGroup.com www.OssidIntegrity.com www.pacproinc.com www.polyclip.com www.myprocessexpo.com www.purac.com/meatandpoultry www.quickdraft.com www.reiser.com www.remcoproducts.com www.rollstock.com www.spray.com/foodsafety www.weberslicer.com www.wlfoods.com www.wtiinc.com

PROCESSOR INDEPENDENT

SM

SERVING SMALL AND MIDSIZE MEAT, POULTRY, AND GAME PROCESSORS

PUBLISHER

Also publishers of: Beverage Industry, BrandPackaging,

Dave Lurie

PRINT, EVENT AND INTERNET ADVERTISING Dave Lurie

Candy Industry, Dairy Foods,

CUSTOM MEDIA

[email protected] • (248) 593-0337

Flexible Packaging,

Rick Parsons

Food & Beverage Packaging,

[email protected] • (248) 593-0337

Dave Lurie

[email protected] • (248) 593-0337

[email protected] • (407) 302-7952

SINGLE COPY SALES/ BACK ISSUES

[email protected] • (415) 387-7784

[email protected] • (248) 405-4061

[email protected] • (630) 962-0094

Ann Kalb

REPRINTS

Jill L. DeVries

[email protected] • (248) 244-1726

Wayne Wiggins Vito Laudati

CLASSIFIEDS

Diana Rotman

[email protected] • (847) 405-4116

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

Food Engineering, Independent Processor,

BNP MEDIA II, L.L.C

Prepared Foods, Private Label Buyer,

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

Industria Alimenticia, Meat & Deli Retailer, Refrigerated & Frozen Foods, Refrigerated & Frozen Foods Retailer, Snack Food & Wholesale Bakery

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

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

Leading the food industry in processing and packaging solutions.


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WITHOUT IMPACTING FLAVOR? Call us today at 877-221-8558 Or visit www.wtiinc.com

Cooking / Chilling Systems

JULY 2011 »

Value added processing made easy. The Thermix™ System is a fully integrated solution to automatically shape, cook, chill and move cooked meat products within the processing system. Typical throughput ranges from 40,000 lbs./day up to 400,000 lbs./day. The main proven benefits of this technology are:

Fully Automatic “In Line” and Flexible System The Thermix System is a fully automatic processing line with one continuous product entry point (molding) and one continuous exit point (demolding). The system works continuously at a steady pace with automated product transfers. The batch cooking/chilling system has fully independent processing tanks and temperature control to allow processing of multiple products and shapes simultaneously. The compact and modular design allows easy system expansion by simply adding more processing tanks. The Thermix System can be synchronized with a fully automated distributor to store the product before slicing or packing. Consistent Product Shape and Dimensions Consistent and repeatable product dimensions are possible with the revolutionary Multimolds™ stacking system. A maximum piece-to-piece size deviation of only +/-2mm can be achieved on the entire length of slicing logs up to 100" as well as +/-2mm on the dimensions of deli products. Yield Improvements The exact product dimensions are enhanced further with the Multimold’s “dimple design” which accommodates the log clips so that they extrude from the product ends, allowing higher slicing yields with much less waste. Maximizing the overall log length to

with water treatments such as ozone, UV-systems or filtration. Food Safety With Full Reporting of Product and Process Data The Thermix System offers full traceability of the entire cook, cool and chill cycles. Full HACCP-type batch reports can be produced for every batch. The fully developed PLC control of the Thermix provides updated event logs, backups and alarms. 60", 72" or 100" also enhances product yields. The Thermix System offers perfectly sharp and sliceable ends and uniform dimensions throughout the entire log length. The highly consistent cooking and chilling temperatures throughout the processing tanks provide important benefits in cooking yields and product quality. Thermal Transfer Efficiency Water cooking and chilling by immersion is proven to offer the best possible temperature homogeneity within the processing tanks – a temperature variance of no more than +/-2°F within a fully loaded (up to 20,000 lbs. of product) Thermix™ processing tank. Cycle times are dramatically reduced thanks to the consistent heat application and distribution around each product. Chilling can be most efficient using brine chilling to reach lower final core temperature.

Sanitation All modern sanitary design principles are integrated throughout engineering and manufacturing. The system features on-line washing of the Multimolds after each use. Maintenance The Thermix System provides greatly reduced maintenance costs, with no maintenance needed on the Multimolds. The robust system easily meets the 24/7 demands of North American processors.

Service/Parts/Support Trained service technicians and spare parts are available through Wolf-tec, Inc. in the U.S.A. The system can be configured to allow remote control, self-diagnostics and troubleshooting.

Reduced Manpower Only two employees are necessary to produce and handle 20,000 lbs./hour without any difficulties. Energy and Water Savings Energy cost savings of up to 30% can be achieved due to full recycling of hot, cold and chilled water, cycle after cycle, into three external storage tanks. The water “shelf-life” can be extended to up to six months or more

Proven Worldwide Technology Armor Inox has become the most recognized name in fully automated cooking and chilling systems. More than 50 high-capacity Thermix Systems are in operation throughout Europe, North America and Asia, with proven reliability for more than 20 years.

Cooking / Chilling Systems

Making and packagi

S

ince environmental exposure is a major source of Listeria monocytogenes contamination on fully cooked ready-to-eat products, cook-in-the-bag processing has become very important. By not exposing the product to the environment between cooking and packaging, the chance of Lm contamination is eliminated, which reduces the need for some of the antimicrobial agents and the post-packaging pasteurization process to eliminate Lm on ready-to-eat meat products. Cook-in-the-bag deli products were being made safer for consumers long before processors were aware of the risk of environmental contamination by Lm. Assuming that the cooking procedure provides sufficient lethality, there should be no Lm in the package up to the point that the package is opened by the end-user. This By Lynn Knipe, product has long been underOhio State University stood to have a shelf life that Editorial Board was more than twice as long Member as products that were exposed to the environment, before the final vacuum-packaging process. Using steam or water cooking methods, this product also cooks faster than the traditional oven-cooked products. Moisture-impermeable casings have become more popular as a means to cook and distribute wholemuscle products and luncheon meats without exposing the product to the environment between cooking and packaging. Smoke, spice, and surface coloring technologies have been developed to allow for the application of colors and flavors to the inside of the impermeable casings or pouches, so that products that were traditionally made in a smokehouse or oven could be made using a cook-in-the-bag process. In addition to the food-safety advantage, these products cook faster in hot water or steam than the traditional oven-cooked products. More recently, the co-extrusion process for making sausage links has incorporated the cook-in-the-bag concept into the processing of sausage links. This has been accomplished by treating the surface of the links, so that they are firm enough to be loaded into the package for cooking. The final cooking of this product

eb

» CCS-4

is done in the same package as is used for distribution to consumers, eliminating the chance for post-lethality environmental contamination by Lm. Even more recently, the food-safety benefit of cookin-the-bag technology has progressed to natural casing products. To accomplish this with natural casing links, these products are partially cooked (to about 130ºF internal), and smoked (either liquid or hardwood smoke),

COOKING / CHILLING SYSTEMS | THE NATIONAL PROVISIONER | JULY 2011

Cooking / Chilling Systems

ing a safer sausage

Courtesy of Lynn Knipe

then loaded into retail packages, vacuum-sealed and cooked in either water or steam. The partial cooking allows time for smoking of the links and to firm up the link enough so that they can be handled during the packaging process. Grilling could potentially be used as the initial cooking step, to apply grill marks and surface browning to links that are not smoked. In addition to the increased safety of this product,

the shelf life of this fully cooked product is increased, some as high as 120 to 150 days. This isn’t actually a new process, as some readers will remember. In the past, it was common to smoke natural casing links in a smokehouse, and then cook the links in hot water using a Jordan cooker. One advantage to this process is that it can be adapted by smaller processors who are making natural casing products. For smaller volume production, it might also be adaptable for making skinless links. For larger processors, equipment and a process have been developed by ALKAR-RapidPak, Inc. (PureLink) to do this on a continuous basis. A big advantage to this process is that the finished product isn’t exposed to the environment between the time of the lethality process and when the end-user opens the package. This means that this process is not subject to the “430 regulations (9 CFR Part 430)”. For products that are not post-lethality exposed, a Listeria control plan is not required, which means that the processor would not need to comply with the requirements included in one of the three Alternatives, and that antimicrobial agents may not need to be added to the product. This would apply to all of the products discussed earlier, in which the final cooking step is done in a vacuum-sealed bag. This process would require a stable formulation, in order to prevent moisture and fat cookout in the package that your final consumer will see. Some products that are made entirely in an open oven may not adapt well to this process initially. Some products may require some process and/or ingredient improvements to improve the water and fat-binding capacity of the product to prevent fat and water from being cooked out of the product and trapped in the package. One disadvantage to this process is that because the links aren’t fully cooked at the time of packaging, the packaging process would need to take place in either a separate room or at a separate time from the packaging of fully cooked products, to avoid cross-contamination. For larger processors, this process involves a dedicated line separate from the fully cooked product packaging lines. Because the risk of environmental contamination is eliminated, when the product is not exposed postlethality, the product is not only safer, but the regulatory requirements for antimicrobial ingredients, post-lethality treatments, sanitation programs, and product testing are reduced. Although this concept is not without some challenges, it has the potential to be a win-win situation for everyone. JULY 2011 | THE NATIONAL PROVISIONER | COOKING / CHILLING SYSTEMS

» CCS-5

Cooking / Chilling Systems

Food

safety, in the

BAG Cook-in-bag technology is quickly gaining popularity for its contamination elimination. By Sam Gazdziak, editor, Independent Processor

The ongoing focus on food safety has forced food manufacturers to re-evaluate every aspect of their operation, from the raw materials that enter their facilities to the packaged products leaving them. The cooking and chilling process has not gone overlooked in the search for pathogen-free products, and some of the latest developments in cooking process are making great strides toward that goal. Though recent reductions of capital spending industry-wide have slowed the growth of in-package pasteurization systems, the technology is continuing to become part of the mainstream. In the process, products are partially cooked or smoked to provide

» CCS-6

COOKING / CHILLING SYSTEMS | THE NATIONAL PROVISIONER | JULY 2011

the necessary smoke color and make the product firm enough to handle. Then, they are taken from the dry-heat system, packaged and put through a hotwater pasteurization and cold-water chill system. The benefits to the system are significant, in that it eliminates the handling of product once it has been cooked, and therefore eliminates the risk of postcook contamination. “The food-safety side of this is really unmatched, because you have no ready-to-eat area in a system like that,” says Bob Hanson, founder of HansonTech, a consultant firm that specializes in thermal processing of meat products. A plant that converted

30,000 sq. ft. of fire and ice Fire up your products at the Tech Center, your full line plant away from home. Portioning ‡ Slicing ‡ Coating ‡ Frying ‡ Filtration ‡ Cooking Searing ‡ Grilling ‡ Char-marking ‡ Chilling ‡ Refrigeration Freezing ‡ Testing ‡ Technical Support ‡ Training

www.jbtfoodtech.com

The Tech Center. This is where you will find the best equipment there is: Stein ‡ Frigoscandia ‡ DSI ‡ Double D ‡ Northfield

Stein GYRoCOMPACT® II-1000 Oven

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Stein JSO IV TF Jet Stream® Oven

The GCO II-1000 Oven represents our latest and most successful oven technology. Functionality, operation and throughput have been enhanced resulting in a high volume oven that delivers more consistent quality and higher yields.

The GCO II-600 oven represents our latest advance in oven technology. Functionality, operation and throughput have been enhanced in a compact design that delivers consistent product quality and higher product yields.

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Cooking / Chilling Systems

Courtesy of HansonTech

Marinated bone-in chicken thighs cooked in an impingement oven.

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completely to this approach, he says, would only have raw areas and packaged areas, with no chance of post-cook contamination. “As such, a converted plant would have a significant manufacturing, food safety, regulatory and yield advantage over conventional plants,” he says. Jeff Sindelar, assistant professor/extension meat specialist at the Meat Science & Muscle Biology Laboratory at the University of Wisconsin-Madison, notes that this relatively recent technique relies on an extremely time-tested cooking method. “Cook-in-bag technology is a great way of taking old technology, which is water — one of the best mediums for heat transferability and cooking — and applying that to a product where you can maximize quality, shelf life and food safety, CCS-10

just by adjusting your process,” he says. “The trick is, how do you do that and still make the wide variety of products that are made, and make them with the characteristics and properties that we see today,” Sindelar adds. Dr. Cathy Cutter, associate professor and food safety extension specialist-muscle foods at Penn State University, said that she has worked with a processor that incorporated a cook-in-bag and chilling process in its facility. As a result, the company was able to land a large retail contract, thanks to the food-safety benefits of the process as well as the quality of the end product. “We have to marry the safety issues with the quality, because you can do everything [to ensure food safety], but if it doesn’t look right,

COOKING / CHILLING SYSTEMS | THE NATIONAL PROVISIONER | JULY 2011

nobody’s going to buy it,” she says. Cutter notes that the technology is not just for companies with large capital-expenditure budgets, either. “This has potential for even small processors, if you can build a system and make it do everything you want,” she says, referring to a processor she knows who found commercial systems too expensive. “So he took some of the parameters and built it himself.” Currently, most of the products made using cook-in-bag technology are links, but it could be expanded to include items such as non-sliced deli meats and hams, Hanson notes. The process itself can also be adapted to either a continuous or a batch process. “The in-package pasteurization process itself is independent of the machinery, and so it is readily adapted to batch processes,” he

ing times, which will require a significant amount of in-plant data generation.

Cooking up new ideas While in-package pasteurization has come on strong in recent years, there are a wide variety of cooking methods available, and plenty of cooking equipment in the market for processors. “If you’re making a typical cooked sausage, say a frankfurter, you could purchase equipment depending on your facilities, your line speeds, your volume, how much money you have, the direction you think your company is going to go in the future,” says Sindelar. “That might range anywhere from a simple gravity-flow house to a smokehouse, where you’ve got better control over humidity, to a continuous oven.”

Straight-line impingement ovens have been popular for ready-to-eat products, such as sausage patties and chicken breasts. Hanson notes that the impingement ovens have dominated the rapid-cook end of cooked meats for a long time, but he has seen spiral ovens gaining in popularity. “Impingement ovens used to have a significant edge over spiral ovens for products that needed more browning, but newer airflow designs in spirals have narrowed the gap on browning capabilities,” he says, “and spiral ovens can now make most products that are made in impingement ovens.” The obvious advantage of the spiral ovens is the reduced footprint. “Processors are always looking to use the height of the building instead of a larger footprint, because

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Courtesy of HansonTech

Diagram of batch oven airÁow showing inherent hot and cold zones due to air-handling design.

JULY 2011 | THE NATIONAL PROVISIONER | COOKING / CHILLING SYSTEMS

Cooking / Chilling Systems

explains. While cook-in-bag technology has shown considerable promise, processors must take steps to ensure that they are doing it correctly. Cutter notes that any company looking to utilize the technology must make sure that it is using the right film in its packaging. “You’ve got to work with your packaging film company to make sure it can withstand the heat and chilling that goes with [cook-in-bag technology],” she says. “You’ve got to do the background work to make sure you’ve got film that meets the right temperatures, that it withstands them for the period of time that you’re going to be cooking, and that you’re not going to have a release of chemicals.” She adds that each product cooked with the technology will need its own cooking and chill-

CCS-11

Cooking / Chilling Systems

Courtesy of HansonTech

Example of deli ham cooked using in-package pasteurization in batch equipment. Deli ham was smoked and cooked to 100F in a smokehouse, then hot-packaged and Ànal cooked to 160F using steam.

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of the increased building costs [of expanding]” Hanson says. “By going vertical, they can use the less expensive building space.” Hanson adds that most spiral cookers have two cooking zones, which increases their capacity. The higher capacity allows processors to cook products for a little longer than they would in a linear impingement oven. “The higher-capacity system allows you to ease off the gas pedal and not have to push the product so hard to get a reasonable capacity out of the oven,” he says. “With impingement ovens, you’re always pushing them as hard as you can, because getting a reasonable capacity out of those systems is much more challenging.” CCS-12

Despite the longer cooking times, a spiral oven can produce higher yields, and the longer cook time can also lead to higher lethality of pathogens, he says. The disadvantage, however, lies in the complexity of a spiral oven versus a linear one. “A straight belt is easier to maintain than a spiral belt,” Hanson says. “Even if it’s well-built, there are inherently more parts and more wear areas, and having a belt go in a spiral is harder on a belt, so it will generally be higher maintenance.” When making an evaluation of linear or spiral ovens, Hanson notes that the yield and capacity advantages of a spiral oven and the reduced construction costs have to offset the higher maintenance costs.

COOKING / CHILLING SYSTEMS | THE NATIONAL PROVISIONER | JULY 2011

Cooking technology continues to evolve, shortening cook times and improving food safety. Sindelar notes that a European company has been manufacturing cooking equipment for a dried sausage that stuffs, crust-freezes, chills, slices, thermoprocesses and dries it. “They’re able to speed up the drying process quite a bit,” he notes. “You’re essentially going from days and weeks of drying to minutes and hours.” One of the biggest improvements in cooking technology is the ability to have better controls, which results in more uniform cooking. Sindelar says that future improvements in the technology will help improve that consistency, though it can be an uphill struggle.

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Cooking / Chilling Systems

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“With cooking and cooling, you’re battling product quality, maintaining good cook yields and good throughputs, safety, and you’re battling all that with raw materials, ingredients and processing conditions — such as environmental temperatures — that vary,” he explains. “Regardless of how hard you try, you constantly have a little variation from batch to batch and lot to lot. Most times it’s very minimal, but there’s still a little bit there.” In the meantime, processors can still do much to optimize their existing cooking equipment as much as possible. Hanson points out that the industry’s tendency to get the most out of its cooking machines rather than buy new models, as well as the current economic situation that has stalled some purchases, has made operators more knowledgeable CCS-14

about airflow and process optimization. “If you can just turn a few knobs and make small airflow adjustments to increase plant throughputs instead of buying new capacity, the return on investment is remarkable,” he says. Keeping airflow in balance is one way to keep an oven running as efficiently as possible. Impingement and spiral ovens have airflows with more of a fixed pattern, so they don’t tend to go out of balance as often as smokehouses. Smokehouses, due to their nature, have the potential for variation from top to bottom, side to side, and/or front to back, whereas products on a belt can only have side-to-side variation across the belt. “What I tell my clients is that most ovens are stealing money from

COOKING / CHILLING SYSTEMS | THE NATIONAL PROVISIONER | JULY 2011

you, in the form of out-of-balance airflow, which results in excess evaporation, which is money out the stack that you could have kept in the product and sold,” Hanson says.

Chilling developments The chilling process goes handin-hand with the cooking process, and there have been many efforts made to improve that system as well. Not every attempt worked. Hanson notes that when hot products enter a cold environment, moisture wants to evaporate from it. Some processors have tried to minimize that evaporation by keeping a high humidity in the chiller, an effort that Hanson calls misguided. The humidified chillers used abovefreezing temperatures to prevent coil freeze-up, but the warmer air actually slowed the cooling rate of

as efficiently as possible. the chiller and actually increases cooler losses. “The key to reducing cooler loss is to get the product cold as fast as you can,” he explains. “Once a product is cold, it’s not near as prone to losing moisture. High humidity in the system really doesn’t help.” Blast-chill cells have become more common in the last three to five years, and the most recent designs are equipped with higher air velocities to maximize chilling rates and reduce cooler shrink. “I have found that the best designs are those that deliver an air velocity of 400 feet/minute or higher across all product surfaces in all areas of the chiller,” Hanson says.

Another development is the use of dedicated blast chillers, which may only accommodate one or two smokehouses instead of an entire facility’s worth of products. Those products are then moved into a holding cooler when ready. The holding cooler, Hanson notes, is designed to keep products cool and not chill them down, so any company that is attempting to use a holding cooler as a chiller will not see effective results. Brine chillers are commonly used for high-speed, high-volume applications, when the processor needs to chill products rapidly. “They use a water brine to lower the freezing temperature of the water, and you get very efficient chilling,” says Sindelar.

In order to promote good sanitation, the brine should be treated with either chlorine or citric acid to eliminate salt-tolerant pathogens such as Listeria monocytogenes, Hanson says. “All chillers should be highly cleanable, so that exposed RTE products are not cross-contaminated with pathogenic or spoilage bacteria during chilling,” he adds. Incidentally, using in-pasture pasteurization for cooking products will also aid in chilling them as well. Since products are already in their package when they are put into the chiller, those products will not lose any further moisture. The net result is higher yield and the elimination of cooler shrink.

Cooking / Chilling Systems

Keeping airflow in balance is one way to keep an oven running

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JULY 2011 | THE NATIONAL PROVISIONER | COOKING / CHILLING SYSTEMS

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COOKING / CHILLING SYSTEMS | THE NATIONAL PROVISIONER | JULY 2011

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