Let’s Build a Hygienic · Prof. Dr. Y. Onur Devres ([email protected]) Devres Technology and Consulting Ltd., Istanbul, Turkey “Industry-End Users: Future Vision in Cold Chain”

Let’s Build a Hygienic

Cold Chain in Fresh Fruit

and Vegetables Business

Prof. Dr. Y. Onur Devres ([email protected])

Devres Technology and Consulting Ltd., Istanbul, Turkey

“Industry-End Users: Future Vision in Cold Chain” Panel Strengthening HVAC&R: Building the Future Together

İzmir, April 21-22, 2017

mailto:[email protected]

Devres Technology and Consulting Ltd. 2

Prof. Dr. Devres (ME, 1985-1994: The Scientific and

Technical Research Council of Turkey (TUBITAK), MRC,

Food and Refrigeration Department; 1994-2011:

Istanbul Technical University, Food Engineering

Department; 2006-2009: Head of the Department;

since 07.2011: Devres Technology and Consulting Ltd.).

Devres Technology and Consulting Ltd. is specialized in engineering operations in food industry:

Cold and Frozen Storage,

Fruit and Vegetables Processing Lines:

Fresh, Freezing, Canning, Drying etc.

Packaging,

Hygienic Design in Food Processing Plants,

Training (EHEDG and custom made).

Let’s Build a Cold Chain in Fresh Fruit and Vegetables Business, “Industry-End Users: Future Vision in Cold Chain” Panel


3

Prof. Dr. Devres:

A book on “Drying” published by Istanbul

Chamber of Industry.

Editor and author of a book namely “Food Safety

and Cold Chain” published by Turkish Food

Safety Association and Air Conditioning

Refrigeration Producers Association.

In editorial board of a book “Industrial Kitchens”

published by Boyut Publishing.

Published many scientific papers

(http://www.devres.net).

A patent on a cooking device namely “Device for cooking by means of electrical resistance”.

Devres Technology and Consulting Ltd.



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Prof. Dr. Devres serves both in Turkey and

also in surrounding countries as an engineer,

consultant and business developer;

introduces new techniques, technologies

and products to companies on food

processing.

Devres Technology and Consulting Ltd.



What are the Food Loss and Waste? 5

Food losses refer to the decrease in edible food

mass throughout the part of the supply chain that

specifically leads to edible food for human

consumption.

Food losses take place at production, postharvest

and processing stages in the food supply chain.

Food losses occurring at the end of the food chain

(retail and final consumption) are rather called

“food waste”, which relates to retailers’ and

consumers’ behavior.



What are the quantities? 6

Roughly one-third of the edible parts of food

produced for human consumption, gets lost or

wasted globally, which is about 1.3 billion ton per

year.

In medium- and high-income countries food is to a

great extent wasted, meaning that it is thrown away

even if it is still suitable for human consumption.

In low-income countries food is mainly lost during

the early and middle stages of the food supply

chain; much less food is wasted at the consumer

level.




Roughly one-third of the edible parts of food

produced for human consumption, gets lost or

wasted globally, which is about 1.3 billion ton per

year.

In medium- and high-income countries food is to a

great extent wasted, meaning that it is thrown away

even if it is still suitable for human consumption.

In low-income countries food is mainly lost during

the early and middle stages of the food supply

chain; much less food is wasted at the consumer

level.




The per capita food loss in Europe and North-

America is 280-300 kg/year.

In subSaharan Africa and South/Southeast Asia it is

120-170 kg/year.

The total per capita production of edible parts of

food for human consumption is, in Europe and

North-America, about 900 kg/year and, in

subSaharan Africa and South/Southeast Asia, 460

kg/year.

Food waste at consumer level in industrialized

countries (222 million ton) is almost as high as the

total net food production in subSaharan Africa (230

million ton).



What is Value Chain? 9

Value: the amount of

money that something is

worth.

It is set in the mind of the

person who hold the

money.

But a chain is something

that can be broken, and

breaking the value chain

is to lose all the value of

the product.



What is Cold Chain? 10

Cold chain: The supply

and distribution of

commodities that must

be kept within

a defined temperature

range

throughout the cycle

between production

and consumption.



What is Cold Chain? 11

The aim of the cold

chain is to sustain the

value of the product

from harvesting to

consumption.

The cultivation

techniques affect the

quality of the product in

its shelf life.

Therefore it should be

taken into consideration

primarily.



Shelf Life 12

Step 1

∙ Ingredients

∙ Composition

∙ History/Data

Step 2 ∙ pH

∙ Water activity ∙ Preservative

content/ Preservation technique

Step 3

∙ Storage trials

∙ Product testing

∙ Sensory trial

Product Shelf Life

Primary Product

(F&V)

∙ Cultivation

(fertilizers,

chemicals,

irrigation etc.)

∙ Harvesting

Food Safety

Issues

∙ Maximum

Residue Levels

(MRLs)

∙ Minimum

Hygiene

Requirements

∙ Traceability

A bomb

on the

shelf

A bomb

on the

shelf

∙ Orchard

sanitation

∙ Precooling

∙ Drenching



Shelf Life 13

Shelf life is

extremely

dependent

on storage

conditions.



Traceability 14



Traceability: RFID 15



Traceability 16



Go to Hygienic Design

Production 17

GLOBALG.A.P. Certification covers:

Food safety and traceability,

Environment (including biodiversity),

Workers’ health, safety and welfare,

Animal welfare.

Includes:

Integrated Crop Management (ICM),

Integrated Pest Control (IPC),

Quality Management System (QMS) and

Hazard Analysis and Critical Control Points (HACCP).



Production 18

The GLOBALG.A.P. standard is primarily

designed to reassure consumers about

how food is produced on the farm by

minimizing detrimental environmental

impacts of farming operations, reducing

the use of chemical inputs and ensuring a

responsible approach to worker health

and safety as well as animal welfare.



Product Supply: Contract

Farming

19

Objective of Contract Farming

To achieve consistent quality,

To achieve regular supply,

To improve quality of produce,

To stabilize the agro-raw

produce,

To stabilize the price to each part

as it is not affected by market

prices.



Product Supply: Harvesting 20



Product Supply: Harvesting 21



Distribution 22

Farmer

Agents/ Broker

Manufacturer

Wholesalers

Retailers

Consumer

Farmer

Agents/ Broker

Manufacturer

Wholesalers

Retailers

Consumer

Farmer

Agents/ Broker

Manufacturer

Wholesalers

Retailers

Consumer

Farmer

Agents/ Broker

Manufacturer

Wholesalers

Retailers

Consumer



Product Receiving 23

Specifications should be defined and checked precisely

at the beginning of processing (If they are not already

fulfilled in the orchard/field carefully):

Postharvest disease (especially mold etc.)

Size

Color

Ripeness

Dirt

Under- or oversized

Injured

Squashed

Burst Puffy

Postharvest diseases should not be entered to processing

plant: Microbial resistance against common fungicides.



Processing 24



Water Treatment: Drinking

Quality

25

3-4 more times of

processed fruit and

vegetables capacity.

Raw water tank (at least

5-6 hours of usage)

Processed water tank (at

least 5-6 hours of usage)

Drinking water quality

tank (stainless steel)



Packaging 26

Types of Packaging

Modified Atmosphere Packaging

(MAP)

Shrink Wrap

Packaging

Vacuum Packaging





Packaging: MAP 27

Packaging 28



Storage 29

Cold store types

Precooling: 0ºC/+8ºC

Cool storage: +8ºC/+14ºC

Cold storage: -1ºC/8ºC

Frozen storage: -18ºC/-24ºC

Deep freezing: -35ºC/-45ºC

Controlled Atmosphere Storage

Products



Storage 30

Product storage temperature and relative humidity,

Product entrance temperature,

The amount of daily product entrance,

Storage capacity,

Dimensions of cold store,

Number of rooms and corridors,



Storage 31

Location,

Construction type,

Insulation thicknesses,

Storage room door type and dimensions,

Height from the ground,

Storage room floor type, Packaging sizes.



Boxes 32



Pallets 33

Model Size

EUR, EUR 1,

ISO1

1200 mm x 800 mm

EUR 2, EUR 3,

ISO2

1200 mm x 1000 mm

EUR 6 800 mm x 600 mm

Customized size

USA 1100 mm x 1100 mm

USA 1100 mm x 1200 mm

Customized size



Pallets 34



Cold Store Racking System 35



Processing Plant 36

HYGIENIC DESIGN

Zoning

Avoid horizontal surfaces

Drainability

Pipe connection features

Easy cleanability is a must

Framework features

Open cabling

Welding, Joints, Seals



General Recommendations 37

Drainability

Avoid sharp edges and corners

(r > 3 mm)

Cabinets slope away from

product

No overlap joints or press-fit

Joints continuously welded or

sealed

Avoid soil or microbial

accumulation

Make it close if possible

Keep it covered



Drainability 38

The exterior and interior of all equipment and pipework must

be

Self-draining or drainable, Easily cleanable.

Horizontal surfaces(upwards or downward facing) must be

avoided.

Surfaces should always slope away from product.

In case of external surfaces: slope away from the main product area.

Drainage of condensates should be considered when

appropriate.



Top Rims 39

(a) (a)

(a) (a)

(a)

(a)

! ! !

(a) product area, (b) residues of soil and product, (c) continuously welded rim



Transportation 40

Forklifts

Trucks: Refrigerated

Loading:

Dock levelers and lifts

Hydraulic

Mechanical

Dock seals



Transportation 41

@ 4. MAFEX – Maghreb Food Exhibition, Casablanca Morocco, December 9-11, 2015

Transportation 42

Temperature

Temperature data

loggers/recorders

Spy

Wireless

RFID (Radio

Frequency

IDentification)



Points of Sales 43



Calibration 44

International Bureau of Weights and Measures (BIPM, Paris)

National Metrology Laboratory

(The National Direction of Metrology, Morocco)

Accredited Laboratories

User Testing/Calibration Laboratory



Technology 45

Distribution chain should be well tracked by means

of information technology.

Global Trade and Identification Number (GTIN)

www.gs1.org

Barcodes

eCom Global Data Synchronization Network



http://www.gs1.org/

Training 46

Workers are staying at the heart of the all cold chain operations.

A person in harvesting

A person in packaging

Forklift operator

They shall be trained continuously on fundamental

knowledge; also informed and aware on how he/she

is important individually.



Results 47

Food Safety Expectations in Cold Chain Operations

Cleanable (also drainable)

Reachable to clean and to service

Traceable (on temperature and time basis)

Low T (Temperature difference between evaporator and room temperatures)

Low energy



Results 48

The success of a cold chain is hidden in the value chain:

If you can find a buyer that pays a good price to your

product: it means that your cold chain activities are perfectly

accomplished.

If someone pays a better price to your competitor: it is time to

check your cold chain operations before go to bankruptcy.

So the result is simple:

Quality at the end earns its value. Quality at the end earns its value.



Do you have any questions?

Prof. Dr. Y. Onur Devres ([email protected])

Devres Technology and Consulting Ltd., Istanbul, Turkey



Documents

Let’s Build a Hygienic · Prof. Dr. Y. Onur Devres ([email protected]) Devres Technology and Consulting Ltd., Istanbul, Turkey “Industry-End Users: Future Vision in Cold Chain”