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Food Safety 2020 – Are You Ready?Laura Dunn-Nelson | Jeff Chilton | Dr. Amit Morey
April 15, 2015
Webinar Logistics
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• All lines are in listen-only mode
• Post your questions early and often!
• A link to the webinar recording will be emailed shortly after the event
Today’s Speakers
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Laura Dunn-NelsonAlchemy
Jeff ChiltonAlchemy
Diana PeñaModerator
Dr. Amit MoreyI.D.E.A. Food
Industry Consultants
Agenda
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• Employee Optimization
• Food Safety Controls
• Emerging Pathogens
• New Technologies
• Recap
• Q&A
Food Safety 2020: Employee Optimization
Laura Dunn-NelsonAlchemy
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Workforce Challenges
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• Resourcing and Retention
• Diversity
• Engagement
Employee Resourcing
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62% of organizations identified employee sourcing as the greatest challenge they face in their talent acquisition efforts
Source: Aberdeen Group Research, April 2013
Employee Resourcing
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Employee Retention
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• Turnover has direct costs ~$3,500/employee (and potentially much more in risk). Source: Society for Human Resource Management
• New/replacement workers make more mistakes.
• Lower turnover = greater “institutional memory” and fewer mistakes.
• With high turnover, it’s nearly impossible to build a cohesive food safety culture.
The top reason for employee turnover is lack of training Harvard Business Review
Diversity - Multigenerational
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• 18-24 year olds send/receive an average of ~110 text messages per day (>3,200 per month).
• Half of those in the 18-24 age group would prefer texting over talking to someone and 30% have used their phone to avoid interacting with others.
• 42% of those aged 18-29 reported having trouble doing something when their phone is not available.
• When is the last time you saw anyone under age 25 reading a newspaper?
Generation Challenges
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Generation Type Coaching Strategy
Traditionalist Not necessary
Baby Boomers Does not handle well negative feedback
Generation X Not necessary to receive feedback
Generation Y/Z Constant feedback needed
Diversity – Education Variances
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• 26.5% of the foreign-born labor force >=25 years old have not completed HS (vs 5.4% of native-born).
• Illiteracy rates vary dramatically by region and culture – even within US.
• >75% of students in the Detroit Public School system will not graduate high school
Engagement
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$450 - $550 Billionin lost
productivity
70% of workers are
either unengaged
or actively
disengaged
Source: State of the Global Workforce Report 2013,Gallup
The Power of Engagement
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• Employees receiving predominantly negative feedback from their manager are over 20 times more likely to be engaged than those receiving little or no feedback.
• Managers focusing on employee strengths are 30 times more likely to manage actively engaged workers compared with managers denying feedback.
• Managers giving little or no feedback to their workers fail to engage 98% of them.
*2009 Gallup Survey
Innovations for an Optimized Workforce
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• Robust Organizational Culture
• Big Data Usage
• Effective Training
An industry study revealed an increased compliance rate from 68% to 94% after training and corrective observations occurred
*AFAB, Volume 4, Issue 1 2014
Verification of Behavior Changes
Model
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• Goal: Predict efficiency and safety on specific food manufacturing lines
• Tool: Technology that digests disparate data to create predictive model
• Result: Actionable Data
Predictive Analytics
Technology
Employee Demographics
Training
Throughput
OEE/Yield
Incidents
Quality Records
Customer Complaints
New Data
Prediction
Predictive Analytics
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Augmented Reality
Action Items to Help Prepare
• Initiate Employee Engagement Studies
• Measure Training Effectiveness
• Enhance Employee Skills
• Seek Technology Enablers
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Food Safety 2020: Controls
Jeff ChiltonAlchemy
Current Food Safety Challenges
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• Product recalls due to pathogens, allergens and foreign material contaminations are still occurring at an alarming rate
• Foodborne illness outbreaks impacting public health
– Ice Cream and Caramel Apples
• New USDA regulatory standards & revised sampling methods are tightening Pathogen Performance Standards for Salmonella and Campylobacter in Poultry
– Federal Register Notice January 2015
– FSIS Notice 22-15
What’s Coming
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• USDA HACCP Validation requirements for critical limits and critical operating parameters
• Food Safety Modernization Act – New Standards
– HARPC (Hazard Analysis Risk Based Preventative Controls)
– Produce Safety
– Pet Food
– Foreign Supplier Verification
Action Items to Help Prepare
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• Create more robust Food Safety and Quality Management Systems
• Implement thorough microbial monitoring systems including tier sampling for:
- Plant Environments- Indirect and Direct Food Contact Surfaces - Products
• Administer vigorous internal process validations to assure controls are working as intended in the plants
• Prepare more widespread implementation of anti-microbial agents or processes and post lethality treatments
• Create more widespread implementation of anti-microbial agents or processes and post lethality treatments
Action Items to Help Prepare
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• Create better formulation controls, labeling controls and bar code scanning processes to prevent allergen recalls
• Create new processes to control Food Fraud and Food Defense
• Third party reassessment of existing HACCP Plans/PRP’s
• Gap analysis to compare current systems with upcoming regulatory and updated GFSI standard requirements
• Raise the bar for vendor specification requirements and adherence
• Participate in trade association events to increase knowledge and sponsor needed research for key industry issues
Food Safety 2020: Emerging Pathogens
Dr. Amit MoreyI.D.E.A. Food
Industry Consultants 25
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Infectious diseases whose incidence in humans has increased in the past 2 decades or threatens to increase in the near future
Source: CDC
Emerging Pathogens
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• Bacteria
– Arcobacter butzleri
– Cronobacter sakazakii
• Algae
– Pseudonitzchia pungens
• Parasites:
– Cryptosporidium
– Cyclospora
– Sarcocystis
– Trypanosoma
• Virus
– Astrovirus
– Norovirus and Sapovirus
– Nipha virus
– Rotavirus
• Fungus
– Aspergillus flavusaflatoxin
• Prion Agent:
– new Variant CreutzfeldJacob Disease prion
Major Pathogens Identifiedas Foodborne Since 1970
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• Food trade
• Develop resistance or adaptation
• Improved detection methods
• Changes in
– animal production
– eating habits
– travel behavior
Why Do Pathogens “Emerge”?
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• Increasing vulnerable or susceptible population
• Environmental changes
Source: www.greenpeace.org
Why Do Pathogens “Emerge”?
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• Foreign Supplier Verification
– Food Safety Practices
– Antimicrobial/antibiotic usage
• Robust Food Safety Programs (HARPC, HACCP etc.)
• Validated Traceability and Recalls Program
• Stay Up-To-Date
– Food recalls
– CDC Reports
– Foodborne Disease Trends Nationally/Internationally
• Risk Assessment and Modifications of Existing Practices
– Eg. Rotation of Sanitizers
Action Items to Help Prepare
Food Safety 2020: New Technologies
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Destroy/Rupture Cell wallIntracellular Imbalance
Attack DNA
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Source: www.hyperbaric.com
Advantages Disadvantage
Non-thermal Ineffective against spores(eg. Yeast and Molds, Bacillus subtilis, Clostridium spp.)
All-Natural Intervention Certain enzymes retain activity
Widely Acceptable Expensive than heat treatment
Effective against most spoilage and pathogenic organisms
Batch process
High Pressure Processing
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UV: 254 nm
Advantages Disadvantage
Non-thermal Ineffective against spores(eg. Yeast & Molds, Bacillus sp., Clostridium spp.)
All-Natural intervention Cannot penetrate surface
Effective against certain pathogens Bacteria in shadow-zone are not killed
Continuous process
Used on any surface
Source: www.foodsafetynews.com
Ultraviolet Light
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Source: www.Adelaide.edu.au
Source: www.usda.gov
Advantages Disadvantage
Dry non-chemical based intervention UNDER INVESTIGATION
External Decontamination Costly to produce
No “shadow effect”
Continuous process
Cold Plasma
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• Target pathogen
• Effectiveness of technique against the target
• Effect on food or surface decontaminated
• Validation studies
– Manufacturer
– In-house
• Cost
• Suitability to process and product
Action Items to Help Prepare
Recap
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• Population will continue to change
– Seek new methods to keep them engaged
• Regulatory controls and standards will continue to be implemented
– Create more robust internal process validation methods
• Pathogens “emerge” from many sources like trade and environmental changes
– Stay up-to-date and implement effective food safety programs
• Take advantage of new technologies
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Q & A
