food safety and regulatory issues for 2021
TRANSCRIPT
FOOD SAFETY AND REGULATORY ISSUES FOR 2021
eHANDBOOK
TABLE OF CONTENTSFood Safety and Regulatory Issues for 2021 3
New regimes at FDA and USDA, the pandemic’s after-effects and the evolving
‘New Era of Smarter Food Safety.’
How To Select the Right X-ray Machine 9
Is Excess Capacity Dragging Down the Performance of Your Compressed Air System? 12
Hygienic Design Enclosures Offer Superior Cleanability 15
Protecting Your Customer with Traditional and Magnetic Strainers 18
AD INDEXReid Supply • www.reidsupply.com 4
Industrial Magnetics • www.magnetics.com 6
Heat and Control • www.heatandcontrol.com 8
Kaeser Compressors • www.kaeser.com 11
Rittal • www.rittal.com 14
Sani-Matic • www.sanimatic.com 17
eHANDBOOK: Food Safety and Regulatory Issues for 2021 2
www.FoodProcessing.com
Food Safety and Regulatory Issues for 2021New regimes at FDA and USDA, the pandemic’s after-effects and the evolving ‘New Era of Smarter Food Safety.’
By Food Processing
New year, new president, new heads
of USDA and FDA and the old pan-
demic winding down. One-third of
the way into the new year, the 2021 food
safety and regulatory landscape is starting
to take shape. Here are some of the issues
you and the regulatory agencies will have to
deal with in the coming months.
AGENCY CHANGES? NOT SO MUCH Both USDA and FDA will get new leadership
from the Biden administration in the coming
months, which could change the agencies’
policies and actions somewhat. As of this
writing, a secretary of agriculture has
already been confirmed for USDA, none
other than Tom Vilsack, who held that
same job in the Obama administration.
Despite the Trump administration being
perceived as pro-business and anti-reg-
ulation, USDA and FDA did very little
backsliding in the realm of food safety in
the past four years – except for the reduced
inspections due to the pandemic. So there
probably will be little perceptible change
there. Although one tiny change from FDA:
It looks very likely that the agency this year
will add sesame to its list of allergens that
must be declared on a label.
For the most part, the to-do lists for both
agencies are already set.
In the midst of the pandemic, the FDA
announced in mid-2020 “The New Era of
Smarter Food Safety Blueprint.” It’s kind of a
successor to the 2011 Food Safety Moderniza-
tion Act, FSMA. At this point, the New Era is
just a blueprint, an outline, but in the coming
months the agency will flesh it out into a new
food safety act. It’s clear where the agency
is headed: They want the country’s food sys-
tems to be more digital and more traceable.
The New Era blueprint has four main points:
1. Tech-enabled traceability
2. Smarter tools and approaches for pre-
vention and outbreak response
3. New business models and
retail modernization
4. Food safety culture
eHANDBOOK: Food Safety and Regulatory Issues for 2021 3
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The July 2020 announcement said: “When
we look at how industries track, through
digital means, the real-time movement of
planes, ride sharing and packaged goods
or how firms are harnessing big data to
identify trends, it is clear FDA and our
stakeholders should be looking at how to
tap into new technologies that include, but
are not limited to, artificial intelligence, the
Internet of Things, sensor technologies, and
blockchain.”
FDA also revealed in September of last
year a proposed rule to establish additional
traceability recordkeeping requirements
for certain foods, primarily leafy greens
and fresh cut fruits and vegetables. The
rule follows a number of recent foodborne
illness outbreaks that involved produce
and sprouts, and they proved to be some
of the most difficult to trace back to
the source.
The Food Traceability Proposed Rule will
be a key component of that New Era of
Smarter Food Safety Blueprint and would
implement Section 204(d) of FSMA. Its
specifications for electronic record keep-
ing, especially during what it calls Critical
Tracking Events, indicates what the agency
will be looking for from all food & beverage
processors to quickly identify lots of con-
taminated products and their source. The
FDA right now is digesting comments on its
proposal and will come out with the formal
rule before the end of this year.
EFFECTS FROM THE PANDEMIC Consider for a moment coronavirus’
impact on the manufacturing side of
the food & beverage industry: meat
& poultry plant workers catching the
virus, some dying, plants closing; USDA
and FDA inspectors making fewer
inspections; processors caught with
too much commitment to foodservice
or the wrong products, having to pivot
to make pantry items for retail.
All those conditions and more would be
perfect breeding grounds for a major food
safety incident. Corners could have been cut,
improperly trained employees could be in
place, familiar lines might switch to making
unfamiliar products, no oversight from the
authorities. Successful companies – and most
food & beverage companies were successful
last year – had to quickly adapt and even alter
the way they were operating. But there were
no serious food safety breeches last year.
It may seem counter-intuitive, but since the
beginning of the pandemic, the food industry
has seen lower than normal rates of recalls.
According to Sedgwick Brand Protection
Solutions, which collects data on recalls,
there were 28 USDA recalls in the fourth
quarter of 2019, a typical number. There
were fewer recalls in the next three quarters
combined – six, nine and 10, respectively.
FDA figures were similar: The agency
reported 156 recalls in Q4 of 2019 and 141,
www.FoodProcessing.com
eHANDBOOK: Food Safety and Regulatory Issues for 2021 5
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79, 106 and 92 in the four quarters of 2020.
To the extent inspections did occur, they
were often announced, due to COVID-19
safety protocols at the plants. The rea-
sons why there were fewer recalls in an
otherwise challenging year vary – from
less regulatory agency oversight to sim-
pler products and less variety to increased
sanitation in the facilities. Even more
hand-washing probably helped.
While government inspections in 2020
were scant and sometimes paused, they
undoubtedly will increase as the pandemic
subsides, but they may never reach past
numbers. Not only did USDA and FDA
conduct fewer inspections because of the
pandemic, so did programs of the Global
Food Safety Initiative (GFSI), including
the U.S.-based Safe Quality Food Insti-
tute (SQFI). Some of the 2020 inspections
were replaced with automatic extensions
of food safety certifications, video visits or
more-detailed paperwork.
Both government and non-governmen-
tal organizations have found ways to
make sure companies are doing an ade-
quate job of food safety without as many
in-person inspections. A spokesperson
for SQFI insisted site audits will remain
the heart of that agency’s certification
process. But even GFSI said it’s gearing
up for a new world of auditing with the
inclusion of information and communica-
tions technologies.
THORNY ISSUES TO DECIDE The government regulatory agencies also
face a handful of issues, mostly labeling
and terminology ones, with products that
weren’t around a few years ago. While
they’re not entirely food safety concerns,
they do have food safety implications.
Plant-based analogues made great inroads
in the past year, and the FDA is being
pressured to weigh in on labeling of these
products. For instance, whether a plant-
based patty can be called a burger or in any
way compare itself with meat. Or whether a
soy beverage can be called milk.
Likewise, cultured meats, which just a year
ago seemed far off in the future, suddenly
are approaching near-price parity with tra-
ditional animal meats. An early indication
from the agencies last year indicated FDA
and USDA together will assess their safety.
Cannabis ingredients THC and CBD made
strides in the past year. 15 states have legal-
ized marijuana, and many of those states
also allow the use of its two key compo-
nents in foods and beverages. Someday
soon the FDA will have to face this issue,
not just the for regulatory and labeling
issues, but whether these ingredients are
truly safe to put in foods.
Read the complete story on FoodProcessing.com.
www.FoodProcessing.com
eHANDBOOK: Food Safety and Regulatory Issues for 2021 7
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As a food manufacturer, you make
an enormous commitment to bring
a product to market, so protecting
your brand in the marketplace is critical for
success. The benefits are customer loyalty,
improved market position, reduced liabil-
ity risk, and overall positive branding of
the product. However, because consumers
expect a consistent, quality product, a single
food safety recall could destroy your invest-
ment and reputation for product quality.
Because of this, food manufacturers are more
vigilant to ensure uncontaminated product.
Fortunately, the technology in inspection and
detection equipment continues to advance
so food manufacturers readily can improve
their quality control programs and utilize
more sophisticated inspection equipment
that detects smaller foreign objects, reduces
false rejects, and handles a wider range of
products to assure maximum food safety with
higher productivity.
X-ray inspection and metal detection are
often used in inspection, and because they
find different non-conformances, they are
best used in tandem. X-ray machines can
detect foreign objects or see large gaps in
packaging; metal detectors can only detect
the presence of metals. One advantage of
using X-ray inspection is the ability to find
more than just metal; also, the performance
is not affected by product signal, typical
with metal detectors.
The ability of X-ray inspection systems to
provide unsurpassed detection of a wide
range of physical contaminants – includ-
ing metal (e.g., iron, steel, stainless steel,
aluminum), glass, stone, calcified bone,
and high-density plastics – means they
can be used to keep contaminants out of
the production process, as well as catch
contaminants before products leave
the factory.
X-RAY DETECTION X-rays are generated by an X-ray tube,
and this energy is emitted from the
tube in a focused beam which passes
through the product being inspected.
On the other side is a sensor, called a
photodiode array, which converts the
received energy to light and then to a
voltage. The voltage is transformed to
How To Select the Right X-ray MachineBy Heat and Control
eHANDBOOK: Food Safety and Regulatory Issues for 2021 9
www.FoodProcessing.com
the greyscale image that can be viewed
on the screen or saved as an image.
If inclusions are present which are denser
than the product, these are displayed as
darker patches where less X-ray energy was
received. Voids and fissures are displayed
as lighter patches because higher levels of
X-ray energy were able to pass through to
the sensor.
The system can be set to automatically
reject items that have either type of defect.
As product passes through the X-ray
system, the machine can detect foreign
bodies. The minimum detectable size of
particle varies from one material to another,
the product being inspected, and the sensi-
tivity of the system.
Foreign bodies are not the only inconsisten-
cies an X-ray system can spot. Voids and
broken or missing product pieces become
visible, expanding areas for quality control.
In addition, X-ray inspection can also be
used for other functions, including to esti-
mate weight.
APPLICATION When selecting an X-ray machine,
determine what product is being inspected,
as well as the type of packaging, and
sizes of the products. Is the product
unpackaged, or in glass, cans, metallized
film, foil packaging, or cartons; and
what is the maximum width, height, and
length? The answers will narrow down
the list of potential machines. Another
consideration is the location of the machine
within the manufacturing process.
Because X-ray inspection machines can
be used at various critical control points
(CCP) on a production line, their install-
ment can strengthen both quality control
and quality assurance for a food manufac-
turer. X-ray systems that are commonly
found at the end of the production line are
used to identify defects before products
are dispatched and sent to the retailer
or distributor.
Inspection of incoming ingredients may
offer important benefits, such as protecting
machinery and/or eliminating contaminants
before they can be fragmented ...
Download the complete white paper here.
X-ray machine showing an empty tomato tray
www.FoodProcessing.com
eHANDBOOK: Food Safety and Regulatory Issues for 2021 10
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Is Excess Capacity Dragging Down the Performance of Your Compressed Air System?By Kaeser Compressors
It is rare for compressed air consumption
to be consistent, so it makes sense for
air systems to be sized so that the total
capacity meets peak demand. The problem
is that most systems have far more capacity
than needed.
Kaeser Compressors has performed more
than 10,000 air system audits in the United
States, and we have found that, on average,
users operate at only 44% of total capacity.
Despite a concerted effort by compressed
air professionals to educate users about the
negative impacts of oversizing on operations
and the bottom line, gross oversizing remains
common practice.
How does this happen? In many cases, users
select compressors based on the compres-
sor(s) that they already have, adjusted with
some prognostication about expected busi-
ness growth. Generally, little measurement
and analysis goes into it.
Also, most operators are inclined to up-size
for peace of mind. They don’t want to hear
complaints of equipment with low pressure
alarms, nor do they want to re-revisit com-
pressed air system design every few years as
they grow. So, they purchase as big as their
budget allows at the outset.
Overly conservative consulting engineers
may add to the problem by assuming that
all pneumatic equipment will operate fully
loaded all the time. They may even add a
safety factor on top of that. In nearly all
cases, there’s fudge factor on top of fudge
factor, with all stakeholders believing that
they are acting in the interest of ensuring
compressed air availability, without under-
standing the negative impacts on energy
consumption, maintenance costs and long-
term reliability.
IMPACT OF OVERSIZING ON ENERGY USE Compressed air efficiency is best measured
in terms of specific power, which is most
often expressed in kW/100cfm. Specific
power increases as compressors operate
further away from their full output capacity.
To be clear, higher specific power means
higher power consumption and lower
eHANDBOOK: Food Safety and Regulatory Issues for 2021 12
www.FoodProcessing.com
efficiency. In fact, a specific
power measurement of
25 kW/100cfm is a good
target; 20 kW/100cfm is
considered excellent.
The Compressed Air and
Gas Institute (CAGI) has
an excellent program that
encourages compres-
sor makers to publish the
specific power for each
compressor. This tool is a
great way to compare two
compressors side by side,
but it cannot be used to pre-
dict what the user’s actual
system performance will be.
As the car makers say: “your
mileage may vary.”
So much depends on how
the compressors are run.
The CAGI data sheets
for fixed speed machines
assume 100% load, which
rarely happens in practice.
Whether a single machine
or multi-compressor system,
under-utilized compres-
sors do not operate at
their datasheet perfor-
mance specification.
From our many system stud-
ies, we know that systems
are grossly oversized.
Let’s look at some actual
examples of oversized sys-
tems and the inefficiencies
that resulted.
• Example A. For this green-
field plant, the company
specified dual 125 hp
compressors, two 230
cfm refrigerated dryers,
1,000 gallons of storage,
an air main charging valve,
and a master system con-
troller. The system was
grossly oversized and their
specific power was over
66kW/100cfm (more than
three times as large as the
20 kW/100cfm target).
Their needs could be met
with a pair of 15 hp units.
• Example B. The facility
currently operates with a
50 hp screw compressor,
a 285 cfm refrigerated
dryer, and a 400 gallon
receiver tank. The peak
demand measured was 65
cfm and the average flow
was 22 cfm, so the 236
cfm compressor was far
over-sized for the current
demand. The calculated
system specific power
was also sky high, at just
under 66 kW/100 cfm. The
company would be much
better off with a pair of 10
hp compressors.
• Example C. This facility
currently operates with
three 200 hp compressors,
three 1,000 cfm ...
Read the complete story here.
Customer B 65.54 kW/100 cfm
Customer A 66.28 kW/100 cfm
Customer C 17.65 kW/100 cfm
15
20
25
30
35
40
45
50
55
60
65
70
0 10 20 30 40 50 60 70 80 90 100Sp
ecifi
c Po
wer (
kW/1
00 c
fm)
% of System Capacity
Compressor Control Impact Across Full Operating Range
ModulationVariable CapacityDual Control (1 gal/cfm)
Dual Control (5 gal/cfm)
Variable Speed
Customer A
Customer B
Customer C
Figure 1. Efficiency curves for common compressor control types.
www.FoodProcessing.com
eHANDBOOK: Food Safety and Regulatory Issues for 2021 13
Rittal hygienic design enclosures are engineered to keep you running at peak efficiency while reducing cleaning time and chemical use.
V Sloped tops that stand up to frequent washdowns
V A smooth surface grain with no pores
V No gaps between the enclosure and the door
V Hinges mounted inside the sealed zone
V An integrated, non-detachable rear panel
V Rittal’s signature, easily distinguishable blue gasket
DOWNLOAD OUR FOOD & BEVERAGE BUYER’S GUIDE
HYGIENIC DESIGN FOR YOUR WHOLE LINE
©2021 Rittal North America LLC
Like many industries, the North
American food and beverage indus-
try is changing rapidly. Whether
you brew beer, make wine, bake cakes, or
process dairy or meat products, the chal-
lenges are often similar: labor, energy and
raw material costs are rising; competition
and regulations are tightening; compa-
nies are merging or acquiring each other.
Once stable markets are splitting into
innumerable sub-segments and cross-seg-
ments with increasingly shorter product
life cycles. Updated nutrition guidelines
are leading consumers to demand newer/
better/healthier/safer food and bever-
age alternatives.
To keep pace with these trends, food and
beverage processors must recognize them
quickly and respond appropriately. That
requires the right production technology
(e.g., machines, control systems, motors,
drives, sensors) and the network infrastruc-
ture (e.g., data centers, servers, switches,
enclosures) to connect them to each other.
This technology and infrastructure must
integrate Industry 4.0 tools and efficient
design principles to provide maximum flex-
ibility, modularity, scalability and reliability.
Rittal enclosure, climate control, power
distribution and IT solutions incorporate
these principles, offering food and bever-
age producers the ability to adapt quickly to
evolving market dynamics, capture growth
opportunities, meet safety regulations and
maximize profitability.
BEER/WINE/BEVERAGE/BOTTLING Beer
The North American beer segment of the
industry is booming. With 4,144 breweries
in the United States, output has nearly
quintupled over the last 10 years.
Both large breweries and smaller craft
breweries must respond quickly to
consumer demand for more variety and
distribution. Production assets, including
enclosures and other production IT
components, must be able to adapt
to accommodate these trends. Asset
reconfiguration, such as for switching from
packaging in bottles to cans, often must
happen in a narrow timeframe with limited
delays, disruptions or capital investment.
Hygienic Design Enclosures Offer Superior CleanabilityBy Rittal
eHANDBOOK: Food Safety and Regulatory Issues for 2021 15
www.FoodProcessing.com
Although the risk of contamination is greatly
minimized as a result of the raw ingredi-
ents, end-product and by-products of the
beer-making process, breweries in general
still maintain very high standards of clean-
liness in their production facilities. Stainless
steel is often used for production equipment,
including electrical enclosures, to prevent
corrosion from frequent washdowns.
Electrical enclosures also have sloped tops
and sealed access points to prevent water or
cleaning agent infiltration that could result in
electrical failure, unscheduled downtime and
expensive repairs.
Wine
Like the beer industry, the North American
wine industry is experiencing significant year-
over-year growth, a proliferation of limited/
medium output operations (which represent
99% of U.S. wineries), consolidation/acqui-
sition among and by larger wineries, and
changing consumer tastes and preferences.
Other beverages
Other segments of the beverage industry
include soda, bottled water, sports drinks,
energy drinks, distilled spirits, fruit juices, tea,
coffee, and hard cider. Regardless of bever-
age type, these producers face the same core
market dynamic as beer and wine: rapidly
changing consumer preferences. In general,
the change is away from sugary sodas and
juices to healthier, niche options. This includes
plant-based waters, craft/artisan beverages,
raw/pressed juices, ready-to-drink tea/coffee,
and non-dairy probiotics.
Bottling
Differentiation in the beverage industry
isn’t limited to the products themselves. It
also has dramatically impacted bottling and
packaging. From size variations and multi-
packs to non-traditional form factors (wine
in a can, anyone?) and situational designs,
bottling and packaging innovations have
become the norm for beverage companies
looking for new ways to meet consumers’
changing demands and entice them to buy.
Dairy
Consumers demanding more natural food and
beverage options is good news for the dairy
industry, which has seen inconsistent growth
across the globe. These trends provide an
opportunity for dairy producers to expand
production and distribution of previously or
declining product lines with higher fat content.
Meat processing
The meat industry has experienced signifi-
cant challenges over the last decade in the
forms of disease/contamination, consumer
health fears, and changing consumer habits.
Still, global consumption of meat rose 2%
by volume in 2015, driven primarily by
leaner/healthier options such as poultry and
pork...
Download the complete Buyer’s Guide here.
www.FoodProcessing.com
eHANDBOOK: Food Safety and Regulatory Issues for 2021 16
Protecting Your Customer with Traditional and Magnetic StrainersBy Sani-Matic
Food and beverage processing facili-
ties face many challenges in keeping
their product safe for consumers.
One such challenge is keeping product free
of unwanted contaminants or particulates
as the product is prepared, processed, and
ultimately packaged and sent to either fur-
ther processing or the end user.
How do foreign and unwanted particulates
sneak into the process? They can arrive in
various ways – sometimes coming into the
product from the ingredients themselves,
such as from field produce or from a
water supply that has issues with the feed
piping. Operators can also inadvertently
contaminate the process by dropping
something into any open processing area
such as when ingredients are being added
or the process is being checked on.
In many cases the unwanted contaminants
are a result of the production process
itself – a gasket or seal that breaks off
and is carried along with the process, a
shaving of metal that dislodges from pre-
vious piping modifications, or other similar
events that go unnoticed.
Enter the sanitary process strainer – a
component that has been successfully
helping capture these unwanted con-
taminants for many years. Easy to use,
the strainer element captures the for-
eign material so it can be removed from
the process before ending up in the
final product.
The general idea of any strainer is that it
is capturing particulates – however, there
are many different strainer types and
strainer element sizes and types for differ-
ent applications.
TEE-LINE STRAINER, ANGLE-LINE STRAINER, BASKET STRAINER Tee-Line strainers are often used
for equipment protection (like in
eHANDBOOK: Food Safety and Regulatory Issues for 2021 18
www.FoodProcessing.com
front of a pump) to help keep larger
debris from causing issues for
important process equipment.
Larger strainers like angle-line or basket
strainers can strain larger volumes of
particulates and can also utilize a vari-
ety of element types, such as perforated
or Wedge Wire elements, to strain out
certain sizes of particulates while allow-
ing for product to flow through. Often
times perforated elements utilize mesh
overlays or filter tubes that slide over the
perforated element to strain to finer (i.e.,
smaller) levels.
MAGNETIC TRAP STRAINERS
The strainers discussed so far are
straining particulates out of the process
based on a physical characteristic of
the particle – the size. However, another
type of strainer is a magnetic trap
or magnetic strainer which captures
unwanted particulates from a process
based on their magnetic characteristics.
Iron, carbon steel and sometimes hard-
ened types of certain stainless steel have
varying levels of magnetism that can be
captured by these types of strainers.
Often times these magnetic particulates
are very small pieces or shavings, so
catching them with a traditional strainer
used for larger particulate straining may
not be possible. In that case, a magnetic
strainer (which utilizes magnets enclosed
within a protective stainless-steel barrier
for process compatibility) can help cap-
ture these particulates.
Many of the traditional particulate strain-
ers and the magnetic trap strainers are
different components, installed indi-
vidually within a process line. However,
Sani-Matic’s new Magnetic Trap Strainer
is a 2-in-1 solution that combines the
magnetic trap with the process particu-
late straining capabilities of an angle line
strainer. This solution allows for a single
component installation into the process,
making initial installation and cleaning
and maintenance easier by reducing the
process line breaks needed.
PROTECT YOUR PROCESS While it is smart to identify the risk
of where foreign and unwanted
particulates could be introduced and
try to mitigate these risks, no process
is immune to these issues. It is best
to plan for equipment and product
protection through the strategic use
of strainers of varying types and sizes
– doing so will keep your process
equipment and product safe...
Download the complete white paper here.
www.FoodProcessing.com
eHANDBOOK: Food Safety and Regulatory Issues for 2021 19