26 March, 2018

Global Partnerships in Food Packaging

FoodSure SummitJeff Plank

BIO – Jeff Plank2012 – Present – Land O Lakes, Inc – Corporate Supplier Quality

• Global QA/CI/Food Safety Management for Enterprise-wide Packaging• >125 Supplier sites audited globally across NA, Middle East, Asia

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2002 – 2012 – Ecolab, Inc – RD & E• LSS Black Belt• R&D Packaging Group Leader

2000 – 2002 – Boston Scientific – G & D Catheters – R&D• Packaging R&D

1995 – 2000 – Pillsbury Company – Old El Paso - R&D • Packaging R&D

1992 – 1995 – 3M – Abrasive Systems - R&D • Technical Aid / Lab Assistant

BS – Biochemistry

MS – Manufacturing Systems Engineering

Agenda

1 Introductions / Bio

2Land O’Lakes International Development (ID)• Independent Nonprofit

3 Land O’Lakes Inc.

4 LOL, ID Packaging Assignment:• Fresh Produce - Lebanon

5 Questions

About Land O’Lakes International Development

501(c)(3) nonprofit

Our affiliation with Land O’Lakes, Inc. makes us unique

~250 staff worldwide

PurinaAnimal Nutrition

Solutions that enhance performance and well-being

LEVERAGE EXPERTISE FROM FOUR DIVERSIFIED AGRIBUSINESSES,

DRIVEN BY INSIGHTS & INNOVATION

WinField® UnitedCrop Inputs & Insights

Agricultural products, data, technology tools

and services

LAND O LAKES®

Dairy FoodsMilk-based products

and ingredients

Land O’LakesSUSTAIN™

Environmental sustainability solutions

Where International Development works

Current

Since 1981

ID applies technical expertise from several “practice areas” to create development impact and deliver value to clients

What International Development does

LivestockDairy Crops

Examples of how Inc and ID collaborate

Thought Leadership

Technical Expertise

Leverage Relationships

• Universities and research institutions

• Member organizations

• Suppliers and partners

• Voice on global issues

• Advocacy with key clients

• Enhancing brand image

• Food safety and quality

• Supply chain optimization

• Manufacturing and operational capabilities

What is Farmer-to-Farmer?(F2F)

U.S. Congress enacted program in 1985 and 2008 through Farm BillIn honor of John Ogonowski – a pilot killed on September 11, 2001 and Congressman Doug Bereuter, who championed F2FSends U.S. volunteers overseas on short-term assignments to address the needs of agribusinesses, farmers and support organizations

Problem Statement: Suspected issue with Modified Atmosphere Packaging (film/equipment) contributing to shortened shelf life of fresh produce.

In order to enter the local & eventual export markets, the host, Agri-Fresh needs a Packaging SME to solve problems within its operation, for which it lacks the right knowledge. This will only be achieved through the help of an expert volunteer.

The main objectives can be summarized as follows:1. Selection of the right package for the product – (MAP) Modified Atmosphere Packaging (%

Oxygen, Carbon Dioxide and Nitrogen) to enable optimal shelf life (7-8 days, 4-5% in-pack O2)2. Optimize production process, product shelf life and ensuring good and hygienic practices3. Assess current operating & cleaning practices4. Evaluate Food Safety conditions of the facility & recent 3rd Party Audit

DURATION OF ASSIGNMENT = 2 weeks (September 2016)

Assignment Scope & Objectives

Lebanon

Capital: BeirutTime Difference: + 7 hoursPopulation: 6.1 MillionCurrency: Lebanese Pound (LBP)Language: Arabic & French (English)

The Bekaa Valley is the central highland between the Mount Lebanonrange and the Anti-Lebanon Mountains. The Bekaa is the country's chiefagricultural area.

LogisticsDay 1: Depart 8pm

Day 2: Arrive Beirut 8pm (via CDG/Paris) –Boutique Hotel

Day 3: Open

Day 4: Briefing; Domonaco Foods Visit

Day 5: Youssef Group Visit, Travel to Zahle –Hotel St Jean

Day 6 – 8 – Agri-FreshDay 9 – 10 (Weekend) – Open

Day 11-15 – Agri-Fresh

Day 16 – Project Debrief; depart from Beirut

AgriFresh – Doummar Foods TeamZahle, Lebanon

The presentation is made possible by the generous support of the American people through the United States Agency for International Development (USAID). The contents are the responsibility of Land O’Lakes and do not necessarily reflect the views of USAID or the United States Government.

Agri-Fresh Products

1. Observe2. Measure / Assess process &

facility3. Analyze critical attributes 4. Recommend improvements5. Maintain & Control

Project Road Map

Facility Overview

(Incoming) Cold StorageObservations:• Open doors• Relative humidity (no control)• Temperature can vary above ~7-8C (45-

46F) with doors opening constantly. • Stacking causing product damage

Initial Preparation / Visual Inspection

Observations:• Sorting/organizing on the floor • Proximity to green trash

receptacle and floor cleaning tools.

• Unmarked containers

Preparation Unit Operations – Washing, Cutting, Drying

Observations:1. High level of Enterobacteria measured in

rinsing water & “Day 0” shelf test2. Drying process (chopped parsley) took

~24 hours

Processing

Converting

Packaging / SealingPackaging Process:Vertical Form-Fill-Seal (VFFS):Modified Atmosphere Packaging100% Nitrogen Flush

Observations:• Inflexible discharge conveyor / product

clearance• Channel leaks, pinholing, scratching of the film

through process• Inadequate in-line QA headspace test or

sampling plan frequency• Team unclear of the criticality of the “Time-

Temperature-Pressure” function

3 Critical Factors requiring a hermetic seal:Time, Temperature & Pressure

Packaging / Discharge Conveyor

Observations:

Cabbage Package:Discharge conveyer carrying cabbage up to the metal detector and headspace test area. There is good clearance for the cabbage to pass from the wrapper to the conveyor.

Observations:

Lettuce Package:Not enough clearance to pass through consistently.

Could cause damage to the package (pinholes or scrapes in the film) or product itself.

Raising the shield or modifying it so that all variations in product size can easily pass through.

Packaging / Discharge Conveyor

Leading/Trailing End SealsObservations:

Excessive wrinkling will cause channel leaks which will increase the oxygen level and subsequently decrease shelf life.

Monitor Package Integrity with Headspace Analyzer that reseals during test (use ‘rubber nickel’)

RecommendationsUpgrade/Improve the water sanitation system

• Replace filters (sand, chlorine, softener & carbon)

Establish Relative Humidity / Humidified application controls in the storage areas.(critical to shelf life)

Improve VFFS Wrapper to insure time, temperature & pressure specifications & product flexibility

• Factors critical to Time, Temp, Pressure• Safety screen

Establish improved Package Integrity Monitoring & sampling plan:

• Headspace Analyzer implementation w/ “rubber nickel”

• Seal Integrity

Employ an ATP monitoring system for use in performing micro checks around the facility, drains, etc.

Improve GMP’s!! (HACCP Plan very good)

Machine Calibration – manufacturers service rep should make regular visits (Metal Detector Ferrous)

Invest in a Hydrator for products requiring drying (i.e. parsley)

Cost Savings on the packaging film

Zahle, Lebanon

Zahle, Lebanon

Baalbek, LebanonTemple of Bacchus

Temple of Jupiter

Umayyad City of Anjar or Gerrha

Anjar, Lebanon

Beirut, Lebanon

Want to sign up?

Volunteering is rewarding!• Be an American ambassador of goodwill• Realize personal and professional growth• Gain new insights related to your field of

expertise and interest• Make a positive difference in the lives of

others• Gain international work experience

2-3 week assignments with all expenses paid, just donate your time, expertise & knowledge and write a report!!

What makes a greatvolunteer?

Adventurous self-starterPatient / FlexibleCulturally sensitiveHands-on experience with latest technologyGood healthSense of humor

Motivated by serviceUses “show me” approach, more than just lecturesWillingness to share expertise and experienceGood communication skills

Learn More

View potential assignments & register on Land O’Lakes’ Career Portal: https://lol.avature.net/Careers/SearchJobs/Farmer%20to%20Farmer

Reach out to Gretchen Hanson:GHanson@landolakes.com651-375-3577

QUESTIONS?

Questions?

www.landolakes.orgJeff Plank

jwplank@landolakes.comMobile 651-271-0990

www.landolakes.org

Jeff Plankjwplank@landolakes.com

Mobile 651-271-0990

Thank you