Recalls on the Rise: How to Design Food Safety into Employee Welfare Areas

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Recalls on the Rise: How to Design Food Safety into Employee Welfare Areas

Food safety has never been more important at processing and manufacturing facilities.

One in six Americans gets sick every year from eating contaminated foods, according to the Centers for Disease Control and Prevention. Plus, the problem is only growing: Food safety regulators in the U.S. are recalling about twice as many products now as a decade ago.  

While there are numerous best practices for incorporating food safety into the actual processing, employee welfare areas are a critical point of potential risk that can’t be ignored. This is especially true for facilities that have both raw and ready-to-eat (RTE) operations.

Let’s examine the various touch points employees encounter at a facility and how to design these spaces to maximize food safety.

 

How an Innovative Starbucks Processing Plant Takes Food Safety to New Levels

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How an Innovative Starbucks Processing Plant Takes Food Safety to New Levels

Photography: Robert Pepple

In response to the growing demand for home-brewed instant coffee that delivers true “coffee shop” flavor, Starbucks came to Stellar wanting to build a unique soluble coffee plant. The award-winning facility in Augusta, Georgia, was designed to produce the company’s VIA® instant coffee products, and it’s cutting-edge in every sense of the word.

Among the plant’s many innovations, food safety was a top priority. There are several lessons food and beverage manufacturers can learn from how Starbucks addressed this critical issue.

 

How to Keep Your Food Plant Construction Project on Track

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How to Keep Your Food Plant Construction Project on Track

Technology and ever-increasing consumer demand are driving food and beverage companies to compete at a different level than ever before. Speed to market is increasingly important to doing business — the faster a new plant can be built or renovated, the sooner it can begin producing a return on investment.

So how can you ensure your next construction project stays on track? Let’s look at five ways to set yourself up for success, whether you’re tackling a greenfield project or a retrofit.

 

Back to the Basics: How to Optimize Your Clean-in-Place System

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Back to the Basics: How to Optimize Your Clean-in-Place System

A number of food manufacturing facilities have been utilizing clean-in-place (CIP) for years. It’s the method of cleaning processing equipment and piping without disassembling it. While most of us already know what CIP is, when was the last time you performed a thorough audit of your system?

Over the years, changes to the systems being cleaned may have caused the CIP system set-point ratios to change without notice to the operators — making it more out of whack than you may realize.

 

6 Points, One Stone: How Low-Impact Development (LID) Can Help Achieve LEED Certification

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6 Points, One Stone: How Low-Impact Development (LID) Can Help Achieve LEED Certification

If you’re not familiar with low-impact development (LID), you may want to keep reading before building your next facility or warehouse. Thanks to recent changes in LEED requirements, we’re going to see an increase in projects utilizing LID in the near future.

What exactly is low-impact development? How can you make the most of LID and maximize it when applying for LEED certification? Let’s unpack what it means for your next project.

 

Food Plant Sanitation: Choosing Flooring, Walls, Ceilings and Doors to Improve Food Safety

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Food Plant Sanitation: Choosing Flooring, Walls, Ceilings and Doors to Improve Food Safety

Whether you’re designing a new food and beverage facility or renovating an existing one, it’s important to consider the materials you choose for to surround your processing — literally.

When it comes to food safety, these features sometimes get less attention than other factors — such as equipment, ingredient storage/segregation and product handling — but they can be a plant’s Achilles heel if ignored.

Today, we’re going to look at the best practices when selecting materials for your facility’s flooring, walls, ceilings and doors.

 

The Underrated Value of Industry Conferences: Reflections from the 2018 IIAR Natural Refrigeration Conference & Expo

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The Underrated Value of Industry Conferences: Reflections from the 2018 IIAR Natural Refrigeration Conference & Expo

I had the opportunity to attend the 2018 IIAR Natural Refrigeration Conference & Expo in March, and it got me thinking about the value in these industry events. Why do we attend them?

There are countless niche conferences that cover every segment of the food and beverage industry, from packaging to refrigeration and from dairy to meat. These events bring professionals together from across the country and world — but why are they so important?

 

Preventing Allergen Control Failures and Labeling Mistakes

How to avoid the biggest cause of food recalls in 2017

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Preventing Allergen Control Failures and Labeling Mistakes

There were a total of 440 recalls of FDA and USDA regulated food products in 2017.

The single leading cause of recalls last year? The presence of undeclared allergens and the misbranding of products.

A total of 218 recalls (nearly half of the total) were announced because a product contained ingredients that weren’t declared on the label, such as:

 

How a Facility Assessment Helped Royal Cup Coffee Build, Expand and Renovate Efficiently [Case Study]

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How a Facility Assessment Helped Royal Cup Coffee Build, Expand and Renovate Efficiently [Case Study]

In our industry, the best project outcomes require a great deal of planning. When it comes to greenfield and renovation projects, that means formulating a manufacturing analysis and a strategic plan. Before investing in any changes, however, a crucial step is understanding the status quo:

  • How is your facility performing?
  • How efficient are your processes?
  • What can be optimized?

A comprehensive facility assessment can answer these questions and more.

 

[Infographic] 7 Best Practices for Gluten-Free Manufacturing

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[Infographic] 7 Best Practices for Gluten-Free Manufacturing

The demand for gluten-free products isn’t just a passing trend. In fact, the gluten-free foods market is projected to be valued at $7.59 billion by 2020. Plus, researchers have noted a rise in celiac disease rates in recent years — just more evidence that the need for GF products isn’t going anywhere anytime soon. Before you begin producing gluten-free products in your facility, however, consider these principles to ensure you cater to this growing market safely, efficiently and effectively.