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Threats to the Food Supply April 9, 2013
Robert “RJ” Hope, CPP Department Manager – Global Security
Justin Hamilton Project Manager – Manufacturing Operations
Bill Sokolowsky Director – Manufacturing Systems & Engineering
Overview
• Overview of the state of affairs • Food Safety and Food Defense in the industry
– Plant wide initiatives – Operational initiatives
• What to do to prepare
FSMA?
• Food Safety Modernization Act – 01/04/11 – Since President Teddy Roosevelt – Proactive vs. Reactive
• Recall • Outbreaks
– “From Farm to Fork” – Why now?
• Operation Enduring Freedom – 2007
The Global US Food Supply
Manufacturer/Processor
Manufacturer/Processor Warehouse
Warehouse
Distributor Grower
Grower Importer
Retail
Food Service
Foreign
Domestic
Source: Leavitt Partners
US Food Supply - Size
• Imports account for 15% of US food supply – > 75% of seafood – > 60% of fresh produce
• Imported food has increased dramatically over the last 10 years and will continue to increase
Source: USDA Economic Research Service
US Food Supply - Fragile
• Grocery store – 1 to 3 days supply • Americans want it all
– 0 tolerance for unsafe food – Place responsibility on producer – Like local feel – Chemical adverse – Consumers can reek havoc on a brand
US Food Supply - Threats
• Natural/Accidental – Chemical – Microbial – Decay – Foreign matter – Animal pests
• Manmade – Chemical – Microbial – Biological – Radiological – Foreign matter
US Food Supply - Regulation
• Food Safety – Accidental – GMP – HACCP
• Food Defense – Intentional – ? – Food Safety Modernization Act (FSMA) –
January 4, 2011
Tea Leaves
• FSMA – Section 418 – Hazard Analysis and Risk-Based
Preventive Controls – Section 104 – Performance Standards
• Chemical Facility Anti-Terrorism Standards (CFATS) – 18 RBPS
Tea Leaves
• FSMA – Section 418 – Hazard Analysis and Risk-Based
Preventive Controls – Section 104 – Performance Standards
• Chemical Facility Anti-Terrorism Standards (CFATS) – 18 RBPS – Risk Based Performance Standards
Burns Ketchup Co.
Sugar VinegarSalt Etc.
Water
Process Mixing
Sugar VinegarSalt Etc.
Water
Process Mixing
Burns Ketchup Co.
Water
Step 1: Raw Materials
Burns Ketchup Co.
Tomatoes
Sugar Water VinegarSalt Etc.
Burns Ketchup Co.
Step 1: Raw Materials
Sugar Water VinegarSalt Etc.
Burns Ketchup Co.
Step 1: Raw Materials Step 2: Processing
Process Mixing
Sugar VinegarSalt Etc.
Water
Process Mixing
Step 3: Filling
Step 2: Processing
Burns Ketchup Co.
Step 1: Raw Materials
Sugar VinegarSalt Etc.
Water
Process Mixing
Step 3: Filling
Step 2: Processing
Burns Ketchup Co.
Step 1: Raw Materials
Sugar VinegarSalt Etc.
Water
Process Mixing
Step 3: Filling
Step 2: Processing
Burns Ketchup Co.
Step 1: Raw Materials Step 4: Packaging
Sugar VinegarSalt Etc.
Water
Process Mixing Step 4: Packaging
Step 3: Filling
Step 2: Processing
Burns Ketchup Co.
Step 1: Raw Materials
Sugar VinegarSalt Etc.
Water
Process Mixing Step 4: Packaging
Step 3: Filling
Step 2: Processing
Step 5: Warehousing & Distribution
Burns Ketchup Co.
Step 1: Raw Materials
Sugar VinegarSalt Etc.
Water
Process Mixing Step 4: Packaging
Step 3: Filling
Step 2: Processing
Burns Ketchup Co.
Step 1: Raw Materials
Step 5: Warehousing & Distribution
Sugar VinegarSalt Etc.
Water
Process Mixing
Step 3: Filling
Step 2: Processing Step 4: Packaging
Burns Ketchup Co.
Step 1: Raw Materials
Step 5: Warehousing & Distribution
Org Chart Burns
Ketchup Company
Marketing R&D Engineering Operations
Plant/ Manufacturing Supply Chain Suppliers
Transportation & Warehousing
Impact on Manufacturing/Operations
• Applies to entire supply chain
• Several control points inside plant walls
• Transportation and Warehousing
• Customers
Tools & Systems to Leverage
• Quality Assurance • Total Productive Maintenance • Health, Safety & Environmental • Standards & Procedures • Education & Training
Opportunity: Improve Other Key Business Results while Implementing FSMA Compliance
Engineering/R&D
• Facility and Plant Design • Equipment and Tools • Automation • Packaging • Formulation • Processing
Business Model
• Incorporate FSMA into Front-End Design • Integrate FSMA into existing systems • Recognize links to other key metrics • Embrace challenge; involve and educate
employees • Leverage as a marketing opportunity
FSMA – Food Defense
• Food Defense – “Reasonable foreseeable hazards” – Preventive measures – Monitoring of effectiveness
FSMA – The Future
• Surgical vs. Carpet Bombing • Determine Contaminants • Viability of “expanded” HACCP • Manufacturing Process Evaluation
FSMA
• Prepare • Plan • Prioritize Risk • Master Plan
