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KRISP-PAK
Offers More Than Just Fruits and Vegetables
Fresh Cut
January 2003
You know exactly where the company’s focus is just by reading its
slogan: “If it’s fresher than KRISP-PAK, it’s still growing.”
But slogans and gimmicks are not what the KRISP-PAK Company Inc. is all
about.
KRISP-PAK, located in Norfolk, Va, is a regional manufacturer
of fresh fruits and vegetables for retail and food service customers.
According to company owner and president Paul Battaglia, delivering the
freshest and safest food products to the consumer is the goal of every
KRISP-PAK employee. “For more than 50 years we have been delivering
perishable processed produce over a 500 mile radius,” says Battaglia.
KRISP-PAK operates a fleet of more than 15 trucks, making deliveries on
a daily basis covering areas from Maryland to South Carolina.
Back in the 1950s, the Hampton Roads area that collectively
includes Norfolk, Hampton, Newport News, Virginia Beach, Portsmouth, Chesapeake
and Suffolk, was the southernmost pre-pack company in the nation. “My
father, Gaspary, actually started the company in 1950 repackaging southern
greens, kale, collards, turnip, mustard and Hanover for the retail trade,”
says Battaglia. “From there it evolved into a large company, which
today employs in excess of 100 workers.” Currently, KRISP-PAK sales
are equally split between the retail and food service industries. Battaglia
says the company cuts and packs everything from alfalfa sprouts to zucchini.
Safety First
With so much emphasis placed today on food safety, a portion
of KRISP-PAK’s mission statement includes “…it is a joint
effort among management, employees and vendors to provide the safest,
most convenient food products for everyone.” KRISP-PAK’s efforts
include a hazard analysis critical control point program and third party
audit to ensure the safest vegetables and fruits available. Refrigerated
trucks and a very efficient cold chain system are also employed during
KRISP-PAK’s delivery cycle.
Inside the company’s 45,000-square-foot facility
workers process in excess of 250,000 pounds of product each week. Just
about every item processed by KRISP-PAK is available in a retail package,
which range in size from 8 ounces to 3 pounds. Some of those products
include various sprouts, fruits and tomatoes, onions, peppers, potatoes,
leafy vegetables, carrots, celery, squash, cauliflower and broccoli.
Another aspect of the safety process includes empowering
employees to serve as check points along the way. “At KRISP-PAK,
personnel have the authority to hand inspect and/or reject a product at
any point along the line,” explains Battaglia. “Having the best
employees in the industry is our key to getting the job done. Our team
will do whatever it takes to satisfy the customers’ needs.”
Battaglia emphasizes that safety sells itself. “We
spend more than $1,200 a month on various lab tests alone to ensure our
products are safe for the customer,” he says.
Here’s to Your Health
Not only does Battaglia believe his products are good,
he emphatically believes that they are good for you, too. “With the
cancer rates skyrocketing, I know that eating veggies on a regular basis
will fend off cancer and fight free radicals in your body,” says
Battaglia. “Free radicals accelerate aging and make you more susceptible
to chronic illness.”
Last year, KRISP-PAK joined the Brassica Protection Products
Group. This group of 17 sprout growers around the country is part of a
Johns Hopkins University program that produces a product called BroccoSprouts.
BroccoSprouts broccoli sprouts are the first and only
product with a guaranteed amount of SGS, sulforaphane gulcosinolate, a
naturally occurring antioxidant compound in broccoli. Researchers at Johns
Hopkins believe that many phytochemicals including sulforaphane may help
explain why diets rich in fruits and cruciferous vegetables are associated
with good health. BroccoSprouts represent the first time that a plant
has been grown for its antioxidant function.
Brassica Protection Products introduced BroccoSprouts
into Chicago-area food stores and supermarkets in the spring of 1998.
BroccoSprouts are produced under BPP’s stringent guidelines for purity,
quality and consistency of SGS levels (a guaranteed minimum per serving).
For example, all BroccoSprouts growers use specified broccoli seeds, adding
only water and light, and must submit weekly samples of sprouts to the
company’s laboratory for comprehensive testing. No other sprout is
grown according to the Johns University procedures for growing and ensuring
SGS content.
In March 1999, Brassica Protection Products rolled out
BroccoSprouts to food stores and supermarkets via a nationwide network
of licensed sprout growers, including KRISP-PAK. BroccoSprouts are a zesty,
flavorful food that can be mixed in salads or soups, added to sandwiches,
vegetables and wraps, or sprinkled on crackers. They are low-fat, contain
only 10 calories per serving and are a good source of vitamin C, providing
15 percent of the daily value. A portion of BroccoSpouts sales is contributed
to The Brassica Foundation for Chemoprotection Research to support further
research into the link between nutrition and cancer.
“We are really proud to be a part of this program,”
says Battaglia. “This is truly doing something to benefit everyone’s
health.”
Community Involvement
The employees at KRISP-PAK are also involved in several
community events. “Each year we participate in the ‘Race For
The Cure’ for breast cancer awareness in October,” says Battaglia.
In April, the company holds a month-long promotion. Stickers are placed
on bags of vegetables and with each purchase, a portion of the amount
goes toward the local Children’s Hospital of the King’s Daughter.
KRISP-PAK is also involved in an annual fall food show that benefits local
charities.
© 2003 Columbia Publishing
Attendees
Ask: “How Can Ozone Work For Me?”
Fresh Cut
January 2003
The Ozone III conference, held recently in Fresno, Calif, examined the
various uses and applications of O3. With its lengthy title “Agricultural
and Food Processing Applications of Ozone as an Antimicrobial Agent,”
the three-day conference focused on experimental results of ozone generation,
its biocidal efficacy in food as well as ozone’s agricultural applications.
Ozone, a form of oxygen, has proven to be effective in
destroying microorganisms. While it has been used for years as a disinfectant
in many industries, its use has been limited in food processing. However,
in 1997 that changed when a national expert panel declared ozone as Generally
Recognized as Safe (GRAS) for use on foods. But it wasn’t until last
year – June 26, 2001 to be exact – when the FDA blessed the
use of ozone for use in food contact applications.
“At Ozone III, there was finally FDA and USDA approval
for use of ozone on foods,” said Dr. Rip Rice, a long-time researcher
and consultant in the ozone field. “Now, more potential end users
were in attendance, and they wanted to know ‘How do I use ozone for
MY application?’ Since FDA/USDA have approved ozone, all the answers
must be in hand somewhere.”
Looking for Answers
One attendee who was looking for answers was Brian Bassett.
An agronomist for Wm. Bolthouse Farms, Inc. in Bakersfield, Calif., Bassett
was investigating the possible use of ozone at his Bolthouse carrot farm
operation. “We do everything in the process from growing carrots
to bagging them,” said Bassett. “I see ozone as potentially
a very effective tool for our operation.”
The Ozone III conference addressed many topics concerning
the use of O3. The list of attendees - 135 in all - was a virtual Who’s-Who
in the ozone community. A few of the presenters included Dr. Dee Graham,
Dr. Rip Rice, Dr. Ahmed E. Yousef, Dr. Jurgen Strasser, Dr. Joseph L.
Smilanick, Dr. James Yuan and Paul K. Overbeck, to name a few.
Subject categories included ozone’s roles in agricultural
security, food safety and quality, water reuse, advanced technology, synergistic
combinations, and legislative impacts on use of ozone.
Many attendees were specifically concerned about the fresh-cut
industry and ozone’s potential impact. “I believe the fresh-cut
industry has probably the greatest need to implement ozone,” said
Dee Graham, an ozone consultant from Walnut Creek, Calif. “There
are significant public health risks associated with distribution of unprocessed
produce. An example is the current concern about salmonella in cantaloupes.
Ozone properly used can help reduce such risks.”
Dr. Yaguang Luo, a research food technologist with USDA,
offered her comments on the use of ozone in the flume wash system. “Unlike
most other sanitizers that are currently used in the fresh-cut industry,
ozone leaves no residual after treatment,” she said. “However,
the large organic load produced by the leakage of cellular components
of cut produce may present a major challenge to the ozone system. More
creative ways must be identified to overcome this issue.”
Dr. Luo cited another potential technical issue: How to
find the optimum exposure time and ozone concentration. “Since ozone
is a strong oxidizer, excessively high concentration and lengthy exposure
can cause tissue injury to fresh produce, which may result in loss of
quality and storage life,” she said. “I agree with other presenters
that there is no ‘plug and play’ application for ozone in the
fresh-cut industry. Scientific studies must be performed for each application.”
Optimism Prevailed
Bill Nelson, of Clean Air & Waters Systems in Poulsbo,
Wash., echoed Dr. Luo’s sentiments. “The combination of time,
temperature and proper ozone treatment will extend shelf life and make
food safer,” he said during his presentation on the use of dual ozone
sanitation systems for food safety and quality. “One thing that is
really nice about ozone is that it doesn’t penetrate the product.
Thus, when you cut an onion, for example, it still smells like an onion.”
During his delivery, Dr. Ahmed Yousef from The Ohio State
University, said, “Compared with other industries, the produce industry
will benefit greatly from the ozone technology. Ozone and produce are
a perfect fit. It varies with cut produce, however. I don’t feel
that ozone is a suitable application with cut tomatoes. But, cut lettuce,
cabbage, carrots and similar products are excellent ozone applications.”
Attendee Angelo Mazzei was also optimistic about O3’s
potential applicability. “Ozone has a place in the fresh-cut industry,”
he said. “In particular, the demands by the consumer for safer foods
and the applicability of ozone treatment to organically grown foods seems
to be a good marriage of quality and safety. In fact, the next Ozone conference
should have many more actual applications in the food industry.”
According to conference coordinator Greg Schwaller, the
Ozone IV conference is tentatively scheduled to take place in the first
quarter of 2004 in central California.
© 2003 Columbia Publishing
Cancer-Fighting
Tomato
Fresh Cut
January 2003
Tops America's 2002 Best in Biotech
Consumers select top five biotech advances of the year
The prospect of a cancer-fighting tomato has been named
the top development in food biotechnology in 2002, according to a Roper
survey of 1,000 randomly selected American adults.
When asked which publicly reported development in food
biotechnology during 2002 was considered most valuable, two-thirds of
respondents selected a research program that is enhancing tomatoes with
a higher quantity of lycopene, an antioxidant believed to help fight cancer.
The tomato is currently undergoing field tests.
Other top developments from more than 20 achievements
by government and academic institutions include: sweet potatoes that can
ward off a devastating plant virus; bananas and potatoes that contain
a vaccine for a human virus associated with cervical cancer; produce that
can stay fresh longer; and field crops that can thrive in extreme climates.
"It is these types of advances through biotechnology
that can make our foods more functional and truly benefit the healthfulness
of people over the long-term," said Mary Lee Chin, a registered dietitian
who is a nationally recognized expert on nutrition trends and significant
health and food issues. "As our society struggles with a growing
range of health and nutritional issues, biotechnology is a tool that can
help us grow foods that are better for our health."
Chin said food biotechnology is hitting its stride after
20 years of development and six years of commercially planted varieties
that first emphasized managing pests, such as insects and weeds.
"This year's top advances in biotechnology represent
a shift in the focus of plant biotechnology beyond pest management,"
Chin said. "More and more, biotechnology is moving toward products
that will offer direct benefits to consumers, such as improved nutrient
profiles and enhanced tastes." After ranking the top developments
in food biotechnology, 6 of every 10 respondents said they support the
use of biotechnology in agriculture, while 2 out of every 10 were neutral
and 2 out of every 10 expressed opposition. The study is considered to
have a margin of error of plus or minus 3 percentage points at the 95
percent level of confidence.
The Top Five Developments
#1 Cancer-fighting tomatoes. (65 percent of respondents
ranked as "valuable") Field tests currently are underway for
a new cancer-fighting tomato variety, which has been under development
for a decade by Purdue University and the U.S. Department of Agriculture's
Agricultural Research Service. The new variety offers more than three
times the amount of the antioxidant lycopene compared to conventional
varieties. Lycopene is known to trap harmful molecules that damage human
body tissue and could lower the risk of breast and prostate cancers, as
well as coronary heart disease. The development was discovered when attempting
to lengthen the shelf life of tomatoes.
#2 Virus-resistant sweet potatoes. (61percent ranked as
"valuable") A new sweet potato variety has built-in resistance
to a devastating virus that consumes more than three-fourths of the annual
harvest. Scientists at the International Service for the Acquisition of
Agri-Biotech Applications' AfriCenter in Nairobi, Kenya, the Kenya Agricultural
Research Institute and other research institutions developed the improved
sweet potato, a staple in many African countries. It is being field tested
and likely will be commercially available in a few years to help in the
fight against global hunger.
#3 Banana and potato vaccines. (56 percent ranked as "valuable")
Bananas and potatoes have been developed that contain a vaccine for Human
Papillomavirus (HPV), one of the most prevalent sexually transmitted diseases
and the cause of almost all cervical cancer in women. Researchers with
the University of Rochester have tested varieties equipped with the vaccine
and work is now entering the third stage of clinical evaluation.
#4 Fresher produce. (54 percent ranked as "valuable")
A gene that produces a plant hormone that counteracts aging and keeps
fruits and vegetables fresh longer was recently discovered at the University
of Leeds in the United Kingdom. Researchers currently are investing practical
applications for the commercial food marketplace that would help lengthen
the shelf life of fruits and vegetables and ensure they reach consumers
#5 Hardier crops. (52 percent ranked as "valuable")
Hardier varieties that would allow crops to flourish in extreme climates
are being developed at the University of Sheffield in the United Kingdom.
Researchers there have enhanced a thale cress plant, an herb from the
mustard family, to have a higher tolerance to heat and light stress. This
research translates into an opportunity to develop plants that could grow
in extreme climates. Currently, this research is being examined for use
in plants such as maize (corn), potatoes and other staple crops that are
often grown for survival in the arid developing world.
The Council for Biotechnology Information commissioned
the Roper survey to gauge consumer interest in new biotechnology developments.
The organization provides science-based information about how biotechnology
is providing more and better food while protecting the environment. To
learn more about biotechnology and agriculture, visit the Council for
Biotechnology Information's Web site at whybiotech.com or call (202) 467-6565.
© 2003 Columbia Publishing
United
Moves Headquarters to Washington, D.C.
Fresh Cut
January 2003
After 25 years across the Potomac River in Alexandria,
Va., the United Fresh Fruit and Vegetable Association is returning its
national headquarters to the nation’s capital, just three blocks
from the White House. In early January, United will move its headquarters
to 1901 Pennsylvania Avenue, Northwest.
United’s Board of Directors voted to move the headquarters
location to downtown Washington, D.C. in May 2001, at the same time it
decided to open a West Coast office. “With the opening of our Salinas,
CA office and the decision to move to D.C., the Board wanted to get closer
to both our member companies and the nation’s government and policy
leaders,” said United President Tom Stenzel.
“With our new headquarters so close to the action,
we’ll be able to increase daily interaction with Congress, regulatory
officials and the White House, schedule regular breakfast and lunch meetings
in the office, and host receptions and political events for Members of
Congress,” said Stenzel. United will occupy the entire top floor
of the new building, providing a professional image for the produce industry
before the nation’s opinion leaders, and allowing space for growth.
“We’ll also provide some spare offices and conference areas
for our member companies and associations to increase their own outreach
in Washington and work together with staff at our headquarters,”
added Stenzel.
United constructed its present headquarters building in
1978, moving from the District of Columbia at a time of significant business
exodus from the downtown area. “With the extensive redevelopment
and major growth in the District over the past decade, there’s no
better place for a national trade association to conduct the business
of its industry,” Stenzel said. “Our new location will increase
our ability to work even more closely with other associations such as
the Food Marketing Institute and National Restaurant Association, since
most major national trade associations are in D.C.“
© 2003 Columbia Publishing
Innovations
in Food Safety
Fresh Cut
January 2003
According to Food Spectrum industry estimates and projections,
prepared refrigerated foods sold through U.S. supermarkets will grow from
$9.5 billion in 2001 to $12.2 billion by the end of 2005. Of that total,
it is forecasted that the entire category of value-added produce will
grow to $5.2 billion in 2005. Sizable gains in both value-added vegetable
products and value-added fruits will contribute towards the growth of
the produce category. These products, like other fully prepared refrigerated
foods, represent a “new generation” of prepared refrigerated
foods which are growing and evolving very quickly, and are effectively
responding to consumer desires for convenience, variety, quality and health.
However, the dramatic growth in the fresh-cut industry
that is forecasted may lead to a corresponding dramatic increase in the
incidence of food borne disease outbreaks in this country unless preventative
measures are implemented. Food safety is an extremely important consideration
with refrigerated foods in general, and this issue is particularly relevant
with value-added produce products. Although America’s food is among
the safest in the world, 76 million illnesses, 325,000 hospitalizations
and 5,000 deaths annually are due to food borne disease in this country,
according to the Centers for Disease Control and Prevention, and value-added
produce products are a leading cause of these outbreaks.
An HACCP Approach
Adequate food safety of refrigerated foods can only be
achieved with a high degree of assurance by formulating, adapting and
using a Hazard Analysis and Critical Control Point (HACCP) approach. By
judicious application of HACCP systems, the food processor can implement
a program whereby safe production conditions are achieved. HACCP techniques
assess everything from raw ingredients to product packaging and distribution,
define the locations at which potential hazards (microbial, chemical and
physical) may occur, and establish a means of monitoring these points
to eliminate potential hazards.
It is critical to understand the technologies and best
practices associated with the processing of value-added produce, literally
from “farm to fork” as these individually and collectively impact
both product safety and product quality, and ultimately impact the potential
for market viability. New technologies have been recently introduced,
and others are on the horizon. Collectively, they will enable even greater
alternatives towards the development of refrigerated prepared products
that meet consumer needs for safety, as well as quality, convenience,
and overall value. Such technologies are “hurdles” and are preventative
tools designed to provide incremental assurances of safety, and extend
the bacteriological and/or sensory shelf life of the food product. Hurdles
are effectively “tools in the toolbox” that can be utilized
by processors of fresh-cut produce and others involved in the product’s
chain from farm to fork.
It is essential that hurdle technologies be utilized,
because we cannot rely exclusively on the maintenance of refrigerated
conditions to assure the safety of these perishable foods. In fact, refrigeration
alone is not enough to prevent the growth of some infectious or toxigenic
microorganisms. With so few bacterial cells necessary to cause certain
types of food borne disease, growth on infested produce is not a requirement
for human infection, as with most other pathogens. Therefore, refrigeration
of harvested produce is not a sufficient control, although it is of great
value and is a contributing hurdle. In addition, post process contamination,
even at low levels may create a situation where pathogenic microorganisms
may grow to high levels and cause illness and potentially death. Therefore
other barriers to microbial growth must be incorporated into these foods
to yield a safe and stable system.
Clearly, raw material control and superior agricultural
practices are critical to the successful development of value-added produce
products. Variety, source, season, initial maturity, processing maturity,
slicing and cutting equipment, chemical or other treatments and dips,
packaging environment, temperature management, shipping, and handling
all affect the sensory acceptability and attainable shelf life of fresh-cut
produce while impacting product safety.
Key Tools
Preharvest contamination-prevention programs and postharvest
sanitation are key tools to preventing outbreaks. Some farming practices
that were considered safe in previous years are a current liability today.
On-farm prevention programs should include basic sanitation practices
for all harvest containers, contact surfaces, and postharvest washing.
Washing fruit and vegetables with clean, potable water and a chemical
disinfectant will result in a 1-3 log reduction (or 10 to 1,000 fold reduction)
but have not been shown to eliminate microbial contamination. In fact,
some pathogens are very resistant to chlorine, for example, and even sensitive
ones such as salmonella and E. coli may be located in inaccessible sites
on the plant surface. It should be noted that even effective chlorine
concentrations are reduced by temperature, light, and interaction with
soil and organic debris, so wash water should be tested routinely. Disinfectants
utilized include chlorine and chlorine dioxide, hydrogen peroxide, peroxyacetic
acid, bromine, iodine, trisodium phosphate, acetic and /or lactic acids
and ozone. Current best practices also include steam treatment to disinfect
surfaces of whole fruits, for example, which can result in a 5-log or
greater reduction of microbes, including E. coli 0157:H7.
Hurdles can be incorporated further “downstream”
as well. These include direct addition to or on the raw material via wash
aids or other means that incorporate acidulants, antimicrobial agents,
antioxidants, heat (e.g., blanching), and processes that control water
activity. In addition, non-thermal processing hurdles can now be applied
such as ultra high pressure processing, irradiation, and pulsed light
and pulsed electric field processing. And lastly, hurdles can be applied
during the packaging process, and include the application of modified
atmosphere packaging (MAP), clean room packaging, active packaging systems,
intelligent packaging systems, and a variety of alternative packaging
materials. Synergistic results can be achieved when hurdles are used in
combination, and are a very important consideration. Many of these technologies
have been shown to significantly reduce levels of food spoilage and pathogenic
microorganisms such as E. coli O157:H7, salmonella, listeria, and campylobacter.
Modified atmosphere packaging via reduced oxygen may be
a technology chosen to help a fresh-cut processor achieve a much longer
shelf life. However, because MAP results in a dramatic change in the time
it takes for product to spoil, and the type of bacteria that will cause
this spoilage, it creates significant additional risk as well. Because
resultant oxygen levels can be extremely low in the MAP package and held
for a longer period of time, an atmosphere that is conducive to growth
of anaerobic bacteria increases the likelihood that a pathogenic organism
like C. botulinum can grow produce toxin, and cause food borne disease.
However, incorporation of other barriers and microbiological challenge
studies will minimize such risks.
Crisis Management Recommended
Fresh-cut produce processors are strongly encouraged to
implement a crisis management program in light of these potential food
safety issues. This will ensure that a crisis management team and effective
procedures are in place, should there be a need to recall defective products
and ensure the coordination of information and return of defective product
to protect customers from health risk or fatality. A mock recall and trace
back investigation will identify the potential sources implicated in a
food borne outbreak, and determine and document the link in the chain
that has been implicated during an epidemiological investigation of food
borne illness. Fresh fruits and vegetables are extremely difficult to
trace back because in most instances lot numbers and grower identifications
are not used or recorded on receipt and shipping records. For this reason,
it is imperative to identify a crisis management and trace back protocol
that will be quick, efficient and as accurate as possible.
In conclusion, no innovative “magic bullet”
exists that will allow for product safety in value-added fresh-cut products.
Instead, it is the combination of multiple hurdle techniques that will
ensure microbiological safety, extend shelf life and enable successful
marketability.
Editor’s Note: Lou Cooperhouse is president and CEO
of Food Spectrum, LLC, a consulting and research company specializing
in value-added foods. Cooperhouse can be reached at lcooperhouse@foodspectrum.com.
© 2003 Columbia Publishing
>>
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Boskovich
Farms Delivers Quality, Customer Service
Fresh Cut
February 2003
For 88 years, Boskovich Farms, Inc. in Oxnard, Calif.
has employed the philosophy of its founder Stephen Boskovich: “Work
hard, work smart and do whatever it takes to get the job done right.”
The Boskovich story began modestly in 1915, when Stephen
Boskovich, a young Croatian immigrant, began raising vegetables on just
five acres in North Hollywood, Calif. Over the years, family members,
including grandsons George Boskovich, Jr., CEO, and Phillip Boskovich,
Jr., president, expanded the operation that today includes 10,000 acres
in three growing regions.
“Our customers are very demanding,” said Don
Hobson, Boskovich’s vice president of sales and marketing. “We
try to give them exactly what they want. More and more often, they are
looking for the direct relationships with their suppliers where they actually
have some say in everything from what we produce to certain harvesting
practices and processing techniques. They rightfully want to know where
their product is coming from and how it’s handled and processed.”
One area that sets Boskovich Farms apart from much of
its competition is its diverse product line. Boskovich Farms grows, packages
and ships commodity items which include green onions, lettuce, leeks,
radishes, parsley, kale, cilantro, and broccoli. Boskovich Fresh Cut,
the processing arm of the company compliments the business by offering
a full line up of fresh cut items such as sliced green onions, salad mixes
and fresh cut cabbage.
Responding to the customer and adjusting the business
accordingly has made Boskovich Farms one of the largest and most successful
operations in the country. “Whether it’s our fresh commodity
products or our fresh cut line-up, we have a presence in nearly every
region in North America between our retail and foodservice customers”
explained Hobson.
Expanding the Operation
A pivotal year of growth for Boskovich Farms was 1996
when the company purchased an existing fresh-cut operation in Oxnard.
“Expanding into the fresh-cut area was a good fit for us, allowing
us to adapt to the changing marketplace and the growing fresh cut segment,”
said Michael O’Leary, Boskovich’s director of sales and marketing
for its fresh-cut division. “Our products have always had an excellent
reputation for top quality, which was something we could apply and continue
to grow with our fresh cut label.”
Incorporating the value-added concept for the company,
Boskovich today sees roughly one-quarter of its sales in the fresh-cut
area. “We are a vertically integrated company,” said O’Leary,
“and being able to supply customers with whole produce as well as
a wide variety of fresh-cut items is a key element in our continued growth.”
O’Leary added that Boskovich’s fresh-cut operation is heavily
geared to foodservice. “We like where we are and we feel that we’re
transcending as a leader in the industry.”
From the company’s field audit program, to its in-house
sanitation and food safety activities and emphasis on customer service
at the user level, Boskovich controls the entire process. In a move that
will further streamline operations, Hobson said that Boskovich Farms is
currently constructing a 65,000 square foot processing facility at its
Oxnard headquarters. This will enable the company to meet current and
future demands of the fresh cut operations, and will consolidate both
divisions under one roof.
Technology Plays Key Role
When it comes to implementing various technologies within
Boskovich Farms, food safety has been one of the most important areas
of concentration. “We place a great deal of emphasis on food safety
and have put a lot of time and money into ensuring our products are the
best and the safest in the marketplace,” said O’Leary.
Alex Reyna-Benraadt, Boskovich’s director of food
safety, oversees the company’s sanitation programs, conducts research
on safety and quality issues, directs the quality assurance program and
oversees the hazard analysis critical control point (HACCP) program.
Throughout the entire process from plant to plate, safety
measures are in place to ensure that the highest standards of food safety
are employed. The company conducts in-house audits and commissions third-party
audits to verify product safety. In addition, recent food security and
preventative measures have been put into place in response to heightened
possibility of product tampering. Such measures include: photo ID tags
for employees, video cameras and vehicle identification for employees,
24-hour security personnel, visitor restriction and stringently enforced
restricted access to pesticides and spray equipment.
“We do a lot of work with customers in quality control
and watching our product as it goes through the pipeline,” said Hobson.
“We’re very interested in how it looks when it’s finally
consumed.”
Hobson also described other technology that has played
an important role in the continued success of Boskovich Farms. “We
have in place a great software system,” he said. “It’s
all linked together in one system that enables us to monitor and track
every aspect of our process including sales, production, farming, harvesting,
processing, shipping and inventory.”
Boskovich Farms, Inc. will continue to provide quality
produce and quality service to vendors and customers across the country.
“The bottom line is that we know our success is ultimately dependent
on our quality,” explained O’Leary. “Our focus will continue
to be on quality, supply, food safety and value. We’re dedicated
to delivering just that.”
© 2003 Columbia Publishing
Industry
Innovations
Fresh Cut
February 2003
Innovations in Fruit Technology
Innovations in fruit technology, especially in fresh-cut processing, are
helping to propel tremendous growth in this segment of the produce industry
during this decade. Value-added cut fruits effectively respond to consumer
desires for convenience, variety, quality and healthful dietary alternatives.
Food Spectrum, LLC, a consulting and research firm, estimates that in
2001, U.S retail sales of value-added, fresh-cut fruit products totaled
$690 million.
The pioneer of the fresh-cut industry, and an outstanding
example of the dramatic growth that can be achieved, is the pre-cut lettuce
market. As this segment is beginning to mature, pre-cut lettuce has paved
the way for success that can now be attained with fresh-cut fruits and
vegetables.
Prior to 1990, one would have thought it inconceivable
that consumers would purchase bagged and branded lettuce. However, current
sales of bagged lettuce products dominate the value-added produce category
with estimated U.S sales in 2001 of $1.6 billion. Cut lettuce products
will continue to account for a significant portion of category sales volume
for the near term, but its success has opened the door for new opportunities
in other packaged fruit and vegetable products. The convenience of product
use, and the variety offered by prepackaged items, has changed consumer
purchasing behavior and created “halo” effects for other prepackaged
products, such as pre-cut fruits.
Fresh-cut Fruits
In the fresh-cut segment, varieties marketed to date have
been dominated by pineapple, melon (including watermelon, cantaloupe,
and honeydew), citrus products (including grapefruit and oranges) and
grapes. Frequently packaged in polyethylene (PET) containers, these fruits
typically achieve shelf lives of two to four days. Because of this short
shelf life, Food Spectrum estimates that two-thirds of retail sales to
date originate from products that are cut by hand and packaged at store-level,
or within localized facilities that service supermarkets.
In the past few years, and in the years ahead, this category
is projected to evolve considerably because of advances in technology.
New fresh-cut fruit offerings are now available such as pre-cut melons
in party trays with a 10-14 day shelf life. Pre-sliced apples, however,
offer an interesting case study in technology. These are currently being
marketed with a three to four week shelf life, during which time a blend
of additives (such as calcium chloride and ascorbate) provides for an
extension of shelf life by inhibiting respiration and the oxidation process,
and in which packaging is in a simple two to four mil polyethylene (PE)
bag. Sliced apples are also currently being marketed with up to a seven-week
shelf life, and sold together with caramel sauce in two-compartment thermoformed
trays, by firms that use similar rinse solutions, but also utilize modified
atmosphere packaging. Researchers have also demonstrated that 10 weeks
of shelf life is possible for apple slices in syrup, using anti-browning
agents together with ultra high pressure processing as will be discussed.
Impacting Flavor
Numerous interactions impact the flavor characteristics,
sensory acceptability, and therefore the attainable shelf life of fresh-cut
produce such as variety, source, season, initial maturity, optimum processing
maturity, slicing and cutting equipment, chemical or other treatments
and dips, packaging environment, temperature management, shipping and
handling. Research has shown that in order to achieve optimum quality
and flavor, fruit must be harvested at just the right stage of ripeness.
Fruits destined for processing should generally be harvested specifically
for that use, and this may not necessarily be the harvest maturity required
for the fresh market. The achievement of food safety with fresh-cut fruits
requires an understanding of sanitation of the exterior surface.
The rind of cantaloupe melons, for example, can effectively
harbor microorganisms and therefore be relatively difficult to sanitize.
Food borne illness attributed to Salmonella contamination, for example,
has been linked periodically to a number of fruit products, most typically
due to cross contamination from cutting equipment, shipping ice or hydro
cooler water.
A wide array of technologies is now available to manufacturers
of fresh-cut, value-added fruit products. Various methods have been researched
over the years to determine optimal reduction of bacterial contamination.
It has been clearly determined that the combination of multiple hurdle
techniques will ensure microbiological safety, extend shelf life and enable
successful marketability. This may include usage of technologies like
steam treatment, disinfectants, or irradiation of exterior surfaces, and
use of disinfectant wash aids, antimicrobial additives, modified atmosphere
packaging, heat pasteurization, ultra high pressure processing or irradiation
for fresh-cut products.
Historically, use of a chlorine solution at up to 200
ppm has been effective for a 90-99 percent reduction in total bacteria
counts. However, alternative rinse agents are now available, such as the
use of peroxyacetic acid and ozone for fresh-cut fruit processing. Ozone
in particular appears to offer significant promise for reducing or eliminating
potential pathogenic organisms. In addition, unlike other chemical disinfectants
such as chlorine, disinfecting with ozone can be achieved with relatively
low concentrations and short contact times for the reduction of bacteria,
molds, yeasts, parasites and viruses.
Historically, use of antimicrobial agents, like asorbates
and benzoates, also have been utilized in fresh-cut fruits, such as fruit
cocktails, fruit beverages, fruit desserts, pie fillings, etc. These preservatives
have long been proven to be effective against yeasts, molds, and certain
bacteria. In many food products, sorbate and benzoate are used together
to provide greater protection against a wider variety of microorganisms.
However, this is most effective if the pH of the product is below 4.5.
New Technologies
New technology innovations for value-added fruit products
include ultra high pressure (UHP) processing (also referred to high hydrostatic
pressure, or HHP) which imparts pasteurization with little to no heat.
C First generation refrigerated products treated with UHP have included
juices, fruit preserves, guacamole and salsa. Premium refrigerated orange,
apple, and other juices are now utilizing this process, as an alternative
to thermal HTST flash pasteurization processes.
Application of this technology enables minimal processing
to products that meet or exceed government safety standards, while providing
expected “fresh” flavors but with significantly increased shelf
life. Value-added produce, especially cut-fruit products, may retain excellent
quality characteristics and achieve extended shelf lives if processed
using UHP technology. However, this technology may have product limitations
as it can affect changes in structurally-fragile foods, like strawberries
and lettuce, and result in cell deformation and cell membrane damage resulting
in softening and/or browning. Also, the incorporation of anti-browning
agents such as ascorbate, in conjunction with high-pressure treatments
in apple slices in syrup, for example, has shown to result in a shelf
life of up to 10 weeks.
Irradiation has been an extremely controversial method
of food preservation over the years. In fact, fruits were the first item
sold using this technology. Pint containers of the nation’s first
irradiated food, fresh strawberries, were first sold in North Miami Beach
on Jan. 25, 1992. The irradiated strawberries had a 21-day shelf life
compared with seven days for non-irradiated strawberries. In March 1992,
Carrot Top, a grocer in Northbrook, Ill., made national headlines too
as it expanded the breadth of irradiated products to its customers. Carrot
Top offered mushrooms with a three-week shelf life without browning; vine-ripened
tomatoes with a three-week shelf life that didn’t get moldy and didn’t
need ethylene treatment; and onions that didn’t sprout for more than
three months.
This era witnessed the launch of a very aggressive campaign
by a few vocal groups that fought against the introduction of this technology.
Vocal opposition has now dramatically declined, and almost a decade has
passed since the first irradiated foods were introduced. Consumers are
beginning to find irradiation to be an acceptable technology to combat
their real concerns about contracting food borne disease. Highly publicized
outbreaks of E. coli O157:H7, Salmonella, and Listeria have raised consumer
consciousness about the risk of food borne disease. Huge recalls in the
food industry have exacerbated these concerns and created a demand for
mitigating this risk. Irradiation has become a real choice to alleviate
these fears. The emergence of food irradiation using electron beam and
X-ray facilities, which do not involve radioactive substances, has made
this a more palatable proposition for the consumer.
Packaging Options
The packaging stage of manufacturing offers a number of
highly-differentiated options for the food processor as well. Packaging
hurdles include modified atmosphere packaging (MAP), clean room packaging,
and utilization of appropriate packaging materials and packaging systems.
Modified atmosphere packaging, via reduced-oxygen, may be a technology
chosen to help a fresh-cut processor achieve a much longer shelf life.
However, because MAP results in a dramatic change in the time it takes
for product to spoil, and the type of bacteria that will cause this spoilage,
it creates significant additional risk as. Also, incorporation of other
barriers and microbiological challenge studies will minimize such risks.
The growth of the fresh-cut produce industry was the catalyst
that helped the packaging industry evolve, and the refrigerated foods
category evolve as a whole. Films, for example, may contain enhanced barriers
to oxygen, moisture, and/or light, and some may have anti-fog capabilities
to reduce condensation. Laminated materials are widely used in the industry
today, that are manufactured by bonding two or more layers together with
adhesives in which each layer performs a particular role. Microperforation
is a technology that can be used with high-respiring fresh-cut produce,
and offer high moisture vapor transmission rates for products like cauliflower.
Many technology alternatives are now available. Application
of these technologies will enable the marketability of a wide array of
new product offerings for consumers in the years ahead. Improvements in
product shelf life and safety, and the integration of improved refrigeration
units in supermarket produce sections will enable the birth of new product
categories and new markets.
Editor’s Note: Lou Cooperhouse is president
and CEO of Food Spectrum, LLC, a consulting and research company specializing
in value-added foods. The company’s recent report, Retail Prepared
Refrigerated Foods: The Market and Technologies, analyzes products sold
in supermarket produce, deli and meat departments. It offers market size
estimates, forecasts, and market shares held by major competitors, as
well as competitive profiles and a comprehensive analysis of trends affecting
the market. The report also discusses in detail current and emerging process
and packaging technologies driving new and established products. Further
information is available at www.foodspectrum.com. Lou Cooperhouse can
be contacted at lcooperhouse@foodspectrum.com.
© 2003 Columbia Publishing
United
Chairman Appoints 2003 Membership Committee
Fresh Cut
February 2003
Alexandria, Va. - United Fresh Fruit & Vegetable Association
Chairman of the Board Steve Grinstead, Standard Fruit and Vegetable, Dallas,
Texas, has appointed Alec Leach, president, Taylor Farms California, and
Ron McCormick, vice president and divisional merchandise manager of produce,
Wal-Mart Stores, as co-chairs of the 2003 United Membership Committee.
Both Leach and McCormick serve on United’s Board of Directors.
“We’re just coming off the most successful membership
year in a decade, and I couldn’t think of two individuals more motivated
to top last year’s success,” Grinstead said. “Ron was a
great co-chairman last year with Karen Caplan, our incoming chairman.
I know that Alec joins him this year with tremendous enthusiasm and commitment
to spread the word about the value of United membership.”
“After all, membership isn’t an end in itself,
but really the means to increasing our produce industry’s strength
to shape national public policy, address the industry’s most difficult
business and trade issues, and deliver the best possible education and
leadership development opportunities to our industry,” Grinstead
said. “Those of us in volunteer leadership at United believe that
member dues are a small price to pay for the value that this organization
delivers back to our companies - we’re passionate about delivering
the very highest level of value to our members, and passionate in our
commitment to spread the word to every corner of the industry.”
Joining Leach and McCormick on the 2003 Membership Committee
is a “Who’s Who” of produce industry volunteers.
United's 2003 Membership Committee
Alec Leach, Co-Chair, Taylor Farms California
Ron McCormick, Co-Chair, Wal-Mart Stores
John Baillie, Baillie Family Farms/Jack T. Baillie Co.
Michael Brown, Glory Foods
Chuck Ciruli, Ciruli Brothers/Amex Distribution
Brendan Comito, Capital City Fruit Company
Matthew D’Arrigo, D’Arrigo Bros. Co. of New
York
Jan Delyser, California Avocado Commission
Drew Duda, A. Duda & Sons
Tim Fleming, Strube Celery & Vegetable Company
Ron Fode, Fode Farms
Bob Grimm, Grimmway Enterprises
John Loughridge, Del Monte Fresh Produce NA
Dan’l Mackey-Almy, Standard Fruit & Vegetable
Company
Frank McCarthy, Snokist Growers
Lee Ann Oxford, L&M Companies
Frank Pitts, Farm Gate, LLC
Joe Procacci, Procacci Bros. Sales Corp.
Ashley Rawl, Walter P. Rawl & Sons
Kevin Searle, GPOD of Idaho
Dave Smith, Idaho Grower Shippers Association
Debi Street, Frieda’s
Michael Swift, Safeway
Dan Vache, Sensitech
Jaime Weisinger, Six L’s Packing Co.
Suzie Williamson, Andrew & Williamson Sales Company
Chuck Zambito, Zambito Produce Sales
The 2003 Membership Committee will work with United’s
Board, other volunteer leaders, and staff to identify prospects and recruit
companies to become members of United. “The most important membership
recruitment tool at United is an invitation from a peer in the business,”
said United President Tom Stenzel. “On staff, we can produce glossy
brochures and talk all day about the value of our association, but when
business colleagues tell each other they believe in the power of a United
produce industry, our association can grow to heights yet unimagined,”
he said.
© 2003 Columbia Publishing
Reducing
Contamination Risks in Fresh-cut Apples
Fresh Cut
February 2003
Implementing Food Safety Risk Reduction Programs
Assuring adherence to Good Agricultural Practices (GAPs)
is one of the prerequisite programs essential to any fresh-cut apple food
safety program. Microbial contamination of apples can occur in many ways,
including but not limited to: use of contaminated irrigation water, use
of manure containing human pathogens as a soil amendment, harvesting dropped
apples, hydro-cooling apples with contaminated water, etc. In particular,
apples with overt symptoms of decay should be excluded from the raw material
to be processed into fresh-cut apple slices.
If apples are contaminated with human pathogens in the
orchard, at harvest or during post harvest handling, there are currently
no known commercially available treatments, including washing with disinfectants
such as chlorine, ozone or peroxyacetic acid that will completely eliminate
harmful bacteria. Therefore, prevention of contamination is the key to
assuring production of safe and wholesome products.
Food safety programs such as Good Agricultural Practices,
using a preventative approach to contamination, are essential for reducing
food safety risk associated with consumption of whole fresh apples. These
programs are critical for continued long-term success of the fresh-cut
apple category. Stringent adherence to GAPs is not simply another cost
of doing business. Compliance will lead to long-term business survival
and assure that growers can continue to sell apples to a new and potentially
very large fresh-cut apple processing industry.
When apples are processed, they are often removed from
field bins by submerging them in water to reduce mechanical damage. This
water and any water which directly contacts apples should have appropriate
levels of wash water disinfectants present to prevent the potential for
cross contamination. If water sanitizers are not present at sufficient
levels to keep the water sanitary, float tanks and flumes can become potential
inoculation baths contaminating all produce that passes through them.
Processors should monitor and control wash water disinfectant
levels using continuous ORP (oxidation-reduction potential) measurements
or by directly analyzing disinfectant levels to assure they are sufficient
to reduce the risk of cross contamination. Research from the USDA-ARS
has demonstrated that harmful bacteria can be internalized in apples with
an open calyx. Once present in inaccessible areas (calyx and stem areas,
punctures) and even on the surface of apples, harmful bacteria are almost
impossible to remove by washing.
Before cutting begins, apples should be washed and cleaned
with potable water to reduce microbial populations as much as possible.
This is not only a good food safety practice, but it may increase shelf
life by reducing yeasts and molds which commonly shorten the shelf life
of fresh-cut apples. Peeling, coring and slicing knives should also be
cleaned and sanitized as often as possible to reduce the possibilities
that knives will become a source of microbial contamination. Mechanical
peelers, cutting knives and conveyors may also be equipped with wash water
spray bars to remove small apple pieces, skin and debris, thus reducing
the likelihood of cross contamination by food contact surfaces.
The enabling technology for fresh-cut apples has been
the use of antioxidant-based washes or dips to prevent surface discoloration
and tissue softening. However, the cost of the reagents used in the treatment
tank prohibits processors from discarding the treatments after a single
use. The treatment liquid may become contaminated and could potentially
become a source of hazardous inoculation to subsequent batches of apples.
Water disinfectants relying on oxidation reduction potential
(i.e. chlorine, chlorine dioxide, peroxyacetic acid and ozone) or light
energy, such as UV light, to inactivate harmful bacteria, cannot be used
to reduce microbial populations in these liquid treatments simply because
light energy and ORP-based disinfectants would inactivate the high concentrations
of antioxidants used to treat apples.
A number of methods are currently available to reduce
microbial populations within antioxidant treatment liquids:
Exclusion of harmful bacteria in the processing area environment through
proper sanitation.
Refrigeration of browning inhibitor solutions to suppress
bacterial growth (Listeria monocytogenes, however, can grow slowly at
low temperatures).
Rinsing cut apples with sanitizing agent after peeling,
coring and/or slicing to reduce bacterial populations and minimize leaching
of apple solids into browning inhibitor solutions.
Addition of a food-grade preservative to the browning
inhibitor solution.
Microporous filtration or flash pasteurization of the
browning inhibitor solution.
None of these methods can completely eliminate risk because of continuous
introduction of potentially contaminated fruit into the browning inhibitor
solution, the limited efficacy of most decontamination treatments, and
the limited volume of solution that can be treated at any one time.
Flash pasteurization (high-temperature, short-time treatment
of the antioxidant solution) would quickly kill most harmful bacteria,
but requires that the solution be cooled back down before it is reintroduced
into the treatment tank. Such a procedure would likely reduce the functionality
of the antioxidant solution as well as turn the antioxidant solution a
murky brown color instead of its natural clear color.
Microporous filtration may also be used to keep the antioxidant
solution disinfected. This method relies on physically filtering harmful
bacteria out of the treatment solution, often in a multistage process
involving removal of larger debris from the solution before using microporous
filters to remove unwanted microorganisms. Microfiltration can be effective
but filters must be changed often as they may clog due to small particulate
matter and dissolved pectins in the antioxidant treatment solution.
Another effective strategy is to use the antioxidant solution
only once as spray treatment instead of as a dip or submersion treatment.
This may be impractical since the antioxidant treatment solution may be
quite costly. Making smaller batches of the solution, using small treatment
tanks and changing it frequently will also reduce the risk of cross contamination
within the treatment tank.
Value-added Resources
The International Fresh-cut Produce Association (IFPA)
has been involved with the fresh-cut industry almost since its inception
and the association's mission is to advance the industry by supporting
its members with technical information, representation and knowledge to
provide convenient, safe and wholesome food. The IFPA represents and provides
technical expertise to commercial suppliers of fresh-cut produce, as well
as companies affiliated with the fresh-cut produce industry, including
equipment manufacturers, retailers and foodservice operators. We represent
over 500 corporate members who are actively involved in the $10 billion-per-year
fresh-cut industry. The IFPA also has numerous government and academic
members who have the common interest of working on fresh-cut product research
and development efforts. If you are considering launching a value-added
program, IFPA membership would allow you to network with equipment suppliers
and consultants, as well as interact with companies involved in the fresh-cut
industry.
The IFPA wants to team with fruit and vegetable grower/shippers
and let them know about the food quality and food safety resources for
fresh-cut processing that are available through the association including:
IFPA Food Safety Guidelines for the Fresh-cut Produce Industry
Model HACCP Plan for Fresh-cut Processors
HACCP Short Course for Fresh-cut Processors
Access to suppliers and technical information about fresh-cut
apple processing at the upcoming IFPA annual meeting
Technical Hotline
Biweekly Hotsheet: timely up to date coverage of important
industry issues
Other publications such as: “Determining Real Cost
of Production in Small Processing Plants” and “Cost Considerations
in Developing a Value-added Program”
IFPA web site: www.fresh-cuts.org
For more information or membership application visit our website at www.fresh-cuts.org
or telephone the IFPA at 703.299.6282.
Editor’s Note: This is Part II of Jim Gorny’s
report on Fresh-cut Apples.
© 2003 Columbia Publishing
Food
Safety Presentation
Fresh Cut
February 2003
The Unique Safety Aspects of Fresh-cut Fruit
Be aware of the special safety requirements for handling fresh-cut fruit
if you want to avoid serious setbacks in the marketplace.
That was made clear in a recent presentation by Robert
E. Brackett, Ph.D., director of food safety, Food and Drug Administration
Center for Food Safety and Applied Nutrition, College Park, Maryland.
Brackett spoke September 20 during the 9th Annual Fall
Seminar, “Fresh-cut Fruit: Drawing Board to Cutting Board,”
held in Alexandria, Virginia. The day-and-one-half event was sponsored
by the International Fresh-cut Produce Association.
There are reasons why the industry isn’t seeing as
much fresh-cut fruit on the market as other products, the speaker said.
One is the number of foodborne illnesses associated with fruit. These
must be understood and adequate steps taken to ensure food safety.
Published outbreaks of bacterial foodborne illnesses associated
with cut fruit range from E. coli 0157:H7 in apples to Salmonella in cantaloupe,
watermelon and oranges, Cyclospora in raspberries and Hepatitis A in strawberries,
he said.
“Of all the pathogens we deal with, Salmonella in
cantaloupe is the organism responsible for the greatest number of outbreaks
or illnesses,” Brackett pointed out. There also is a report of people
getting sick in Minnesota from eating pineapple believed to be contaminated
with Salmonella but the pathogen was never identified.
Viruses such as Hepatitis A also can be a problem, Brackett
said.
“A lot of times, we’re looking at a handling
problem, where workers handling food are infected with Hepatitis A,”
he said. They can transmit the disease without necessary exhibiting any
symptoms of being infected.
Some illnesses, such as a past Cyclospora outbreak blamed
on raspberries from Guatemala, have demonstrated that imported tropical
fruits can bring in tropical illnesses with them, the speaker said. As
the list of imports grows more and more new pathogens are being discovered.
It is one thing to have a bacterial foodborne pathogen
on a whole fruit and another to have it in cut product, Brackett said.
With some products such as apples, once the skin is breached, be it mechanically
punched or due to some type of abrasion (or even an insect bite), E. coli
0157 can gain entrance and begin growing in the damaged area. Whether
infected with E. coli or Salmonella, which is more often the case in cantaloupe,
most expressed have been in cut, not whole, product.
Factors Influencing Produce Safety
Several factors influence fresh produce safety, Brackett
said. Included where the product was grown and harvesting, processing,
storage and transportation procedures implemented.
Identification of the source of the problem can be challenging,
he said. The analyst has to list each product and identify the diseases
endemic to areas where it was grown. Product microbiology often differs
from area to area and country to country. Fruit products originating in
Florida or various tropical countries, for example, are going to be different
from those originating in the Northwest.
Another factor affecting microbiology is the harvesting
procedures used, he said. Is it hand picked or mechanically harvested?
There are different problems and situations with each.
“In the case of hand picking, you have the issue
of who is picking it?” Brackett said. “Are these people trained?
Are proper sanitary standards being used? In some cases they are, and
in some they are not. Quite often you’ll contract out where the product
comes from, so you may not have any direct control, but nonetheless it
affects the microbiology.”
The cleanliness of harvesting equipment used also can
be a factor, he said, citing examples where fresh-cut processors purchasing
supplies have placed themselves at risk.
“There have been cases of produce coming into terminal
markets in open trucks,” Brackett explained. “Going back the
investigators found that just previous to that there were pigs being hauled
in the truck, and nothing happened in between.”
While not a common in this country anymore, it often is
in some countries, he pointed out, and a lot of the products being purchased
for use in the U.S. industry today are grown elsewhere.
Processing Safety Concerns
“In processing, we do a number of different operations,
each of which will have an impact on microbiology — not just the
pathogens, but spoilage organisms as well,” he said.
Fresh-cut fruit processors must take into consideration
what the consumer is going to do with the product at home, Brackett warned.
Whenever consumers purchase a premium product that is more expensive they
are reluctant to throw it away unless it goes bad. Every effort is made
to extend the shelf life as long as possible, and that must be factored
into a processor’s thinking.
On the storage side, modified atmosphere technology may
be “the single most important technological development that has
helped the produce industry in this country,” but if used improperly
such systems can encourage pathogens growth, he warned.
Past research has shown that when efforts are made to
extend shelf life, if certain pathogens are present that grow in refrigerator
temperatures, the longer you hold the product the higher the population
of that organism becomes, Brackett explained.
Another processing and storage issue is the use of sanitizers
or antimicrobials to help eliminate spoilage organisms, he said. Consumers
may not like spoiled food, but spoilage organisms serve a useful purpose.
They warn consumers that their food has gone bad either from being abused
or around too long.
When you wipe out the natural microflora that cause spoilage
and do have a pathogen in your product, it may grow and pose a serious
risk, he said. The consumer has no way of knowing he is eating a product
that can make him ill.
Transportation issues also are very important, Brackett
emphasized. Not all fruit or produce is transported in trucks or vehicles
where proper attention to temperature control is taken.
“Very rarely will a consumer refrigerate his product
on the way home,” he said. “She may take it home and put it
in the refrigerator immediately, but quite often it will sit out on the
counter. All of this adds time to where anything that may be present can
grow, reducing the safety of the product and microbial stability in general.”
There are a number of ways various pathogens can get into
a product, Brackett said. It can occur before harvest. It can happen from
using contaminated water — and not just irrigation water. Water used
for washing as well as cooling can be culprits. Dogs, cats, goats and
other animals in a field can all impact on the safety of produce.
The other worry is humans, Brackett said. Humans can impact
the safety and microbiology of these products everywhere from planting
through consumption. While great progress has been made with the introduction
of portable toilets and sanitary facilities, fruits and vegetables continue
coming in from countries where none of these helps are provided.
Human contamination can occur all of the way through to
where the produce is cut, handled and, in some cases, sugared, he said.
Sweet products such as strawberries require “a lot of finger type
handling,” serious business if a worker is infected with a particular
disease.
What makes fresh-cut fruit unique?
While fruit may be fruit to a consumer, from a microbiological
point of view there are big differences in the types of fruit used, particularly
in terms of acidity, Brackett emphasized. pH levels vary widely, from
Passionfruit with a pH range of 1.9 to 2.2 to tomatoes at 4.0 to 4.5 and
melons at 6.2 to 6.7.
Not much is going to grow and survive at a pH of 1.9 to
2, but some tropical fruits and melons provide an almost perfect pH environment
for organisms to grow, Brackett noted. Depending upon the particular fruits
selected there is a different susceptibility to growth and survival of
various pathogens.
Salmonella and E. coli do better at the lower pH levels,
but viruses and parasites “don’t care” what the pH is,
the researcher stressed. They can survive at virtually any level.
Another important factor to be remembered is usable sugars,
he said. What makes fruit popular with consumers is the sugar. Bacteria
and other organisms also think they are great. With intact fruit, the
sugar challenge is less of a problem because of the skins or rinds that
prevent the bacteria from gaining access. But once the fruit is cut and
the sugar is expressed there is a new set of challenges. Almost any organism
present can grow, and this has been one of the problems with the stability
of fresh-cut fruit and why it often spoils so fast.
Contamination Potential Is High
Potential for contamination is another major factor with
fresh-cut fruit, Brackett said. Strawberries, cantaloupe and a number
of other fruits are grown close to or in direct contact with the soil.
If the soil is in an area subject to flooding or where raw animal waste
has been used, the risks for contamination are greater than with tree
fruit. However, tree fruit should not be exempted from the risks of becoming
infected with pathogens. Birds roost in trees. There has been a Salmonella
outbreak associated with whole oranges.
The potential for contamination also is related to the
rind or skin of the product involved, Brackett said. Apples and strawberries,
for example, have a much more sensitive skin than cantaloupe or watermelon
and can be more easily nicked by the wind blowing fruit from side to side.
Any such skin breaches allow various organisms to penetrate and cause
problems.
Thick rinds do not necessarily guarantee protection against
foodborne pathogens, the food safety expert added.
Another unique factor with fresh-cut fruit is the way
it is processed, the speaker said. When cutting the product, limit the
amount of damage done to the tissue. The more damage is done, the more
sugars and syrups are expressed and the greater the microbiological risks
involved.
“One of the first things that’s done with any
type produce product to wash and peel or chill and peel it,” he pointed
out. “In some cases it may be brought into the plant and washed again.
I use the term sanitizing loosely here. Let’s say the water is sanitized.
But washing is very important. It usually allows the product to be very
well enveloped and exposed to the water. As mentioned, water quality is
critical.”
If the processor uses river or raw surface water to chill
the product he can actually cause more surface contamination than if he
had taken the product off of the soil and done nothing at all, Brackett
warned. Another concern is that when cooling down a product with chilled
water there is the additional risk of internalization — of absorbing
or drawing contaminated water inside the fruit. He cited the case of mangoes
shipped in from South America several years ago contaminated with Salmonella.
The investigation into why showed that river water was being used to chill
the product.
“Cantaloupe are very good sponges for water, if you
have the temperature wrong,” Brackett said. “Other products
have less porous skins and are more resistant to this but can suck in
water through the ends.”
Risks Associated with Cutting and Slicing
Another unique factor for fresh-cut fruit is the cutting
and slicing required, the researcher said. Once cut and the juices are
released, the microbial organism count can increase a hundred fold or
more, depending on the product. Cut-and-peeled carrots have less of a
problem because the skin is removed. But products such as cabbage, lettuce,
onions and corn are much more at risk.
Why?
“In addition to releasing the sugars you also have
the fact that you are increasing the surface area of these products,”
Brackett pointed out. “There now is more room for these organisms
to grow.”
Another extremely important factor in extending shelf
life is the temperature in which a product is held, he said. The temperature
must be down low enough that organisms present cannot grow. Steps also
must be taken to ensure that the packaging materials actually protect
the product from the pathogens and do not contaminate the product itself.
There have been cases when product contamination was tracked to the packaging
itself, Brackett said. This is a critical point, particularly when marketing
a ready-to-eat product such as fresh-cut fruit.
“Remember, time is your enemy, whether for sales
or microorganisms,” Brackett said. “The quicker the time between
cutting the product and getting it into the consumer’s mouth, the
less likelihood there is of accumulating organisms.”
It should be remembered, however, that there are circumstances
when this may work against processor, he added. If using a product where
the organism generally die off rapidly, cutting the time from the field
to the mouth may actually increase the risk of delivery a product with
the potential to make consumers ill.
Produce managers and others marketing fruit products can
sometimes increase the risk of problem developing, Brackett cautioned,
referring to seeing cantaloupe placed on display in one well-known grocery
chain without ice or any kind of refrigeration. When brought to the produce
manager’s attention he committed to making a change that never came
about. No action was taken.
“Quite often retailers do not see the importance,
but if a product is abused and someone gets ill from it, (consumers) are
not going to blame the retailer or themselves,” the speaker warned.
“They are going to blame the person that sold it to them, which in
the case of a branded product may be yours.”
None Safety Net from Cooking
Another caution to keep in mind is that fresh-cut fruit
products are ready to eat and are not going to be cooked, Brackett said.
There are a greater number of at-risk consumers these days, including
children and the elderly. They like fresh-cut fruits because they are
flavorful and already prepared — no cutting or peeling is required
— and they enjoy the convenience and taking them home to eat. Again,
there is the potential for abuse if not refrigerated and cared for properly.
So how can the risk of foodborne illnesses be minimized
or eliminated?
“One way is to have a set of good manufacturing practices
that keep the product from becoming contaminated in the first place,”
Brackett said. “The second is to implement a good HACCP plan. The
disadvantage with fresh-cut fruits is you don’t have a lot of critical
control points that you know will control the organisms. You pretty much
rely on refrigeration to control any organisms, yet there are things that
you can do as part of HACCP to minimize the problems.”
Be wise with the use of technology, he advised. There
may be a marketing advantage in extending product shelf life as far as
possible, but doing so is not in the best interests of safety. The better
approach is limiting shelf life to what is really needed.
Pre-cut fruits can be a vehicle for foodborne illnesses,
and processors should be aware of the risk factors, Brackett warned. Such
illnesses can be eliminated, or at least minimized, by using proper sanitation
all of the way to the retailer.
© 2003 Columbia Publishing
>>
Return to top
'Fresh'
is the Word at JARD Marketing
Fresh Cut
March 2003
There's one word and one message you receive loud and clear when talking
to anyone from JARD Marketing. That word and that message is "Fresh."
JARD Marketing, which processes and packages fresh-cut fruit under the
Frosty Fresh label, is passionate about delivering fresh products.
"If you're not buying from Frosty Fresh, you're not
buying fresh," claims Joe Gangi, one of the co-owners of JARD Marketing.
Just in case you forget JARD's devotion to freshness, a quick look at
the company web site will refresh your memory. At www.frostyfresh.com,
you'll discover every orange icon turns into the word "fresh"
as soon it's touched by the cursor.
The company's passion for freshness is what made the
Gangi family enter the fresh-cut business in 1996. "There is simply
no substitute for fresh," insists Gangi. Many agreed, as evident
by Frosty Fresh's resulting popularity throughout the Northeastern United
States. To date, the company distributes to every major New England supermarket
chain.
"Our emphasis is on quality and service," Gangi
explains. "We are a regional distributor, and we also work with numerous
suppliers. We have a network of suppliers who provide us with quality
items on a seasonal basis. We also buy from various markets and maintain
good relations with all of our suppliers."
Gangi's brother David, also a part owner, echoes Joe's
feelings. "It's simply what we do," he says. "We don't
mechanize anything. All of our fruit is hand cut. When you start using
machines, the fruit bruises and it just doesn't result in the best product.
Thus, we do it all by hand, cutting the fruit and placing it in bowls
or trays, just like your mother and grandmother used to do - buy the melon
fresh and cut it up fresh."
Company History
The Gangi family didn't just wake up one day and decide to go into the
fresh-cut fruit business. They've had a long history of providing fresh
fruit throughout New England. In 1918, Guiseppe Gangi, an immigrant from
Sicily, began wholesaling bananas at his small grocery story in Lawrence,
Mass. "Right after World War II, our father, his brother and cousin
started into the business, repacking tomatoes and packaging celery hearts,
spinach, radishes and other items for neighborhood markets, which were
serviced by a fleet of route trucks," Gangi recalls. "They were
also members of the Pre-Packed Vegetable Association in the 1950s and
continued full food distribution throughout the 60s."
A side business in the 1960s that turned out to be quite
fruitful was a fruit bar called the Frosty Melon. Located in Hampton Beach,
N. H., this novelty fruit stand offered patrons fresh cut melons, peaches,
bananas and the Gangi family's famous Flavor Fresh fruit salad. "This
is where we got our start," remembers Gangi. "After working
at the stand we (Joe and brothers David and Robert) entered the business
- at the ground level," he emphasizes. Today at JARD Marketing, Joe
is in charge of buying, David takes care of selling while Robert oversees
production.
Over the last 30 years, the Gangis have gained valuable
experience in the fruit salad market. They mastered the art of choosing
the freshest fruit possible and perfected their method of retaining that
freshness all the way to the customer's table.
Through the '80s and '90s, the business continued to
grow. In addition to the foodservice distributors that had always been
the Gangis' biggest customer, local supermarkets began ordering from them
as well. According to Joe Gangi, 90 percent of JARD Marketing's business
today is from the retail sector. A good portion of that increased growth
can be traced directly to Ted Kozick, the company's retail sales manager.
"Since Ted join our sales team in 1996, he's maintained great customer
relations with our major accounts," says Joe Gangi.
Business is Booming
Since 1996, when JARD Marketing established its fresh-cut fruit operation,
the company has grown by about 25 percent per year. And with more than
300 employees, the company is still on a growth pattern. Needless to say,
expansion was inevitable.
A few months ago, JARD Marketing moved into a new facility,
still within the city limits of Lawrence, Mass., where everything began
85 years ago. The old facility was 18,000 square feet and located in the
inner city. However, the new operation is a 30,000 square foot facility
located in an industrial park. According to David Gangi, with everything
more centralized, the entire operation runs a lot smoother. "It's
an easy flow now that all of our operation is better configured. We also
have more refrigeration."
In the new facility, says Joe Gangi, JARD Marketing could
potentially expand its business by up to 40 percent.
JARD Marketing processes more than 500,000 pounds of fruit
every week. The recently harvested fruit is refrigerated at temperatures
appropriate for the specific type of fruit. Then, when it's ready for
cutting, the fruit is moved into a cooled workspace, washed, sanitized,
rinsed and hand-peeled. As David emphasizes, no machinery is used in the
peeling process. The peeled fruit is then washed free of seeds and finally
is hand-sliced. The prepared melons, pineapples, grapes and other fruit
are kept refrigerated until packaging, which is also conducted in a cooled
environment. "No product is made for inventory," says Gangi.
"All fruit is prepared daily to satisfy existing orders. We start
off each day with fresh product, and have zero inventory at day's end.
We don't have any carryover at all."
One unique fruit item that's becoming popular with the
retail and foodservice industries is the Frosty Fresh pomegranate. According
to Joe Gangi, the pomegranate is very appealing to customers because Frosty
Fresh offers just the succulent seeds. "We've been deseeding pomegranates
for nearly two years now, offering them in 4-ounce containers for retail
and 24-ounce containers for the foodservice industry." he says. "The
only thing the customer has to do is open the container and enjoy them."
Commitment to Company
JARD Marketing managers recognize that their employee base is the backbone
of the company. And, they ensure employee needs are met. "We pride
ourselves at taking internal employees and promoting within," says
Gangi. "We truly value our employees, for without them, we could
not produce the quality products we do."
One way of retaining good employees is to train them.
JARD Marketing sends its employees to a Servesafe training program that
is (Massachusetts) state certified. "When employees finish this training,
they are well trained in food handling and sanitation," explains
Gangi.
JARD also offers English classes to its non-English speaking
employees. "They know exactly what to do while on the job,"
says Gangi. "We just want to be able to give them the means of communicating
with fellow employees."
Safety First
"We are constantly on a mission to maintain our high safety standards,"
says Irv Lemack, JARD's technical director. Using current Good Manufacturing
Practices of the Federal Food and Drug Administration, JARD Marketing's
facility operates under the provisions of the Hazard Analysis and Critical
Control Point (HACCP) guidelines. "While employing traditional quality
control to evaluate 'what we did,'" says Lemack, "Frosty Fresh
uses HACCP to control 'what we do.' As a result, we are able to ensure
food safety and high product quality."
JARD employees are also well trained. "Workers wear
disposable garments that they change several times during the course of
each day," says Lemack.
As with any fresh cut fruit product, it is important
to maintain a certain temperature, thus ensuring extended freshness. Keeping
to those standards, Lemack says that fruit is only in the cutting room
for a minimal amount of time. "Once it's cut, we immediately put
it back into the refrigerator until packaging."
Lemack, who's been with the company 41 years, feels the
secret to their success is sanitization and refrigeration. But ask any
consumer and they will tell you JARD Marketing's key to success is its
devotion to 'fresh.'
© 2003 Columbia Publishing
IFPA
Report: 16th Annual Conference and Exhibition Promises to Be the Best
Yet
Fresh Cut
March 2003
by Craig Delaney.
Ready Pac Produce, Inc.
IFPA Vice Chair and Conference Chair
Room reservations are going fast, booth sales on the
exhibit floor at the Tampa Convention Center are running ahead of last
year and everything is set for April 3-5 to make the International Fresh-cut
Produce Association's 16th Annual Conference and Exhibition one of the
best ever.
Always the scene of intense business-and sales-activity,
the show again promises to provide processors from around the world opportunities
to find just the right equipment, technique or service to maintain production
efficiency at state-of-the-art levels. Exhibitors traditionally see the
IFPA show as their most important venue for meeting qualified buyers and
this year interest is running higher than ever in spite of an uncertain
economy.
Appropriately themed "3 Pivotal Days. 1 Prosperous
Year," the 2003 conference also provides plenty of opportunities
to cement those business relationships during the many social events arranged
by IFPA's dedicated conference committee. As always, the conference offers
receptions, workshops and exhibit hall lunches for mingling with an expected
1,300 or more attendees. The IFPA expects a significant turnout from processors
and related industry firms from Europe, Australia and South America because
of the show's location in Tampa this year.
If golfing on the Rolling Oaks Course at Tampa's World
Woods Golf Club (ranked #1 daily fee course in 2000 by Golf & Travel
magazine) isn't enough, then suppliers can invite prospects to a Tampa
Bay Lightning game at IFPA's hockey party Friday night. Food and drink
included in the ticket price make this a complete evening for socializing
and clinching deals.
Another unfailing hit, IFPA's closing StarShip Dinner
Cruise and Casino Night promises to deliver a final chance to hobnob in
a congenial atmosphere while cruising Tampa Bay and enjoying dinner and
games. The lights of the city, along with haute cuisine and live music
will set the mood for this festive conclusion to a great conference. All
activities at the conference except golf are within walking distance of
the convention center.
Mixing business with pleasure is a trademark of IFPA conferences
and this year's workshops, panel discussions and science symposium once
again offer attendees the chance to stay on top of the many issues and
challenges facing the fresh-cut industry.
Keynote speaker Ed Foreman, a New Mexico farm boy who
became a self-made millionaire at age 26 and the only person ever elected
to Congress from two different states, will set the upbeat tone for the
conference at the April 4 awards breakfast and general session.
Later that day, show attendees can glean cutting-edge
ideas from "Marketing to Customer Needs-The Latest Trends,"
a workshop moderated by IFPA board member Marvin List of Del Monte Fresh
Produce, N.A. During this workshop, Joan Centanno of the Perishables Group
will outline the findings of "Fresh Focus 2002: Food Service Opportunities
for Fresh-cut Produce," a food service survey sponsored by IFPA.
Attendees will be able to order the newly printed survey at the conference.
Friday's final workshop, "New Packaging Technologies
to Insure Quality Products," is moderated by IFPA board member Ken
Silveira of Tanimura & Antle and will include presentations by food
scientist Wendy Dunlap of Cryovac Division-Sealed Air Corp. and packaging
consultant Jeff Brandenburg of The JSB Group. Brandenburg is a contributor
to IFPA's new publication, "Fresh-cut Produce Packaging Design,"
which attendees will be able to order at the conference.
At breakfast Saturday, April 5, Dr. James Gorny, IFPA's
vice president of technology and regulatory affairs, will moderate a regulatory
affairs caucus featuring Dr. Robert Bracket of the U.S. Food & Drug
Administration, attorney Mel Drozen of Keller & Heckman, Mahipal Kunduru
of Dole Fresh Vegetables, and consultant Nancy Nagle of Nagle Resources.
Such topics as country-of-origin labeling, proposed FDA voluntary guidelines
for fresh-cut produce, and compliance with the U.S. bioterrorism act of
2002 are sure to be aired.
The breakfast session will be followed by "Creating
the Right Facility: Design, Refrigeration and Environmental Considerations,"
a workshop featuring Ron Frattare of the Austin Co., Robbie Kroeze of
Axiom Engineers, Phillip Ellis of ZEP Manufacturing Co., and IFPA board
member Alan Heinzen of Heinzen Manufacturing International. Phillip Riggio,
also an IFPA board member from Aunt Mid Produce Company, will moderate.
Finally, the conference committee has scheduled the IFPA
Science Symposium for 1:30 p.m. to 3:30 p.m. Saturday April 5. IFPA's
Dr. James Gorny and Dr. John Beaulieu of the USDA/ARS will moderate. Topics
and speakers include: "Chlorine Dioxide and Ozone Gaseous Application,"
by Richard Linton of Purdue University; "Fresh-cut Apple Quality
and Safety," by Peter Toivonen, Ag Canada; Pre-treatment of Whole
Fruit to Extend Shelf Life and Quality," by Jeff Brecht, University
of Florida and Liz Baldwin, USDA/ARS; and "Enhancing Microbial Safety
of Fresh and Fresh-cut Melons," by Trevor Suslow, UC Davis.
A poster session for scientific research projects during
exhibit hours will enable other researchers to present visual displays
explaining their projects. For the first time this year, an award will
be given to the researcher whose poster best communicates his or her research
project.
Packed with so much information and so many opportunities
for networking, this year's conference truly will be "3 Pivotal Days."
Anyone interested in any aspect of fresh-cut produce is invited to attend.
For further information about travel, accommodations and
details about the conference, you can download a brochure and registration
form at http://www.fresh-cuts.org/files/FINALCONFBRO.pdf or call IFPA
at (703) 299-6282.
© 2003 Columbia Publishing
Baby
Gourmet Introduces Children to World of Fruits, Vegetables
Fresh Cut
March 2003
If you're tired of trying to get your kids to eat fresh
fruits and vegetables, then maybe you haven't used the right learning
tool yet.
Late last year, Albertsons grocery stores began carrying
the Baby Gourmet video series aimed at infant to four-year-old viewers.
The series uses humor, creativity, music and skits to highlight the shape,
color, texture, and beauty of fruits and vegetables, and is the first
video of its kind to be sold within the produce aisles of a major grocery
chain.
The mission of Baby Gourmet, according to company spokeswoman
Jill Newhouse-Calcaterra, is to give parents the tools and foundation
they need to instill a lifelong love of healthy eating. The tagline for
Baby Gourmet is: A lifetime of healthy eating starts here with Baby Gourmet.
Available at more than 1,100 Albertsons stores nationwide,
Baby Gourmet videos are strategically placed in the fresh-cut aisles -
right next to the fresh-cut lettuce bags - about eye level for a child
riding by in a grocery cart.
Seeing a Need
The unique video series was the creation of Katheryn and Robert Warren.
In 1999, with the birth of their first child, the Warrens discovered,
after an exhaustive search, there was nothing appetizing or engaging on
the baby/toddler video market available to help introduce and educate
their child to the world of food. "There are hundreds of books geared
toward parents," said Katheryn Warren, "but nothing at all for
children."
Katheryn explained that at four months old, her son Chase
squealed, giggled and cooed with delight every time Robert raised the
Bon Appetite magazine he was reading. "The cherry tart on the cover
absolutely mesmerized him," she said. Thus, through testing and research,
Katheryn and Robert learned that their child, and others of a similar
age, loved looking at beautiful pictures of food.
The resulting Baby Gourmet videos offer a multi-sensory
experience for children designed to introduce little ones to beautiful
fruits and vegetables, the artistry of foods and holidays in a gentle
and amusing way that stimulates both the left and right brain. Highlights
include the Mozart Effect, vocabulary and language, word/picture association,
sequencing and logic, colors, textures and shapes, as well as creativity.
Albertsons' Commitment
"We are thrilled that Albertsons immediately realized that encouraging
healthy eating of fruits and vegetables among their youngest consumers
is vital," said Katheryn Warren. "Not only is the concept of
hooking kids early to positive eating habits a noble one, but based on
our test in several stores, there is a huge desire for this entertaining
and educational product."
To date, more than 100,000 Baby Gourmet videos have been
sold in Albertsons' stores. "Albertsons is committed to programs
which promote not only health and nutrition but also the education and
development of our youth," said Mike Massimino, Albertsons vice president,
general merchandise sales, food stores. "Baby Gourmet is a perfect
fit for this initiative. We are delighted to bring this positive and necessary
video to our consumer families via our grocery stores."
Regarding placement within Albertsons, empirical research
was conducted in four separate Albertsons stores in the Phoenix area.
"We place videos in the baby aisle, the cereal aisle and the produce
aisle," said Katheryn. "The produce aisle outsold the others
by a three to one margin."
Three Videos
The Baby Gourmet video series comes in three flavors.
" "The First Course" introduces infants
and young toddlers to fruits and vegetables in their natural state - in
trees, vines, bushes, and even in the ground! Babies love watching other
babies (and animals, too) explore and taste nature's food. All senses
are stimulated when watching fruits and vegetables gracefully dance to
enchanting classical masterpieces and nursery rhymes. A delightful cherry
harvest segment will educate and entrance parents and children, alike.
Video length is 44 minutes.
" "Spring/Summer Harvest" shows Chef Beary-Good,
a charming little bear puppet, introducing children to the colorful fruits
and vegetables of spring and summer. Classical music from Mozart and many
other composers create the backdrop for an adventure in educational fun.
Mixed with holiday vignettes of Valentine's Day, St. Patrick's Day, Passover,
Easter, Mother's Day, Father's Day and the Fourth of July, it's entertaining
for babies and adults. Video length is 44 minutes.
" "Fall/Winter Harvest" again uses the
charm Chef Beary-Good, who introduces children to the fruits and vegetables
of fall and winter. Classical music accompanies vignettes of back-to-school,
Halloween, Thanksgiving, Hanukah, Christmas and New Year. It's entertaining
for babies and adults alike. Video length is 41 minutes.
What's Cooking
During the coming months, new videos are planned for production. According
to Katheryn Warren, a new video is scheduled to be released this May.
"It's going to be a food safari focus," she said, "kind
of like a history trail of fruits and vegetables."
Location plays an important role in filming the videos.
"We are always looking for great places to film segments of our videos,"
said Newhouse-Calcaterra. "Great field backdrops, processing plants
or other agricultural scenes are the types of locations we're on the lookout
for. If anyone feels they might have a great setting, I'd like to hear
from you."
In the mean time, you can pick up a video at most Albertsons
grocery stores ($9.99). On the web, visit Amazon.com or www.mybabygourmet.com.
Jill Newhouse-Calcaterra can be reached at (310) 471-0197
or via e-mail at jcalcaterra@att.net.
© 2003 Columbia Publishing
Using
the Right Lubricant May Protect Your Company
Fresh Cut
March 2003
Gaining Peace of Mind
While Increasing Safety and
Efficiency In Your Food Plant
by Darren J. Lesinski,
Technical Services Mgr.
Anderol, Inc.
and
by Michael J. Raab,
Industry Liaison
Anderol, Inc.
There are many things to think about when running a food
manufacturing business, and concern over lubricants should not be one
of them. That is why it is essential for companies to use lubricants that
not only exceed governmental standards, but also protect plant output
without degrading brand equity. In addition, the lubricant should ideally
extend benefits to the bottom line, by reducing overheard costs and strengthening
profitability.
Food manufacturers that proactively select a NSF H-1 "incidental
contact" food grade lubricant as part of their business process are
able to meet the dual goals of worldwide compliance and protection of
brand integrity. Taking this precautionary step has become the norm for
companies focused on achieving Hazard Analysis and Critical Control Point
(HACCP) procedures food safety standards and mitigating potential liability.
High quality NSF H-1 type lubricants can also be considered insurance
against plant shut downs. Once in place, the right quality lubricant can
bring added benefits including, maximized return on investment, increased
uptime and cost savings.
Meeting mandatory guidelines and U.S. Department of Agriculture
regulations has become the responsibility of quality assurance and quality
control personnel throughout the fruit, vegetable and other food processing
industries. HACCP guidelines require assessment at each contact point
of the lubricant and critical equipment used for cleansing, sterilizing,
chilling, cutting, slicing and peeling - as a means to prevent contamination
and protect brand quality. It is at these instances, where employing a
non-toxic, odorless and colorless food grade lubricant to pumps, mixers,
tanks, hoses, chain drives and conveyor belts, supports safety of brand
quality, without affecting productivity.
What to Look For
Once the vital issue of safety is addressed, fundamental
maintenance management must be applied to protect equipment life and productivity
levels through use of the proper lubricant. Deciding whether to use a
mineral or synthetic-based lubricant is the next step. Today's trend is
toward the more futuristic synthetics, which have been playing a key role
in maximizing equipment life, decreasing maintenance expenditures and
even lessening the need for frequent lubrication of bearings and gear
components.
Through extensive research and testing, modern synthetic
hydrocarbon and mineral-oil based products with optimized additive package(s)
have been designed to surpass Federal Drug Administration regulation 21
CFR 178.3570 and NSF International standards; they are comparable in performance
to non-food grade, premium lubricants. Alternatively, some mineral-based
products have been known to cause residue buildup requiring frequent change
outs, costing companies thousands of dollars in annual repair and replacement.
A plant's operating conditions may also be the determinant
of whether to choose a high-performance synthetic food grade over a mineral-based
product. For example, synthetic food grade greases must withstand moisture-heavy
or steam environments enabling machinery to perform at optimum levels.
Manufacturers processing under extreme temperatures, such as steam or
refrigeration, find that food grade synthetics are ideal for maintaining
productivity as a result of a higher viscosity and flow rate.
Value-added benefits of synthetics have been demonstrated
by results of regular machinery maintenance tests for deterioration and
cleanliness. Food companies using synthetic products have found little
to no carbonization, clogging, worn components or scaling. On the flip
side, gear boxes, hydraulic systems, valves, pumps and other components
lubricated with a mineral-based product have showed signs of wear without
adequate anti-wear additives or load-carrying characteristics.
Selection is Important
Selecting an H-1 lubricant provider is just as important
as selecting the lubricant. It is essential to choose a lubricant provider
with an understanding of the customer's business while offering a full
range of products for one-stop shopping. In the best of worlds, the provider
will become an extension of a facility's own maintenance department, providing
education and technical support. Additionally, it will have the expertise
to support other value-added services such as plant surveys, validation
of equipment, grade determination, product consolidation, and oil analysis.
Other features to consider include on time delivery of products and services,
accurate response to inquiries and the ability to create tailored solutions.
Employing the right food grade lubricant ensures that
food processing companies can deliver safe consumable products while preserving
brand equity. While either a mineral-based or synthetic lubricant may
be implemented, a plant's own applications must be considered before a
proper decision can be made, including gear type, speed, drives and productivity
levels. Facilities requiring high-performance lubricants are finding synthetic
products play a big role in preventing contamination and promoting brand
integrity. Key to this is partnering with a lubricant provider that has
a full range of products supported through a wide range of services such
as, troubleshooting and oil analysis programs. Taken together, all these
considerations will help solidify a food manufacturer's product safety
and enhance market success.
Anderol, Inc. is a provider of specialty lubricants and
grease products to the food industry. For more information, go to www.anderol.com
or e-mail info@anderol.com.
© 2003 Columbia Publishing
>>
Return to top
When
Opportunity Knocks, Country Fresh Answers
Fresh Cut
April 2003
Exponential growth was the last thing on the minds of
the Country Fresh partners when they formed the company three-and-a-half
years ago. From its humble beginnings with one small fresh-cut processing
facility and 20 employees, Country Fresh now boasts a workforce in excess
of 500, including two co-packer facilities and four company-owned facilities
that deliver fresh-cut fruit to a 18-state area.
Country Fresh partners Sam Petro and Bryan Herr process
primarily cut fruit for retail packaging, but also provide vegetables
for retail party trays. “Currently, the majority of our business
is in the retail sector, about 95 percent,” says Petro. “Foodservice
is something we’ll be looking at down the road.”
Petro, a 40-year veteran of the produce industry, and
Herr, who has worked in the industry for 20 years, combined their efforts
in forming the current company. “Basically, we molded our two expertise
levels, which is what really what makes us tick,” explains Herr.
“He does his thing, I do my thing, and we stay out of each other’s
way. We talk about what we’re doing and what’s best for the
company, and it works out very well. It’s kind of an unusual situation,
actually, but it works very well.”
“If it’s not sales and marketing, he’s
doing it!” Petro emphasizes.
In The Beginning
Herr launched Country Fresh Products, Inc. in 1987 to
grow and market sprouts. This venture evolved into importing and marketing
specialty produce and later organic produce. The Kroger Co., which for
several years had been a major client of Country Fresh, decided to cease
cutting fruit in-store altogether. Kroger officials subsequently requested
Herr take over this operation. “They were my largest account in Houston,”
recalls Herr. “So I considered the option.”
Herr and Reggie Griffin, of Kroger, visited a similar
plant in San Antonio. While walking through the operation, Griffin said
to Herr, “If you can do it this way for Kroger, then we’ll give
it a shot.”
Replied Herr, “So basically, I built a brand new
facility to cut fruit exclusively for Kroger. That’s how I started
in the fresh-cut business.”
Meanwhile, Petro, who had considerable background in fresh-cut,
had been operating a separate produce wholesale business. In addition
to that, an opportunity arose in Florida. Officials at 7-Eleven stores
contacted Petro with an idea of offering fresh-cut fruit in its more than
600 convenience stores in Florida.
“When this opportunity came up, I called Bryan and
presented the proposition to him,” recalls Petro. I knew Bryan was
excellent at production and operations. So, I went to him and presented
the idea. We agreed, shook hands and formed a company. And as they say,
the rest is history.”
Early History
Country Fresh started out by opening a small processing
facility in Orlando in 1999. “After looking for a building in the
6,000 to 8,000 square-foot range, we ended up leasing a building with
18,000 square-feet,” says Petro. “That was all we could find
to suit our needs. We planned on subleasing some of the space. But, little
did we know that as soon as we started cutting for the convenience stores,
other markets cropped up. Before we knew it, we’d outgrown that facility.”
Petro says that they will be opening a new 50,000 square-foot
state-of-the-art facility in Orlando in mid-April.
In addition to its headquarters in Houston, Country Fresh
operates processing facilities in Dallas, Mauldin, S.C. and Orlando, with
co-packers in Grand Rapids, Mich. and Rosenhayn, N.J.
“We are growing at a 20 to 25 percent rate annually,”
says Petro. “It’s actually a little above that. Right now, we’re
processing anywhere from 7 ½ to 8 million pounds of fruit per month.
There’s just no end for continued growth.”
Initially, Country Fresh started with the basics for value-added
fruit. “We did two sizes of cantaloupe, two sizes of honeydew melons,
two sizes of watermelons and two sizes of pineapples,” says Herr.
“It was your basic cut fruit.” But what has evolved is different
blends and mixes. “We feel this offers the customer more value. The
way we look at it, if you’re selling a bowl of cantaloupe, you’re
in competition with the whole cantaloupe. But, if you’re selling
a bowl that has cantaloupe, honeydew and watermelon in it, it’s more
value to the customer.”
Future Trends
“The trends we see in product mix, as Bryan touched
on earlier, are the way to go,” says Petro. “That is where you
offer a real value to the customer. When you put all kinds of fresh-cut
fruit in a bowl, that is the added value to the customer, and they don’t
have to go out and buy each item separately.”
Petro feels that apples will definitely play a big part
in the future of the fresh-cut industry. “They (apples) are going
to allow us, as processors, to do more with different types of fruit salads.
It’s going to open up a lot of doors. There are going to be more
and more items that we’re going to be able to deal with. Because
of limitations, there are certain items we can’t process right now.
But, technology will allow us to expand the variety of items we can offer.
For example, there’s a company right now working on being able to
slice bananas and keep them in an edible state for 8 to 10 days –
that’s sliced and fresh. There’s no limit to where the fresh-cut
industry is going. We’re really in the Ice Age in terms of where
this field is going to be.”
So what type of feedback do Petro and Herr solicit from
their customers? “We ask them every question in the book,” says
Petro emphatically. “We ask them about everything from the quality
of the product to our customer service, and we ask them regularly. We
want to know if we are exceeding the quality standards they expect. And,
if we’re not exceeding them, then we’re doing something wrong.”
Herr agrees, adding, “The quality of our service
is important. The quality of the way our general managers or truck drivers
deal with the people in the warehouses and the buyers in various distribution
centers is very important to us. All these things are watched and are
watched closely by Sam and me. We really feel like when your business
is dependent on you, that you pay closer attention to the everyday details.
We’re not hired to do a job, we are the job.”
Petro and Herr strongly emphasize their commitment to
the customer. “Our strong points are our attention to detail, and
the attention we pay to the customers’ reaction to what we do,”
explains Petro. “We’re only as good as our last order. That’s
why we pay attention to what the customer says.”
Technology
After years of research, SunBlush Technologies in Vancouver,
B.C., introduced a technology call MAPTEK. According to Herr, this technology
extends the shelf-life of fresh-cut fruits, and is based around three
patents they hold pertaining to this process.
“They were in the market place looking for someone
to license that technology to,” says Herr. “They had specifically
developed it for their pineapple plant in Costa Rica, but it also carried
over into other types of fresh-cut fruit. We have since licensed their
technology exclusively. This allows us to produce a product that we can
give extended shelf-life to, while still adhering to the parameters we
need to maintain as far as taste, appearance, and bacteria counts. So,
instead of having 6 days of shelf-life, we’ll be able to extend that
to 10 or 12 days and in some cases 14 days by using MAPTEK technology.
And, we will still have the same quality product that we currently have.”
Herr sees this as great potential for the foodservice
industry. “This will allow us to enter into the foodservice arena
really well because the foodservice distribution chain is a little bit
slower than retail. With retail, we pack it, chill it, put it on a truck,
and it’s there the next morning. With foodservice, it might go through
two distributors before it actually gets to the hotel or cafeteria it’s
going to. So, this opens up a whole other realm for us.”
Another move that promises to strengthen the company’s
profits is the recent integration of an in-house equipment development
operation. “We hired a man who used to build racecar engines for
NASCAR,” says Herr. “That tells you how talented this man is.
We are going to funnel all his energy and talents into designing and developing
machinery just for us. He’s already developed a pineapple-coring
machine that does a superb job.”
Petro adds, “We built our business by doing things
by hand. That’s why our workforce is so huge. Although we have never
felt that we could do as good a job by using equipment, we’re hoping
that by focusing on our in-house people to develop and design equipment,
we’ll be able to match the quality of by-hand processing, while speeding
up the process. However, we will not sacrifice quality for any reason.
That’s why we’ve gotten where we’re at today. We are absolutely
adamant about the quality of product we put out, and we’re both passionate
about what we do.”
Safety First
“We’re as much in the food safety business as
we are the cut fruit business,” says Petro. “We use third party
labs on a daily basis to monitor our products. We have one of the best
Hazard Analysis Critical Control Point (HACCP) programs you could possibly
have, and we think it’s one of the best in the country.” Country
Fresh has highly trained, well educated employees running its HACCP programs.
“That’s what it’s all about,” adds Petro. “The
reason stores don’t want to do in-house cutting anymore is because
of the risk factor. It’s our job to take the risk out of the equation.”
As Country Fresh continues its focus on safety and quality,
plans are to expand into the Canadian market by June. “We’re
going to focus on establishing more relationships with co-packers,”
explains Herr. “All our geographic growth in the future is going
to come from co-packer arrangements, like the ones we have with Sam Pipitone
in New Jersey and Pearson Foods in Grand Rapids, Mich.”
Pipitone, president of F&S Produce Co., Inc. in Rosenhayn,
N.J., has seen his business grow by leaps and bounds since his affiliation
with Country Fresh. “After meeting with Bryan and Sam, and observing
their approach and concept toward fresh-cut fruit, I knew there was definitely
a future in working with them,” says Pipitone. “In a relatively
short time, they’ve taken me to a level that would have taken several
years to achieve without their assistance. I have great expectations for
the future.”
And the future looks bright for the entire Country Fresh
operation. “If you have a co-packer like Sam Pipitone, you know he’s
there, and that he’s interested in the operation,” says Petro.
“He cares as much about quality as we do. It’s a win-win situation,
not only for our working relationship, but for the eventual customer who
purchases our products.”
For Country Fresh, what could be sweeter?
© 2003 Columbia Publishing
IFPA
Report: Don’t Miss the Thrills Fresh-cut Offers
Fresh Cut
April 2003
Our 16th Annual International Fresh-cut Produce Association Conference
& Exhibition is traditionally a time for changing the guard and for
taking a look at the accomplishments of the past year. As we meet in Tampa
April 3-5 for our annual conference, we can look back and say the fresh-cut
produce industry is more than alive and well. It is still exciting!
Interest in our conference is running high. Exhibitors
have an intense interest in showing their wares to the industry and attendees
are registering to visit the show at an excellent pace.
The keynote speaker for our conference, self-made millionaire
Ed Foreman, was recently featured in Forbes magazine as “The Guru
in the Vegetable Bin,” who has been hired as a consultant by Albertsons
CEO Lawrence R. Johnston to “energize” 10,000 store managers
to compete with Wal-Mart.
Having grown up in the produce industry, Foreman made
a name in politics, then developed the “Successful Daily Living”
formula he has used over 25 years in working with Johnston at General
Electric—and now Albertsons. Since Johnston told Forbes, “Positive
attitude is the single biggest thing that can change a business,”
Foreman’s message at IFPA’s April 4 opening breakfast should
be powerful indeed.
During my year as chairman of the board, many people have
given unselfishly of their time and have helped our association make great
strides toward our goals.
Growing Industry
Fresh-cut produce is still growing and changing and perhaps
the most pivotal thing we did during the past year was to hold a strategic
planning session with communicator David Henderson to look at where we
are headed as an industry—and as an association. He helped our board
of directors take a hard look at who we are as an association and what
we provide in service and support to our members.
We defined fresh-cut produce as “wholesome, convenient
and ready-to-use fresh fruits and vegetables” and pinpointed our
role as a representative for “leaders in the fresh-cut produce industry
worldwide who specialize in today’s fastest-growing fresh food category.”
We also recognized that we provide “members with competitive advantages
through networking, advocacy, guidelines, forums and expertise focused
exclusively on the fresh-cut produce industry.”
With such a clear mission statement, we now feel better
prepared to focus on our “core business” of serving the changing
needs of members in this new millennium.
While serving as chairman, I have seen IFPA’s board
of directors and staff making progress on a variety of fronts to help
improve our service to members.
Information is indispensable to fresh-cut processors and
IFPA’s mission includes a significant effort to provide members with
cutting-edge information. During the past year alone, we initiated “Fresh-cut
Technology: Basic Training,” a course for processing personnel, and
dedicated our Annual Fall Seminar to fresh-cut fruit. Our second Basic
Training course, just held in February, attracted a sell-out crowd and
the standing-room-only fall seminar was so popular we’re planning
to repeat the topic next fall.
In our continuing effort to provide better marketing information
to the industry, we completed “Fresh Focus 2002: Food Service Opportunities
for Fresh-cut Produce,” interviewing restaurateurs about how they
buy and use fresh-cut produce in their kitchens. Now available for purchase,
this survey provides solid, usable information to help processors build
business.
In the technical formation category, we have added two
more publications to IFPA’s library designed to support the fresh-cut
industry. “Fresh-cut Produce Packaging Design” is a manual that
provides processors with tools to help them communicate with packaging
suppliers to get just the right package for each fresh-cut application.
The other book, a Spanish-language version of IFPA’s landmark “Food
Safety Guidelines for the Fresh-cut Produce Industry,” will be a
welcome aid for processors who have bi-lingual workforces.
As part of our commitment to provide information to members,
we expanded and upgraded our web site, www.fresh-cuts.org, with a searchable
study center filled with useful publications as well as a searchable member
database to facilitate networking. These features and others are helping
us achieve our goal of building a “virtual office” or library
for members to use in fine-tuning their operations.
One priority the board identified during strategic planning
was that of expanding IFPA’s leadership role and level of awareness
in the industry.
Our Sole Focus
IFPA is the only association solely focused on the unique
needs of fresh-cut processors and the industry they have created. The
organization should be synonymous with fresh, wholesome, convenient fruits
and vegetables that provide nutrition to the world.
To accentuate the role our industry plays in the food
chain, we recently hired directors for both our marketing and communications
departments to help acquaint not only the industry but also the world
with the unique story of our important segment of the food industry. In
partial fulfillment of this mandate, we have stepped up the frequency
of our Hot Sheet members-only newsletter to a weekly schedule.
As I mentioned above, the industry is still exciting,
still evolving and we need to move a little faster to stay with it. One
of the ways we do this is by holding our Annual Conference & Exhibition,
an event that promises to be better than ever this year.
Don’t miss out on the conference and don’t pass
up your opportunity to serve the industry by taking an active role in
IFPA. Together, we can stay a step ahead of the needs of our industry
and make sure it is every bit as exciting 10 years from now as it is today.
See you in Tampa.
© 2003 Columbia Publishing
Issues
and Innovations in Temperature Control
Fresh Cut
April 2003
Temperature is the most important and most obvious criterion
for maximizing the shelf life of fresh-cut produce products, and all refrigerated
foods for that matter, yet it is frequently misunderstood and overlooked.
The temperatures encountered at each link of the chain have a direct bearing
on the shelf life, quality, and potential safety of fresh-cut products.
The Cold Chain
The cold chain for fresh-cut produce truly begins in the
field, and does not conclude until the product has been consumed. The
importance and dramatic benefits of utilizing rapid cooling techniques
immediately after harvest to retard microbial growth and enzymatic activity
have been well documented. These include hydrocooling, in which product
is sprayed with chlorinated water at a temperature of around 33°F,
and vacuum cooling, in which air is evacuated from an enclosed area to
remove moisture and heat.
Other techniques include forced-air cooling, in which
refrigerated air is moved rapidly over fruits and vegetables, and package
icing, where an ice slurry is placed into vegetable containers. Following
this first link in the chain, product temperature must be maintained in
raw product storage, in the trim/core and washing operation, during packaging,
in finished product storage, and during the many points that occur during
distribution.
Temperature Abuse
Distribution, including practices that occur at retail,
has frequently been regarded as the Achilles’ heel in cold chain
management, and has been attributed by many to be a major impediment limiting
the potential growth of the fresh-cut category. Despite the standards
and information provided by federal, state, and county agencies, minimal
education initiatives are in place and various surveys have shown that
temperatures of foods in U.S. chilled food distribution channels are frequently
in the range of 45°F–55°F.
Temperature abuse can, and does, occur too frequently
during distribution and during the retail sale of fresh-cut produce products.
Truckloads of perishable items are occasionally shipped above 50°F
because of ignorance, negligence, or mechanical breakdowns en route. Abuse
can also occur at the loading docks of the processor, during transportation
to a regional distribution center, at the loading dock of a regional distribution
center, in the cooler of the regional distribution center or warehouse,
during transportation in refrigerated trucks to the retailer or foodservice
operator, at the loading dock of the individual retail store or foodservice
operator, etc. It is also becoming increasingly difficult to schedule
supermarket delivery times, and as a result trucks may shut off their
refrigeration units during the period prior to offloading. In addition,
pallets of perishable goods occasionally may sit on the receiving floor
of a supermarket for up to several hours during a mid-summer day until
they have been properly placed into refrigerated storage.
Store Level Temperature
Although a great deal of temperature abuse can occur at
many points during distribution prior to the placement of product in the
store’s retail case, a significant amount of abuse occurs after product
has been displayed for sale. Many fresh-cut products spend a great deal
of their shelf life sitting in a display case at retail. The design and
functionality of the retail case itself has a major impact on product
shelf life. Most supermarkets and grocery stores have trouble keeping
their produce cabinets below 45°F, and studies have shown that the
refrigerated cabinets in the produce section of the store maintain some
of the warmest temperatures in the entire supermarket - even though products
sold there are among the most susceptible to spoilage.
By design, most retail cabinets, especially open cabinets,
were developed for the merchandising of fast turnover products, not the
effective long-term storage of products. Built into most systems are defrost
cycles, lights, ballast, etc. that impair their effectiveness, and air
curtains that are easily disturbed during normal operation. Proper circulation
of cooling air is essential if temperature control is to be maintained.
Unfortunately, overstocking, promotional materials, etc. often impair
this circulation. In addition to light-induced temperature changes that
can occur, placement of products near lights and ballast can increase
product temperature by as much as 10°F. Products located at the bottom
of horizontal display cases or the back of vertical display cases are
generally the coldest products in the case. This is due to the circulation
of colder air, greater distance from store ambient temperatures, and the
near absence of radiant heat from lights.
Standard equipment in most refrigerated display cabinets
is the display case thermometer, a potential source of both information
and deception. These thermometers, usually required by local or state
laws, have sensing elements that are frequently situated directly in front
of incoming blower air and are therefore, even if calibrated, more indicative
of the blower temperature than the actual product temperature. Studies
have shown that the average actual temperature of refrigerated product
can be as much as 10 degrees warmer than the temperature indicated on
a thermometer next to the blower. Similarly, defrost cycles in a refrigerated
case have been shown to result in a short-term spike in which product
internal temperature briefly reaches 60°F, and this may happen twice
a day every day.
Temperature abuse certainly also occurs during the trip
from the supermarket to the home, due to outside temperatures and/or lengthened
times until products are properly stored. In addition, the home refrigerator
is frequently a location for temperature abuse. An Audits International
Home Food Safety Study found that lack of education and lack of motivation
were typical reasons why refrigerator temperatures are set too high in
many homes. Many consumers simply do not know at what temperature a refrigerator
should hold product. In addition, many refrigerators are set too warm
simply because many refrigerators lack a thermometer.
Superchilling Solutions
“Superchilling,” also called “sub-zero
degree chill,” “deep chilling,” and “supercooling,”
is generally agreed to be the temperature just above the freezing point
of the product or raw material…for fresh-cut produce, this would
equate to a holding temperature in the range of 33-35°F for most products.
It has been determined that at these deep chill temperatures most microbiological
activities are kept at a minimum. It has also been determined that shelf
life is 1.5 to 4 times greater for products stored at these temperatures
versus those stored at conventional refrigeration temperatures of 40–45°F.
Superchill temperatures make chemical and biochemical processes go slower
and provide opportunities for improved product quality in almost all cases.
The inhibition of growth of a majority of pathogenic and
food spoilage microorganisms is an extremely important advantage with
superchilling. The effect of low temperatures on different microorganisms
is well documented in the literature. The growth of bacteria and their
ability to produce toxins are strongly temperature dependent. At temperatures
just above the freezing point of a food, most pathogenic bacteria have
lost their ability to form toxins and their growth rates are significantly
reduced. In addition, some bacteria are very sensitive to a sudden drop
from their normal growth temperature to a temperature near the freezing
point. This “cold shock” is most commonly associated with gram-negative
bacteria, such as Escherichia coli, in which bacterial counts drop dramatically.
However, it should be noted that pathogens such as Listeria monocytogenes,
Yersinia enterocolitica, and Aeromonas hydrophila have shown growth in
foods at these superchill temperatures, although their potential has been
lessened.
Temperatures must, of course, be precisely monitored.
Fruits and some vegetables are very sensitive to ice crystal formation
because the cell walls are easily damaged. As fruits and vegetables are
physiologically active after harvesting, each plant has its own optimum
temperature at which it should be stored. Most fruits and vegetables have
water content between 80 and 95 percent. If the temperatures of fruits
and vegetables are reduced towards the freezing point, respiration and
transpiration rates are also reduced. Although low temperatures in most
cases have a favorable effect by reducing reaction rates, care must be
taken against ice crystal formation.
What Can We Do Now?
As a measurement to reduce the risk of foodborne disease
outbreaks, improve product quality, and increase shelf life, fresh-cut
processors can immediately begin using superchill temperatures as a replacement
for standard chill temperatures within their internal operations. This
includes storage of raw materials, work-in-process products, finished
products, and shipments to distribution depots. Food manufacturers can
also actively promote superchill distribution of fresh food via cooperation
and joint ventures with equipment manufacturers, wholesalers, transportation
companies, and major consumer outlets.
Temperature recording devices are valuable tools, and
should be incorporated in each stage of the cold chain as part of an overall
HACCP plan. Many such indicators exist. New systems are now available
for distribution that utilize wireless sensors and sophisticated web-based
tracking capabilities, and provide a quicker ability for monitoring and
alerting should a problem occur.
Other options now available include “Intelligent
packaging” systems, which consist of sensors that provide information
about the product to the consumer, foodservice operator, or other user.
The most widely known intelligent packaging system is the time temperature
indicator (TTIs). These indicators track the relationship between time
and temperature and their impact on spoilage or some other end-point to
product acceptability. They must be individually developed for specific
products. The degree of color change will reflect any temperature abuse
encountered, integrating time and temperature in an exponential, irreversible
relationship.
Time-temperature indicators have been available for well
over a decade, but have been only sporadically utilized in industry. Unfortunately,
a major reason that their use in industry has been minimal to date is
because these indicators do in fact provide “real” information
on abuse that occurs during the cold chain. Food manufacturers and retailers,
for example, feel that recognition of these facts will result in increased
“finger pointing” between these buyer and seller parties. If
TTIs were to be utilized, for example, a dramatically increased rate of
spoils and credits for product may result due to realistic information
concerning product spoilage. Cost has also been a concern to industry,
especially when the indicator is used for consumer shelf life communication
purposes rather than for manufacturer quality assurance purposes. In a
consumer application, for example indicators are typically added to every
primary package; in a less costly application, indicators are statistically
applied to cases or pallets of product instead. It should also be pointed
out that TTIs do not reflect the microbiological quality or safety of
a product. If a few organisms of E. coli O157:H7 are present on a cut
fruit or vegetable, for example, then regardless of what happens to the
population of spoilage organisms and the pathogen's ability to compete
with them, the product is compromised from the start. Nevertheless, manufacturers
and retailers can use TTIs, and the information they provide, to instill
refrigeration discipline during product distribution.
New Standards Needed
The current industry “standard” for refrigerated
holding conditions is 40°F. Health departments, federal and state
agencies, and safety education programs are in place to educate the public
that a refrigerator set at 40°F or below will protect most foods.
Although federal and state agencies use the temperature of 40°F as
the “standard” for refrigeration, both the safety and quality
of refrigerated foods would benefit greatly if recommended temperatures
were less than 40°F. Certain pathogenic microorganisms, which can
grow at temperatures below 40°F, would be less likely to cause foodborne
disease if products were in fact kept at colder temperatures. Product
quality has been shown to be demonstrably enhanced and extended at temperatures
that approach the actual freezing point of foods.
The optimum temperature for holding refrigerated foods
should be in the superchill range. It is recommended that the setpoint
and standard for refrigerated foods holding temperatures be established
as 33°F (1°C). It is also recommended that a national awareness
program be developed to encourage manufacturers, distributors, retailers,
foodservice operators, consumers, and all those involved in the cold chain
to keep refrigerated foods at a setpoint of 33°F and not 40°F.
Perhaps a refrigerated icon (such as a thermometer or refrigerator symbol)
should be developed and a nationwide awareness program implemented to
communicate that product must be kept cold at this new setpoint. It is
believed that food safety nationwide would be dramatically improved if
a national awareness program was created to inform consumers, and others
involved in the cold chain, about this new standard.
Editor’s Note: Lou Cooperhouse is Director
of the Food Innovation Research & Extension Center of Cook College
and the New Jersey Agricultural Experiment Station at Rutgers University.
He has also recently published a comprehensive study entitled Retail Prepared
Refrigerated Foods: The Market and Technologies. For further information,
please contact Lou Cooperhouse at 732-537-1901 or at cooperhouse @aesop.rutgers.edu.
© 2003 Columbia Publishing
>>
Return to top
Mercer
Ranches – Giving Customers Exactly What They Want
Fresh Cut
May 2003
For more than 20 years, Mercer Ranches, Inc. has provided
quality carrots to customers. But with consolidation dominating the 1990s
and the industry emphasis on developing relationships, the Washington-based
company expanded its operation over the last few years to accommodate
its customers’ wishes.
“Four years ago, we could only grow and ship carrots
for about six months out of the year,” explains Keith Price, Mercer’s
head of sales and marketing. “At that time, our operation included
only the southeastern Washington plant. Today, however, we have a comparable
operation set up in Holtville, Calif., just east of San Diego.”
Adding the Holtville operation has allowed Mercer Ranches
to provide that same quality of carrots on a year round basis. “We
wanted to be more than a seasonal-regional grower-packer-shipper,”
explains Price. “That’s when the Mercer family made a decision
and committed to increasing the operation to what it is today.”
And what an operation it is. Mercer Ranches farms roughly
12,000 acres between the two locations. “We’ve had excessive
growth during the last four years,” says Price modestly.
Based in Prosser, Wash., Mercer Ranches process carrots
in Washington from June through December and switch operations to its
Holtville, Calif. processing facility from mid-December through May.
With steady customers like Costco, Wal-Mart, Safeway,
Albertsons and Kroger, it’s easy to see why expansion was a natural
progression for the 44-year-old company.
Consolidation Dictates Business
“As I said earlier, consolidation has dictated the
way we do business,” Price emphasizes. “A great deal of our
relationships involve contracts. A lot of it is developing that relationship
with the buyers so when the contract is up you’re part of the bid
process. You have to earn the right to stay with them.”
Price, who’s been working in the carrot industry
for more than 15 years, has received some sagely advice over the years.
When he first started working with a company as an engineer, Price’s
mentor imparted the following:
“You can tell me about the wonderful things you’re
going to do to improve this facility, but let me tell you how it really
works: When the carrots come in good, the plant runs good. And when the
carrots come in bad, the plant runs bad. It’s just that simple.”
With an emphasis on producing quality carrots, Mercer
Ranches, Inc. focuses heavily on its employees. The company vision statement
is the road map for Mercer’s future. “Our Vision 2006 is simple,”
says Price. “Mercer Ranches is the most trusted provider of produce
solutions and fresh agriculture products in North America. We create the
highest quality products and offer the best services through our family
of employees who take great pride in growing better every day. Basically,
we all need to be on the same page when it comes to customer service.”
Another area where customers are more demanding is in
the food safety arena. “When we train our employees, we also change
their thinking habits regarding food safety,” says Price. “I
liken this to the concept of wearing a seatbelt. You don’t wear it
because you’ll get a ticket if you don’t. You wear it because
it’s the right thing to do. Likewise, we change the mindset of our
employees when applying food safety measures.”
According to Rob Mercer, the company’s general manager,
food safety at Mercer Ranches is an integral part of the entire operation.
It includes growing, harvesting, warehousing, packing and shipping. It
also includes non-production items like the aforementioned employee training.
“Food safety is not a static program,” says
Mercer. “It is dynamic in nature. Each and every management action
ensures that food safety not only fits comfortably into the overall objective
of Mercer Ranches, but that it is also understood and easily executed
by each and every employee.”
In addition, the company has had a hazard analysis critical
control point (HACCP) program in place since 1995. “The HACCP plan
has been very effective in assisting management to look at the critical
processes of production,” explains Price. “It ensures quality
and lets the sales team know they can guarantee product quality and safety.”
Mercer Ranges also employs good agriculture practices
(GAPs), good management practices (GMPs) outlined by the FDA and statistical
quality control programs in pursuit of growing exceptional carrots.
Company History
The company was formed in 1959, switching from livestock
and dry land crops to irrigation when the John Day Dam on the Columbia
River was constructed in 1968. Mercer Ranch is less than a mile from the
Columbia. The original crops of wheat and alfalfa, grown for cattle feed,
and sugar beets were barely profitable. Thus, the Mercer family began
a search for higher value crops in the early 1970s. That search became
even more important when the U&I Sugar plant in nearby Toppenish Wash.
closed its doors in 1978.
Preliminary carrot plantings were initiated in 1981. Success
with the crop led to construction of the fresh carrot plant in 1985 and
the addition of cut-and-peel carrots in 1988. Throughout the next 10 years
it became apparent to the Mercers that the “old carrot shed”
would no longer be adequate to meet the needs of increased production.
In 1995, a complete overhaul transformed the old carrot shed into a state-of-the-art
facility.
To further meet the needs of customers, Mercer Ranches
purchased an existing facility in Holtville, Calf., refurbishing it to
meet the high standards of the Prosser Wash. plant. In excess of $3 million
in improvements were made resulting in today’s year-round operation
from a vertically-integrated 250,000-square-feet of processing plants.
According to Price, about 80 percent of Mercer’s
business is in the retail market. In addition to growing carrots, the
company introduced last summer value-added packaged ready-to-cook sweet
corn. “We invested more than a year of research and development to
come up with a safer, more convenient packaging system that combines FDA-approved
microwavable tray stock and film,” says Price. With Mercer’s
new product, consumers can place the entire package, containing four ears
of super sweet corn into the microwave and enjoy it in eight to 10 minutes.
Mercer offers a variety of carrots, including cello, clip-top,
jumbos, cut processor carrots and baby peeled carrots. Those who attended
the recent International Fresh-cut Produce Association’s 16th annual
meeting in Tampa, Fla. Last month will surely remember Mercer’s mouthwatering
carrots. During the conference, 1,500 bags of baby carrots were given
away to visitors and show attendees.
In summarizing the company’s success Price says,
“You obviously have to provide excellent quality on a consistent
basis; you also need to say what you do and do what you say.”
© 2003 Columbia Publishing
16th
Annual Event IFPA Conference Round Up
Fresh Cut
May 2003
What a show it was. Last month’s International Fresh-cut
Produce Association’s 16th annual meeting was nothing short of perfect.
The venue – Tampa, Fla. – offered a spectacular setting for
every aspect of the three-day conference and exposition. Some may argue
that the entire event should have been held outside because of the daily
80-plus degree weather. Such is life.
Some of the extra curricular activities were indeed held
outdoors. The early morning outing en route to Rolling Oaks Course at
the World Woods Golf Club was well worth the hour’s drive north.
Rolling Oaks was ranked the No. 1 daily fee course in 2000 by Golf &
Travel magazine. It didn’t disappoint any of us duffers. Adding to
the course’s ambiance were the many aged oak trees lining most of
the holes; some picturesquely draped in Spanish moss.
IFPA officials were careful to offer a mix of great presentations
and symposiums, coupled with the “fun things,” like the Tampa
Bay Lightning vs. Philadelphia Flyers NHL hockey game and the StarShip
Dinner Cruise and Casino Night.
Starting things off on Friday morning was the annual presentation
of The Produce News’ Fresh-cut Produce Award, which went for the
first time to an international company/individual: Rob Robson, CEO of
Harvest Freshcuts and The Harvest Company. Based in Brisbane, Queensland,
Australia, Robson, the humble recipient, has been at the pioneering edge
of fresh Australian produce for more than 25 years. Harvest Freshcuts,
in the fresh-cut business since 1995, has been featured twice in recent
issues of Fresh Cut magazine. The company processes leafy-based salads,
including Caesar, coleslaw, garden and Italian salads and vegetable mixes.
Edifying Ed
Shortly after Robson received his award, Ed Foreman delivered
the keynote address. He basically set the tone for a “terrific”
conference. The self-made millionaire, congressman from two different
states and developer of the “Successful Daily Living” formula
kept everyone on their feet, literally and figuratively. His rousing presentation
included many jumps up to and on top of several chairs, coupled with high-pitched
southern drawl antics when making his point.
Two other awards were given out during the conference.
Nancy Nagle of Nagle Resources was given the IFPA Technical Award. Her
research and consulting firm specializes in produce food safety and good
agricultural practices. She is based in Pleasanton, Calif.
Another award recipient was Steve Gill of Gills Onions.
He received the first-ever IFPA “Member Magnet” award for his
work in bringing new members to the organization.
The real meat of this conference was the amount of information
imparted during the various sessions. There is such a wealth of knowledge
and information within this industry. For instance, the 3rd annual Science
Symposium, held on the last day of the conference, had six participants,
including two moderators. All six individuals held PhDs.
Other seminars on new packaging technologies and how to
create the right facility design also offered up-to-date information on
those respective topics.
Show Stoppers
Walking the showroom floor was and still is one of the
most effective aspects of this or any conference. This one-on-one face
time with customers, clients and new acquaintances is invaluable beyond
any dollar amount.
According to IFPA officials, 110 exhibitors attended the
show accounting for 225 booth spaces. In all, more than 1,100 individuals
attended the 16th annual conference.
Of course, this conference would not have been possible
without the tireless efforts of a handful of people, namely the IFPA staff.
Many thanks go out to the IFPA’s president Edith Garrett, vice president
of technical and regulatory affairs Jim Gorny, director of membership
Reta Jones, director of communications Ken Hodge, director of marketing
Loren Queen, exhibits manager Martha Krafton and new IFPA staff member
Linda McDonald.
Next year, during IFPA’s 17th annual conference,
patrons won’t feel so bad about staying in doors. The event will
be held in Reno, Nev.
© 2003 Columbia Publishing
IFPA
Workshop: Marketing to Customer Needs — the Latest Trends
Fresh Cut
May 2003
To be truly successful fresh-cut processors must know what their customers
need before they need it, and in the fresh-cut industry those needs are
changing at an unbelievable pace. How do you remain on the cutting edge
of those trends?
To address this subject, Marvin List, with Del Monte Fresh
Produce, N.A., moderated a session, “Marketing to Customer Needs
— the Latest Trends,” which took place on Friday, April 4.
Panel participants and their respective topics were:
Loralee Lyman, Flipside Design, Inc., Carmel, Calif., “Judging a
Product by Its Cover.”
Steve Junqueiro, Save Mart Supermarkets, Modesto, Calif.,
“Marketing to Tomorrow’s Retail Consumer.”
Bruce Axtman, The Perishables Group, Chicago, “Food
Service Opportunities for Fresh-cut Produce”
Importance of Cover Design
Loralee Lyman reminded her fresh-cut processors that consumers
purchasing their products can only rely on appearance to make judgments,
and that the majority of these consumers are women. She emphasized the
importance of package design.
Lyman’s colorful and innovative designs have graced
numerous packages of whole and fresh-cut produce as well as packaging
for domestic and international food and beverage processors.
Today’s consumers want timesaving products and convenient
healthy choices for themselves and their kids, she said. Judgments are
often made based on the appearance of the cover label.
Stressing the importance of visual communication, she
encouraged group members to pretend they cannot talk and to show consumers
in their package designs what their product is, its health benefits and
how they will save them time.
In product development, she also stressed the importance
of creating a name and slogan that will effectively position a particular
product in consumer minds.
Marketing to Tomorrow’s Consumers
Director of produce and floral for Save Mart Supermarkets,
Steve Junqueiro noted that today’s consumers can be divided into
various categories, including male/female, various generations (traditionalists,
baby boomers, Generation X and Millennials), ethnicity and economics.
The customer is becoming more complex, he said.
Lifestyles are driving purchase decision, he explained.
These vary from single men and women to small and large households, soccer
moms and dads and retirees. But three words describe their differing lifestyles:
busy, busy, busy! Most are time- and solutions-starved, crave information,
are concerned about maintaining good health and are demanding satisfaction.
On the positive side for fresh-cut fruits and vegetable
processors, today’s older adults are focusing more on making up for
lost time, acknowledging that if they knew they were going to have lived
this long, they would have taken better care of themselves. Forty percent
of today’s young adults are self-proclaimed vegetarians and are very
health minded, he added.
“How do we satisfy our consumers?” the speaker
asked, responding that the answer is providing them with fresh fruits
and vegetables. Good taste and convenience must be a part of the package,
he stressed.
“We are on our way,” Junqueiro promised. “Categories
are exploding, consumption is growing and the future is bright, if we
continue to answer the demands of tomorrow’s consumers today.”
Foodservice Study Report
The marketing and strategic planning visionary for the
Perishable Group, Bruce Axtman reviewed the Summary of Fresh Focus 2002
Foodservice Survey, a research survey conducted to help IFPA members better
understand foodservice operator practices, decision-making processes,
criteria and requirements, and better address their customers’ needs.
The study showed that fresh-cut vegetable products continue
to be more widely purchased than fresh-cut fruit items, although the fresh-cut
fruit revolution is well under way. More than 70 percent of operators
said they currently purchase fresh-cut vegetable items verses 18 percent
for fresh-cut fruit items. Operators who purchase fresh-cut fruit are
moderately satisfied with product quality. The primary motivating factor
to purchase these items in the future is a menu-change, he reported.
As for desired new packaging options for fresh-cut produce,
Axtman pointed out that smaller pack sizes and improved packaging and
freshness with extended shelf-life are at the top of the wish list.
When selecting a fresh-cut produce supplier, 69 percent
of operators placed some level of importance on customization capabilities,
he said. Nearly 40 percent want their fresh-cut produce supplier to offer
them promotions, and of that group 60 percent would like to be offered
price discounts.
Branding also is important, Axtman pointed out, because
more than half of the operators surveyed said they buy branded fresh-cut
produce — 75 percent national brands, 20 percent regional and 10
percent private labels. Quality and consistency are the most important
reasons to have a national brand (to communicate the brand to the consumer),
he said
The deciding factors for choosing a fresh-cut produce
supplier include product quality, meeting supply scale/quantity needs
and pricing, the speaker reported. Packaging options offered also are
figured in the selection equation.
On the bright side, fresh-cut is seen as the hottest trend
in overall produce, Axtman said. Next in importance are organics and packaging
innovations.
Food safety and shelf-life extension were cited most often
as important influencers for fresh-cut produce now and in the future,
the speaker said.
© 2003 Columbia Publishing
IFPA
Science Symposium Held
Fresh Cut
May 2003
This year’s IFPA 3rd Annual Science Symposium, held
April 5, tackled a variety of technical topics with the goal of fostering
interaction between researchers and the fresh-cut fruit and vegetable
industries.
The symposium was presented in cooperation with the Postharvest
Quality and Safety in Fresh-cut Vegetables & Fruits (S-294) Cooperative
Research Project Technical Committee.
Moderated by IFPA’s Jim Gorny and John Beaulieu,
with USDA/ARS, panel members and their respective topics were:
Richard Linton, Purdue University, “Chlorine Dioxide and Ozone Gaseous
Application”
Peter Toivonen, Ag Canada, “Fresh-cut Apple Quality
and Safety”
Jeff Brecht, University of Florida, and Elizabeth Baldwin,
USDA/ARS, “Pre-Treatment of Whole Fruit to Extend Shelf Life and
Quality”
Trevor Suslow, University of California, Davis, “Enhancing
Microbial Safety of Fresh and Fresh-cut Melons”
All of the participants, including the moderators, hold PhDs.
Gaseous Chlorine Dioxide Work
In terms of pathogen reduction strategies using gaseous
chlorine dioxide, Linton concluded that for Cl02, the gaseous form is
more effective than the aqueous form. Also noted were that concentration,
RH and produce surfaces all play an important role.
As for treatments more effective (quality) for whole versus
cut produce, use may be limited to processing steps prior to cutting,
slicing and juicing, he said.
Looking ahead, Linton said his future research will focus
on optimization of treatments and developing/studying pilot-scale treatment
systems.
Safety, Quality of Apple Slices
Based on his studies, Toivonen said it appears impractical
to design an optimal MA package for apple slices. Hence, designing a “safe
bag” is important.
On quality/sanitation issues, if a proper dip is used
(e.g. Nature Seal™), cut-edge browning should not be a problem, he
said. However, secondary browning is associated with microbial growth.
Cut-edge browning usually develops within a few days, while microbial
browning occurs over several weeks.
“Cut-edge usually is non-localized, whereas microbial
is often (but not always) localized,” he explained.
How might microbial browning occur?
Degradative enzymes injure cells, leading to the mixing
of polyphenol oxidase with phenolic substrates, the researcher explained.
Many fungi produce laccases which act to directly oxidize phenolic substrates.
Sanitation is a very important issue for quality as well
as safety, Toivonen stressed. One solution is to use low volume sprays
instead of dip tanks for sanitizing and anti-browning application.
The researcher said he also is looking at using mild heat,
but there have been quality problems. Also being considered is the use
of natural anti-microbials as post-processing or in-package applications.
Most quality associated microbes appear to be fungal, he said.
Extending Shelf Life, Quality
Jeff Brecht and Elizabeth Baldwin focused their presentation
on the pretreatment of whole fruit to extend shelf-life and quality. Among
their conclusions:
Based on appearance, an ethanol treatment extended shelf life.
Ethanol treatments produced an off-flavor.
Heat treatments gave apples a good appearance.
Heat treatments caused volatile loss.
1-MCP caused increased decay in ‘Gala’ apples.
1-MCP worked well for cut ‘Braeburn’ apples
in New Zealand.
1-MCP treated mangoes scored well in sensory panels.
The two researchers hope to show that altering metabolism can improve
and maintain fresh-cut fruit sensory quality. Their goal is to extend
the period during which acceptable sensory quality of fresh-cut fruits
is maintained. Doing so would lead to improved market penetration and
create whole new markets.
Enhancing Microbial Safety
“How do we kill the ‘nasties’ without killing
the product?” asked Trevor Suslow, addressing his part in the science
symposium, “Enhancing Microbial Safety of Fresh and Fresh-cut Melons.”
The researcher is coordinating a USDA National Integrated
Food Safety Initiative Project awarded to the University of California
Agricultural Experiment Station at Davis. Concerned over the microbial
food safety of melons, particularly cantaloupes, the team hopes to address
what it feels is an urgent need for the development of a standard method
for pathogen testing and detection.
Suslow and Marita Cantwell, both at UC Davis, hope to
expand understanding of the potential for internalization of Salmonella
into subsurface rind tissue of cantaloupes co-invaded/colonized by fungi
commonly associated with all melons during post-harvest storage. They
will be evaluating the impact of post-harvest handling and shipping and
conditions on the survival, attachment and internalization of Salmonella
on melons. They also will determine the inter-strain competitiveness of
different Salmonella serotypes for survival and growth and evaluate the
impact of treatments applied to export melons for fresh-cut applications
on the survival and attachment of Salmonella and E. coli.
© 2003 Columbia Publishing
IFPA
Workshop: New Packaging Technologies to Ensure Quality Products
Fresh Cut
May 2003
New advancements in packaging technology are revolutionizing what can
be packaged and safely sold in the fresh-cut fruit and vegetable industries.
Keeping abreast of what is happening can be a challenge, as demonstrated
in a second workshop, “New Packaging Technologies to Ensure Quality
Products,” held April 4.
Ken Silveira with Tanimura & Antle, Salinas, Calif.,
served as moderator. Panel participants and their respective topics were:
Wendy Dunlap, Cryovac Division/ Sealed Air Corporation, Duncan, S.C.,
“Technology Hurdles to Packaging Fresh-cut Fruit and Vegetables”
Jeff Brandenburg, The JSB Group, Greenfield, Mass., “Packaging
Technology: A Practical Approach”
Technological Hurdles
Dunlap underlined the difficulty of processing and packaging
fresh-cut produce successfully. Produce products are living tissue, she
explained. They undergo many changes in response to processing (injury),
bringing about changes that have to be addressed.
Among the challenges associated with processing fresh-cut
fruits and vegetables cited were: (1) ethylene product; (2) increased
respiration rates; (3) detrimental enzyme activity; (4) bruising; (5)
microbial spoilage associated with food safety; and (6) water loss.
All of these challenges prevent processors from successfully
offering the products consumers demand, Dunlap said. Vegetables with high
respiration rates and most fruits are particularly difficult to package.
Pre- and post-processing treatments can be used to address
such challenges, the speaker said, mentioning various chemical dips and
washes, ozone, mild heat treatments and irradiation.
There also are various “in the package” technologies,
Dunlap explained. These range from high-pressure pasteurization to modified
atmosphere packaging (MAP).
To achieve optimal results against multiple challenges,
she suggested combining several technologies, such as chlorinated warm
water wash plus irradiation; ozone and MAP; and anti-microbial and anti-browning
dip with high OTR packaging.
Before making a packaging choice, Dunlap advised her audience
to consider technologies being used in other industries. Most packaging
suppliers are in several food markets, she explained, with everything
from trays to soaker pads.
Tour local grocery stores and specialty stores, particularly
the refrigerated sections, for new ideas, she suggested.
Understanding Packaging Needs
Brandenburg stressed the importance of thoroughly understanding
a product’s packaging requirements and desired results. The more
different vegetables, for example, a processor packs into a particular
package, “the more compromise you make,” he said. Matching requirements
to properties, understanding the language and selecting and designing
the proper package are all critical to making a wise decision.
“Technologies available today for fresh-cut produce
have grown exponentially from just two or three years ago,” Brandenburg
said. However, to take advantage of these advances, the different segments
“must talk to each other.”
Relevant industries include growers, processors, converting,
transportation, film, resin and additives, he said. Produce requirements
vary according to product, product type, weight, respiration rate, optimal
atmosphere, desired shelf life, target storage temperature and microwave
requirements.
Package design must consider everything from produce to
marketing, converting and filling machine requirements. There also are
differences in required on-going quality and testing requirements.
Also important in packaging selection are marketing requirements,
which must take into consideration appearance, construction, graphics,
stiffness, economics, nutritional labeling, he pointed out.
Add all of these considerations together and it soon becomes
apparent that picking the right packaging for a fresh-cut product requires
technical know how, the speaker said. There is a huge selection of products
on the market, from perforated materials (macroperforated, microperfortated,
patch technology, etc.) to various polymers and films in a number of sorts
and types.
“There are tremendous options out there and new products
coming out all of the time,” Brandenburg said. “The windows
of possibilities are opening and are changing almost daily.”
© 2003 Columbia Publishing
Creating
the Right Facility
Fresh Cut
May 2003
Design, Refrigeration and Environmental Monitoring Considerations
With many fresh-cut fruit and vegetable processors either expanding or
building new facilities on an ongoing basis, how do you make a wise choice?
How do you build the best and safest facility possible?
Monitoring the discussion on that topic during the April
5 morning workshop, “Creating the Right Facility: Design, Refrigeration
and Environmental Monitoring Considerations,” was Phil Riggio, CEO
of Aunt Mid Produce Company, Detroit. Panel members and their respective
topics were:
Frank Spano and Ron Frattare, Cleveland, with The Austin Company, “Site
Selection, Design and Construction of Salad Bagging Plants”
Adel Makdesi, ZEP Manufacturing Company, Atlanta, “Incorporating
Sanitation, HACCP and GMPs”
Robby Kroeze, Axiom Engineers, Monterey, Calif., Refrigeration
Considerations”
Alan Heinzen, Heinzen Manufacturing International, Gilroy,
Calif., “Equipment and Process Design”
Importance of Site Selection
Making a site selection and determining the right design
and construction of a salad bagging plant involves a number of serious
considerations, Spano said. He stressed the importance of:
(1) Developing a location criteria — considerations
include transportation requirements, labor characteristics, operating
schedules, inter-facility movements, site size and configuration, desired
site environment and image, utility requirements and political realities.
(2) Conducting a favorable area analysis — identifying
the region that offers the most favorable operating costs and service
characteristics.
(3) Conducting a community/site analysis — identifying
the community and site or building that best meets the operating requirements
of the proposed facility.
(4) Conducting pre-acquisition site due diligence/final
incentive negotiations —such things as having an option property,
arranging contract services, negotiating a purchase agreement, negotiating
final incentives, reviewing zoning and building codes, and establishing
a permit schedule.
(5) Selecting the final location — making the final
determination and implementing the plan.
Frattare reviewed the importance of the design and construction
process as well as what he described as “typical building issues/elements.”
The process can be described as a “five-act drama:”
(1) conceptual design; (2) design development; (3) construction; (4) bidding
and negotiations; and (5) construction,” he said.
The final act, field construction, can be the most challenging
part, taking six to nine months to complete, if remodeling of an older
building is planned, or nine to eighteen months, if a new facility, he
said.
But once all of this has been completed, there still remain
two more “very important” steps, Frattare said. These are: (1)
commissioning of the building systems to be used, and (2) installation
of the processor’s equipment, including utilities connection, testing
and training.
Sanitation Practices Important
Addressing the topic, “Incorporating Sanitation,
Hazard Analysis Critical Control Point (HACCP) and Good Manufacturing
Practices (GMPs),” Makdesi noted that along with significant increases
in the consumption of raw fruits and vegetables in recent years has come
corresponding increases in food poisoning.
The fresh produce industry is uniquely different from
traditional processed foods, posing greater microbiological risk, he said.
Produce contamination can easily occur from contact with the soil and
human pathogens. Good temperature management to retard microbial growth
and produce deterioration is important.
Fresh produce quality and safety is best provided through
HACCP, GMPs and sanitation programs, Makdesi said.
“Documenting the use of safe raw produce is an essential
part of a HACCP program,” the he stressed, adding that produce sanitation
should start in the field during growing, harvesting, handling and processing.
HACCP, GMPs and sanitation are interdependent food safety
programs, he explained. GMPS and sanitation provide the foundation for
HACCP. HACCP functions as the final stage of an integrated food safety
program.
“Food safety is everybody’s business,”
Makdesi warned.
Focusing his comments on refrigeration considerations,
Kroeze spelled out the pros and cons of using ammonia versus Freon. Ammonia
is more efficient, is less expensive and is less threatening to the environment,
he said.
Refrigeration Considerations
Kroeze also detailed various air coolers, water chillers
and pre-coolers. Among the air cooler types cited were room coils, make-up
air units and air handlers. Water chillers mentioned were air handlers,
shell and tube, and falling film types. Two pre-coolers, hydrocoolers
and vacuum tube systems, were noted. He reviewed the advantages and disadvantages
of each.
Equipment and Process Design
Speaking on equipment and process design, Heinzen emphasized
the importance of taking time to plan. “Unless you do, a lot of money
will be wasted,” he warned.
He reviewed several points important in an overall plan:
(1) What is the right facility design? “Optimize
your resource dollars,” he advised. “Produce the best product
at the lowest price.”
(2) Analyze production capacities.
(3) Estimate future product and capacities.
(4) Develop a project budget that your production can
afford.
(5) Think about the ideal process facility.
(6) Start with the largest capacity line at the packaging
end.
(7) Remember the packaging equipment range for VFS to
pre-made bags and tables
Heinzen also reviewed various types of product drying,
dewatering equipment and wash systems. Also discussed were slicers, trim
lines, product in-feed and conveying systems and the importance of adequate
waste water management.
“Be conservative on your budget. There is always
other stuff,” he underscored, cautioning the group to remember that
“Your first cost is your cheapest cost.”
Once the equipment has been selected and the process is
done, the refrigeration and building can now be fit into the process,
he said.
© 2003 Columbia Publishing
Fresh-cut
Citrus Target of Questionable “Wisdom”
Fresh Cut
May 2003
I about fell off my chair a few weeks ago after reading
a diatribe in a competitor publication. A particular writer decided that
value-added just didn’t cut it in some areas. His target was Sunkist,
which recently announced that it was going to join the fresh-cut arena
later this year, specifically with fresh-cut oranges. The writer stopped
just short of calling consumers idiots for buying anything fresh-cut.
The scores of individuals employed in the fresh-cut industry will, no
doubt, be happy to correct his misconception.
What I found ironic was the timing and placement of the
editorial. A few pages after his negative comments about fresh-cut, there
appeared a full-page ad from none other than the Fresh-cut Produce Association.
Whether it’s fresh-cut onions, fresh-cut apples or
fresh-cut oranges, the bottom line is fresh-cut is here to stay. The numbers
don’t lie. Just look at those “idiot” consumers’ collective
reaction to the fresh-cut industry. The following statistics are from
the IFPA:
76 percent of U.S. households purchase fresh-cut produce at least once
a month.
38 percent of these households buy fresh-cut produce at
least once a week.
Although purchase of both fresh-cut vegetables and fresh-cut
fruit are quite high, consumers have been quicker to adopt fresh-cut vegetables:
82 percent say they buy fresh-cut vegetables every few months or more,
while 70 percent purchase fresh-cut fruit at the same frequency.
Sales of fresh-cuts have grown from approximately $5 billion
in 1994 to $10-12 billion currently, which is about 10 percent of total
produce sales; this includes retail and foodservice sectors.
Users are most likely to say “convenient” (83
percent) and “nutritious” (76 percent) to describe fresh-cut
produce.
Sunkist’s Plans
Which brings me back to Sunkist and its plans to enter
the fresh-cut arena. Speaking at Sunkist’s 109th annual grower’s
meeting in late February, Sunkist CEO Jeff Gargiulo announced, “It’s
time to enter the cut-fruit market because Americans seem more willing
to buy prepared melon, bagged salad and pre-cut vegetables rather than
taking the time to peel an orange.”
I applaud their efforts. I, for one, love oranges, but
don’t like the orange fingernails, time-consuming picking-away of
orange membrane, and smelling like an orange all afternoon when I peel
and eat one for lunch. Thus, fresh-cut oranges are very appealing to yours
truly.
In the aforementioned editorial knocking Sunkist, the
writer continued his assault on the citrus giant:
P.T. Barnum is credited with noting that there is a sucker
born every minute. More power to Sunkist if it can convince some consumers
that it is easier to open up a plastic package than to peel or cut an
orange. But if this item succeeds, it really does say something about
the American consumer, and it is something that doesn’t bode well
for the produce industry.
What could be further from the truth? Convenience is the
dominating factor in the fresh-cut industry. That’s why this industry
is so successful. They’ve listened to and answered customers’
requests.
More than 65 million households are dual working, according
to estimates. These time-starved consumers want foods that are quick and
easy to prepare, easy to eat, and nutritious.
For most consumers, the value-added concept equates to
time. In my opinion, fresh-cut citrus will be no different. I don’t
think P.T. Barnum had the fresh-cut industry in mind when he declared,
“There is a sucker born every minute.”
© 2003 Columbia Publishing
C.H.
Robinson Debuts New Fresh-cut Produce Line
Fresh Cut
May 2003
With consumers’ growing demands for healthy lifestyles
and convenience food items, C.H. Robinson recently introduced its new
line of fresh-cut side dish products: Fresh ‘n Easy™.
“Consumers are looking for fresh, convenient, healthy
alternatives to current center of the store offerings,” says Bud
Floyd, vice president of C.H. Robinson Produce Marketing. “They want
a ‘from scratch’ fresh taste to their meals but don’t have
the time to prepare it. Thus, Fresh ‘n Easy was born.”
The Fresh ‘n Easy line was created to meet the needs
of the time-constrained consumers of today. “All 11 varieties, including
green beans, southern greens, sugar snap peas and corn on the cob, are
pre-washed, pre-trimmed and pre-peeled,” says Katie Reilly, communications
specialist for the company. “Consumers need only open, rinse, heat
and serve.”
Floyd explains that other benefits for both consumers
and retailers include enticing packaging graphics that assists in complete
meal planning and purchasing, year-round product supply, contract pricing
and a wide variety of product options.
“When you think of these as side dishes,” Floyd
says, “there are a couple of things we’re doing. First, we’re
giving the consumer an idea of how to use them. We’re also going
to offer you not only the mainstream items like broccoli and things of
that nature, but also regional favorites, like Southern greens and green
beans.”
When C.H. Robinson was incorporated in 1905, the company’s
main business was in sourcing fresh produce. Today, the company still
procures produce for retailers, wholesalers and foodservice operators
nationwide.
According to Floyd, in addition to sourcing the highest
quality products, C.H. Robinson also integrates value-added logistics
and distribution services every step of the way. “Rather that simply
providing customers with commodities, we customize a complete supply-chain
solution that meets each individual customer’s needs,” he says.
“We understand how to maintain the cold chain.”
Based in Eden Prairie, Minn., C. H. Robinson is a global
provider of produce sourcing, branding and distribution services.
© 2003 Columbia Publishing
>>
Return to top
Fresh-cut
Pears a Delight in Oregon
Fresh Cut
June 2003
HOOD RIVER, Ore.—Gorge Delights' philosophy of 'doing
business to help the little guy' is literally paying dividends for everyone
involved in this fresh-cut pear endeavor.
A family-owned and operated, value-added fruit company,
Gorge Delights uses a 100 percent natural dip that prevents oxidation
of sliced fruit for up to two weeks.
"Anjou and Bosc pears, as well as Fuji and Gala apples
are sliced, then dipped in a calcium and vitamin C mixture to prevent
premature browning," says Gorge Delights co-owner Ron Wherry. "With
a shelf-life of 14 days for pears and 21 days for apples, the fruit is
offered in a convenient, ready-to-serve, re-sealable package."
The cut pear idea stemmed from the Willis family, which
had been growing fruit in the Columbia River Gorge for more than half
a century. A few years ago, the family resolved to find a new and different
way to market pears and apples. They decided the way to add value to their
fruit was to make it more convenient - easier to eat and store. With the
help of HR Mtn. Sun, a consulting company specializing in new product
development and value-added products for small growers, Gorge Delights
began slicing fresh pears and apples and packaging them in re-sealable
containers for sale at area groceries.
"We're unique in cutting pears," says Wherry.
"We do everything by hand. It's not our goal to take on everyone
in the apple or pear industry. Our primary emphasis is to work with pear
growers in the Hood River Valley as an alternative outlet for their pears."
New Facility
And what an outlet that's grown into. With the recent opening of a new
15,000- square-foot plant, Gorge Delights has a workforce of around two
dozen. According to Wherry, the company expects to hire nearly 100 employees
by year's end.
"Growth trends are looking quite positive for us," he says.
"We anticipate going to multiple shifts in the near future. We've
got the customer demand to support it."
Gorge Delights' current business market is based in the
Pacific Northwest. But, that will change in the coming months.
"We have distribution abilities through various foodservice
companies," says Wherry. "We have distribution channels in place;
that's not an issue. We can deliver anywhere in North America."
According to Wherry, the company's sliced fruit is distributed
and sold through grocery stores, convenience stores, delis and restaurants.
Gorge Delights has a mix of retail and foodservice customers with products
also sold to schools, nursing homes, hospitals and city and county governments
throughout Oregon. Fresh sliced fruit has grown rapidly over the last
several months, expanding well beyond Columbia Gorge communities. Portland
area schools have signed on to large orders, and WinCo Foods, a grocery
story chain with stores in Oregon, Washington, Idaho, California and Nevada,
signed a contract with Gorge Delights earlier this year.
Pear Bars Developed
The development of the pear bar is another innovative method of adding
value to the pear market in the Columbia Gorge region. USDA's Agricultural
Research Service scientists developed technology for the pear bar. The
bars, about the size of a typical granola bar, will be made and marketed
by HR Mtn. Sun, which holds an exclusive license for the novel technology.
Like fresh pears, pear bars provide fiber, vitamin C
and several minerals including iron and potassium. But, unlike the fresh-market
fruit, pear bars are not perishable and will be available year-round.
"The military is currently examining the use of pear
bars in its MRE (meals, ready-to-eat) program," says Wherry. The
pear bar has also been nominated for the Prepared Foods Magazine "Spirit
of Innovation Award" as one of the best products for 2002. Prepared
Foods Magazine covers R&D, marketing, quality control and business
topics for the food processing industry.
According to Wherry, HR Mtn. Sun granted the right of
production to Gorge Delights. The technique for producing the bars is
fast, easy, energy-efficient and relatively inexpensive.
"The bars are made by processing pears into puree,
with that mixture then being shaped into bars," explains Wherry.
"It's shelf stable, which means it can be sent to countries that
normally don't have fresh fruit readily available. The really important
fact is that each 40-gram bar offers the same nutrient value as two fresh
pears. One bar, which contains only 130 calories, provides two-fifths
of your daily fruit requirement." Not only will pear bar production
be a boon to the region's producers, consumers will benefit by being able
to enjoy these perishable fruits year-round in pear bar form.
This USDA-developed technology isn't restricted to only
the pear industry.
"If someone came to me and had a bunch of tomatoes,
we could certainly make a bar with that product," says Wherry. "We
could do the same for any surplus product, like broccoli, spinach, potatoes
or any other vegetable, it just depends on what you (the grower) want
to do."
Working in Tandem
HR Mtn. Sun and Gorge Delights will work with the government to help farmers
who might be interested in applying this technology.
"What can we do with surplus products in order to
turn the item into an edible form?" asks Wherry. "We're talking
with government officials right now to address that topic," he says.
In fact, Wherry will present information on applying
this technology when he speaks at an international conference later this
month. Hosted by the U.S. Agriculture Secretary Ann Veneman, the international
Ministerial Conference and Expo on Agricultural Science and Technology
will take place in Sacramento, Calif. June 23-25. Ministers from more
than 180 countries have been invited. Highlights will cover an array of
technologies, including food processing and packaging, food safety, and
agricultural transportation, distribution and marketing, to name a few.
"I will be addressing specifically value-added development
for food products," says Wherry.
With a company philosophy of helping the little guy succeed,
Gorge Delights may soon transcend borders and assist other 'little guys'
half way around the globe.
Information:
Gorge Delights: www.gorgedelights.com
HR Mtn. Sun: www.hrmtnsun.com
Agricultural Research Service: www.ars.usda.gov
© 2003 Columbia Publishing
UVC
Emitters™ Help Eliminate Mold, Extend Shelf-Life at Martin Farms
Fresh Cut
June 2003
Maintaining a clean indoor environment - whether to satisfy HAACP guidelines
or to optimize product shelf life - is a concern of every produce grower
and packer. John B. Martin and Sons Farms, Inc. of Brockport, N.Y. is
no exception.
"We wanted to find a way to reduce mold counts in
the room where we process butternut squash, but our facility did not lend
itself to a true clean room environment," states Peter Martin, production
manager for Martin Farms. "Instead, we have had excellent success
using a surprisingly simple solution: We pressurized the space and installed
ultraviolet-C (UVC) lights manufactured by Steril-Aire, Inc. to function
as an air cleaning mechanism. Our mold counts have dropped dramatically,
our air quality has improved and our shelf-life has increased dramatically
as a result."
Before arriving at this solution, Martin Farms was experiencing
high mold and yeast counts, based on weekly product sampling performed
by Primus Labs. This task was part of the company hazard analysis critical
control point (HAACP) program. Yeast occurs naturally in the squash itself
but can multiply to undesirable levels if ambient conditions allow. High
levels of yeast can also promote mold proliferation and can actually mask
the presence of mold spores, a problem that sometimes occurred in the
butternut squash processing room.
High Counts Confirmed
High mold and yeast counts from puree test samples were confirmed when
a technical consultant, FP Technologies, Inc. of N. Tonawanda, N.Y. performed
both air sampling and swipe (surface) sampling in the process area. Both
types of samples showed very high counts of airborne and surface mold
spores and yeast: about 20,000+ colony-forming units (CFUs) per cubic
meter of air. "We suspected the cause to be cross-contamination from
the far end of the building where we produce raw cabbage product,"
states Martin.
Working with FP Technologies, Martin learned of a new
generation of devices that use ultraviolet-C energy to eradicate both
surface and airborne mold and bacterial contamination. The UVC wavelength
targets the DNA of microorganisms. This causes cell death and makes replication
impossible. The new-generation devices are designed to produce optimum
energy output in cold and moving air environments. This makes them ideally
suited to food and beverage processing lines, cold storage areas, air
conditioning systems and similar applications.
A research study, conducted by the University of Tulsa
in a 286,000-square-foot building, found that Steril-Aire UVC light fixtures
installed in the air-handling units were effective in reducing mold contamination
by as much as 99 percent. Based on research results and positive experiences
of other users, Martin thought the technology was worth a try.
The Solution
The main component of the new system is a 3,000-cubic-feet-per-minute,
make-up air unit that serves to pressurize the 800-square-foot room where
butternut squash is peeled, de-seeded, cubed or halved and tray-wrapped
in preparation for retail distribution under the Golden Acres label. Two
commercial-style UVC light fixtures with 24-inch long tubes are installed
inside this air-handling unit.
The lights operate round-the-clock to eradicate any airborne
microbes that may pass through the system - including mold, bacteria,
viruses and other contaminants. The UVC energy emitted by the lights provide
safe, continuous, non-chemical cleaning, keeping the inside air fresh
and preventing cross-contamination from other areas.
Martin Farms operates this line on a seasonal basis from
September to Easter. They are now in their third year of using UVC lights.
"During the production season, we run the lights 24-hours-a-day.
Based on that schedule, we get two seasons' use from the lights. When
we replaced the Emitter tubes after the second season, it was as easy
as changing light bulbs. The devices have not required any other maintenance,"
says Martin.
The Results
Since the system started operating, FP Technologies has performed periodic
air and surface sampling tests to monitor results. Mold and yeast have
dropped from the previous level of 20,000+ CFUs per cubic meter of air
to a range of 1,800 - 2,200 CFUs - an approximate tenfold reduction. Tests
on product samples reveal similar reductions.
Before Martin Farms instituted a HAACP program in this
area of the facility, shelf-life of the butternut squash was typically
just under one week. "We increased shelf-life to 10 days once the
HAACP program was in place," says Martin. "Then, after pressurizing
the room and installing the UVC lights, we experienced another big improvement:
We now average up to two weeks for shelf-life."
Martin continues: "This doubling of product life
gives us a great deal of flexibility. And since we now have more time
for shipping, we've been able to expand our geographical marketing area.
We're pleased with how the UVC devices are working, and we're investigating
additional uses for the product," he notes. Martin Farms officials
plan to install additional lights in the HVAC system, opposite the cooling
coils, to improve air quality over the coils and eliminate the organic
buildup that naturally occurs on coil surfaces.
"UVC in this application will not only keep the air
cleaner but will also improve the operating efficiency of the HVAC system,"
says Martin. He has learned from Steril-Aire that UVC coil-cleaning applications
yield a very rapid payback because of the resulting savings in energy
consumption. He is also evaluating UVC for upper-air application in cold
storage areas and for potential use over conveyor lines.
Martin's Goals
"Our goal is to achieve the best possible product quality with the
longest possible shelf life," says Martin. "To attain this goal,
we use a complex equation that includes not only UVC but also a good HAACP
program, sound management practices in the plant, good refrigeration after
processing and much more. UVC has definitely improved the equation,"
he says.
Company Profiles
John B. Martin and Sons Farms, Inc.
The Martin family has been farming in upstate New York since 1919, with
three generations of Martins overseeing production. The company is now
one of western New York's largest and best-equipped growers, packers and
shippers of butternut squash, cabbage and other items. They have been
in the fresh-cut industry since 1995. To contact Martin and Sons Farms,
Inc., call (585) 637-3351, e-mail: info@martinfarms.com or visit the Web
site at www.martinfarms.com.
Steril-Aire, Inc.
For further information on UVC, contact Steril-Aire, Inc., 11100 E. Artesia
Blvd. #D, Cerritos, CA 90703; phone (562) 467-8484; fax (562) 467-8481;
e-mail: sales@steril-aire-usa.com or visit the company's Web site at www.steril-aire-usa.com.
© 2003 Columbia Publishing
Brazilian
Researchers Find Pears, Apples Benefit Weight Loss in Women
Fresh Cut
June 2003
The apple of the famed old health adage may also help
reduce the feminine pear shape more rapidly. Adding apples and pears to
your daily diet may melt pounds away faster, according to new research
from Brazil. Study findings were recently published in Nutrition, the
international journal of applied and basic nutritional sciences.
Researchers from the State University of Rio de Janeiro
studying the impact of fruit intake on weight loss report that overweight
women who ate just 300 grams of apples or pears - that's the equivalent
of three small fruits a day - lost more weight on a low-calorie diet than
women who didn't add fruit to their diet. In addition, the fruit eaters
ate fewer calories overall, boosting their weight loss efforts.
"Results indicated that overweight, [high cholesterol]
women have important changes in their body weights and metabolic profiles
by adding fruits to their diet," Maria Conceiçao de Oliveira,
R.D., Ph.D., and her colleagues wrote.
Researchers suggested several theories as to why apple
and pear consumption may promote weight loss. First, fruits like apples
and pears are "low energy-density" foods - that is, they have
a relatively low calorie count compared to other non-fruit foods.
Second, research has shown that eating a high-fiber diet
(calorie intake being equal) promotes post meal "satiety," meaning
we feel fuller and for longer after eating a high-fiber meal. Apples and
pears are both important sources of fiber, delivering five grams per medium-sized
apple and four grams per medium-sized pear.
And finally, research has also established that eating
a high-fiber diet decreases total calorie intake, thus contributing to
weight loss. In other words, eating a high-fruit diet tends to make it
more difficult to overeat, because eating a lot of low energy-dense fruits
like apples and pears crowds out other foods, reducing total caloric intake.
"While several recent studies have suggested apples
may provide a 'whole body' range of health benefits, this is the first
published study to demonstrate that eating an apple before every meal
can help increase weight loss," said U.S. Apple Association (USApple)
nutrition communications specialist Julia Daly. "This has intriguing
implications for those of us who are trying to lose a few pounds."
"We are excited to see a published study that has
established a connection between weight loss and daily intake of fresh
pears," said Kevin Moffitt, Pear Bureau Northwest president and chief
executive officer. "We've long been saying that fresh pears are healthy,
delicious and sweet, and now we have an additional tool to help us convey
this message."
USApple and the Pear Bureau Northwest are jointly promoting
the Brazilian study's findings to American consumers. This is the second
time the two groups have partnered in recent months on a promotional activity
with the recognition that raising fruit consumption overall is a benefit
to all fresh produce industry members. Earlier this year, the two groups
and the Almond Board of California sponsored food page artwork promoting
apples, pears and almonds as health-boosting snacks. The snacking food
page is now appearing in newspaper food sections nationwide.
© 2003 Columbia Publishing
Why
Clean and Core Lettuce in the Field?
Fresh Cut
June 2003
by Ralph Schneider
Why clean and core iceberg lettuce in the field during
the harvesting process instead of afterwards at the processing plant?
First and foremost, this process increases yield. Less
useable product is damaged during handling and transport to the processing
plant. Second is labor savings. The head of lettuce does not have to be
handled twice, once in the field and again in the processing plant. The
third benefit is to leave most of the culls/waste in the field. There
is a significant reduction in the amount of culls/waste the processing
plant has to handle and throw away.
My interest in this practice began in 1989 when I could
not get a satisfactory answer to the question, "Why is the cull chute
at the fresh-cut plant full of lettuce that was in perfect condition a
few hours ago when the harvest worker cut it from the ground?" Further
investigation of field harvesting and transportation practices refined
this question to, "Why are we damaging so much of the best, greenest
part of the lettuce in transportation and handling?" Interestingly,
back then, even when the cull and labor issues were acknowledged, the
yield issues were generally unrecognized or misunderstood.
Closer Examination
Look closely at the traditional methods of harvesting. A worker on a lettuce
harvesting crew bends down and cuts a whole head of iceberg lettuce from
the ground and then proceeds to cut off the large, weathered "wrapper
leaves." Assuming there is no other damage or disease to the head,
this person now holds in his or her hand a head of lettuce consisting
of 85 percent useable lettuce and 15 percent core. (An aside: In 1991-92,
I was able to quantify the amount of lettuce being lost in handling and
transport with statistical process control testing in the field and processing
plant. Give or take a couple of percentage points, no one has ever questioned
these results.)
Next, the worker would either throw the head into a harvest
bin located on a truck or place the head on a conveyor, which would elevate
the head and drop it into a harvest bin on a truck. In either case, a
number of leaves would be damaged and/or fall off the head. After transport
to the processing plant, the bin full of lettuce heads would be dumped
onto a conveyor, further damaging and/or knocking off more leaves. The
resulting yield at the local plant would be between 65 percent and 70
percent. The difference between the potential 85 percent in the field
and the actual 65 percent in the processing plant is what I observed going
down the cull chute back in 1989.
This practice remains unchanged today for harvesting bulk
bin lettuce.
Field Process Today
The practice of cleaning and coring lettuce in the field today consists
of the following procedures:
" Performing the cleaning and coring operations in
the field so the head is not handled again at the processing plant.
" Leaving the waste on the ground, thereby vastly reducing the amount
of waste the processing plant has to handle and throw away.
" Transporting the head (gently) into a 600-lb. plastic harvest bin
or (even more gently) into a 40-lb. plastic tote.
" Spraying the cored cavity in the head with sanitized water. This
is necessary in order to keep the cored area from browning during transport
to the processing plant.
Also, the product is inspected by the workers at every
step along the way to ensure that 100 percent useable product goes into
the bin or tote. Further, the product is inspected at the processing plant
after being dumped from the bin or tote and on its way to the cutting
operation. I use 95 percent yield in my spread sheet.
This practice of spraying the core cavity reveals the
fundamental weakness of using bulk, cleaned and cored lettuce in regional
processing plants. For example, if the cored area is discolored when it
arrives back East and needs some 'touching up' on the regional plant's
lettuce line, this will add to the cost and reduce the yield. Regional
processors have reported to me that bulk bins of cleaned and cored lettuce
often require 'touching up' and that yields range from 85-88 percent on
product that was nominally 100 percent useable when it left the West Coast.
This begs the question: Even if the core area is not discolored
when it arrives at the regional plant, should the product be 'touched
up' anyway so some of the product won't discolor prematurely in the bag?
My personal opinion is that regional processors cannot
fully avail themselves of the economic benefits of the practice of cleaning
and coring lettuce in the field and are at an economic disadvantage vis-à-vis
the so-called source processors. I use 85 percent yield in my spread sheet
for regional users of bulk, cleaned and cored lettuce.
System's Weakness
To be thorough, I should point out a potential weakness of cleaning and
coring lettuce into harvest bins. If the cored heads are placed on a conveyor
which drops them into the harvest bin just like it is done with whole
heads, there is still the potential for leaf separation and damage, perhaps
even more so than with whole heads because the core is no longer holding
the head together. Totes, like cartons, are filled by manually placing
each head into position in the tote - no bouncing and banging going into
the tote and far less when being dumped out.
While the argument can be, and has been made, that using
totes ensures better protection and quality than bins, clearly, using
totes is more labor intensive. I don't come down on either side of this
argument. I think the 600-lb. tote (bin) and the 40-lb. tote are both
the wrong size for the job. The systems in use today are designed to accommodate
existing totes rather than optimized for quality and productivity with
a purpose-built tote.
My Cost Analysis of Cleaned and Cored Lettuce vs. Bulk
Bin Lettuce spread sheet only covers raw product cost and labor cost savings.
The cull savings are not included. In fact, I've never calculated them.
They are dependent on the individual deals that companies make with ranchers,
farmers, landfills, etc. One fresh-cut company CEO told me he never bothered
to figure out the cull savings because the savings from just the yield
and labor were more than enough to justify cleaning and coring lettuce
in the field.
Editor's Note: Ralph Schneider has worked for
a host of fresh-cut operations during the last two decades. His start-up
company, Mongoose Onions, will begin processing fresh-cut green onions
this fall.
© 2003 Columbia Publishing
Innovations
in Produce Packaging Technology
Fresh Cut
June 2003
By H. Louis Cooperhouse
The tremendous growth in the fresh-cut produce industry over the past
15 years would not have occurred if it were not for advances in packaging
technology. The development of the branded cut lettuce category, in particular,
acted as the catalyst that helped to launch the entire fresh-cut industry
and ushered in the new generation of convenience foods that are available
throughout the food industry today. Cut lettuce products will continue
to account for a significant portion of category sales volume for the
near term, but their success has opened the door for new opportunities
in other packaged fruit and vegetable products. The convenience of product
use, and the variety offered in prepackaged items, has changed consumer
purchasing behavior and created "halo" effects for other prepackaged
products.
Evolution of the Produce Aisle
The produce aisle will continue to transition from a commodity to a branded
orientation over the decade ahead. Packaging technology will play a central
role in how these brands are displayed and communicated to the public.
In addition, packaging technology will serve as an integral part of the
product's overall HACCP program and will be key in providing maximum attainable
levels of product safety, quality and shelf life.
In the years ahead, the fresh-cut category is projected
to evolve considerably because of continual advances and applications
of packaging technology. New fresh-cut fruit offerings are now available,
such as pre-cut melons in party trays with a 10-14 day shelf life and
pre-sliced apples with a 3-6 week shelf life. Innovations in packaging
technologies have created new marketing opportunities as well, such as
component products that allow the user to combine fresh and processed
ingredients for a "freshly-prepared" or "freshly-assembled"
salad product. Such products are now being offered to foodservice operators
and retail customers, in which fresh and/or processed ingredients, dressings
and/or seasonings are separately packaged and combined at store, on the
go, or at home. These freshly prepared component kits provide products
not previously available, such as Chicken Caesar Salad or a Chef Salad.
Packaging Hurdles
The packaging stage of manufacturing offers a number of highly differentiated
options for the food processor. These packaging hurdles include modified
atmosphere packaging (MAP), clean room packaging, packaging materials,
active packaging systems and intelligent packaging systems. Used alone
or in a combination, these technologies can be employed to improve product
quality and/or safety. Application of these technologies, and the incorporation
of a complete HACCP system, will enable the marketability of a wide array
of new product offerings for consumers in the years ahead.
Modified Atmosphere Packaging
MAP is used regularly today as a hurdle for value-added produce, but differs
dramatically in its application based on whether the product being packaged
is still respiring or if it has been inactivated by cooking, blanching
or other such processes. In the MAP process, product is packaged in an
atmosphere that is different from that of air. Air normally contains 78.08
percent nitrogen, 20.96 percent oxygen and 0.03 percent carbon dioxide.
Frequently, MAP is a two-stage process. It begins when
a vacuum is first pulled on the product so that as much oxygen as possible
can be removed from the system. This is then followed by a "back
flush" of nitrogen and/or carbon dioxide and/or other gases. Nitrogen
is used as a sterile filler gas to dilute the concentration of carbon
dioxide and oxygen in the package. Carbon dioxide has bacteriostatic and
fungistatic properties, but at too high a level the formation of carbonic
acid can give the product an acid taste over time; package collapse may
also occur.
Variations of the MAP process exist, including controlled
atmosphere packaging (CAP), vacuum packaging (VP) and vacuum skin packaging
(VSP). CAP is an active system that continuously maintains the desired
atmosphere within a package throughout the shelf life of a product. VP
is a form of MAP in that it reduces the amount of air contained in a package
yet doesn't replace the diluted air with a predetermined mixture of a
new gas. VSP uses a highly flexible plastic film that molds itself to
the contours of the food being packaged.
MAP via reduced-oxygen may be a technology chosen to help a fresh-cut
processor achieve a much longer shelf life. However, because MAP results
in a dramatic change in the time it takes for product to spoil, and the
type of bacteria that will cause this spoilage, it creates significant
additional risk as well. Conditions can be created in which an anaerobic
pathogen such as C. botulinum can grow, produce toxin and cause food-borne
disease. This is due to a number of factors such as extremely low oxygen
levels, prolonged shelf life and potential for temperature abuse. However,
incorporation of other barriers and microbiological challenge studies
will minimize such risks.
Packaging Materials
Packaging materials may contain enhanced barriers to oxygen, moisture
and/or light and may have anti-fog capabilities to reduce condensation.
Laminated materials are widely used in the industry today. They are manufactured
by bonding two or more layers together with adhesives in which each layer
performs a particular role. Microperforation is a technology that can
be used with high-respiring fresh-cut produce. It offers high moisture
vapor transmission rates for products like cauliflower.
Produce commodities are often classified by their respiratory
requirements. Potatoes, radishes and tomatoes are generally considered
low respirers, while asparagus, broccoli and mushrooms are considered
heavy respirers. Once commodities are cut and handled, product deterioration
accelerates. As the respiration rate is increased, the tissue becomes
more susceptible to oxidative discoloration and microbial growth is enhanced.
By reducing a product's respiration rate, senescence (the ripening process)
can be delayed. Packaging plays a unique role by matching the respiration
rate of the product with the transmission rate of the packaging material.
By definition, the transmission rate is the rate at which a gas like oxygen
or carbon dioxide passes through a given material. It is critical to match
the oxygen transmission rate (OTR) of the packaging material with the
respiration rate of the product.
New innovations are on the frontier in which antimicrobial
agents are being incorporated into films. Agents that have been tested
and which have shown efficacy include: carbon dioxide, sulfur dioxide,
grapefruit seed extract, nisin, lysozyme (an enzyme found in eggs) and
allyl isothiocyanate (a component found in horseradish oil). Challenges
exist with respect to optimizing the release of the antimicrobial agent,
while ensuring minimal flavor migration and maintaining desired gas permeation
rates.
Clean Room Packaging
A "clean room" is an area in which a statistically defined level
of particulates (like dust, bacteria, molds, etc.) is permitted in the
air. The level is measured as the number of particles per cubic foot of
air according to a federal standard. In the food industry, it is typically
most relevant to install a clean room within the packaging area of the
plant as a way to minimize post-processing contamination. Positive air
pressure in the packaging area and HEPA (High Efficiency Particulate Air)
filters over 99.97 percent effective for particles one micron or less,
will create a clean-room atmosphere. Makeup air is one of the central
issues in maintaining clean airflow in the processing plant. The highest
positive, filtered air pressure should be where the product is last in
touch with the environment, normally the packaging area. Air should flow
from processing/packaging to raw material preparation to raw material
receipt in one direction and should be positive to the outside.
The effects of a clean room can be quickly compromised
by the actions of employees in the same area. Other mitigating factors
include the movement of materials in and out of the clean room and the
manner of air distribution. Clean room procedures, and the entrenched
training regarding "high risk" and "low risk" locations
and practices, are very common in European refrigerated food factories
and serve as outstanding models for refrigerated foods manufacturing and
employee training.
Active Packaging Systems
Many advances in active packaging have occurred in recent years and many
more are forthcoming. Active packaging technologies involve an interaction
between the packaging used and the food and may include a visible or invisible
packaging additive that extends the food's shelf life and quality.
Oxygen scavenger systems work in concert with the MAP
process to reduce the residual oxygen level to minimal levels. New oxygen-absorbing
films are now available, are "invisible" to the consumer and
can increase the shelf life of products by 50 percent. The film remains
dormant until it is activated on the packaging line by ultraviolet lights
that trigger the scavenging reaction through a patented activation process.
Many consumers find stand-alone sachets with "do not eat" and
other necessary language, or a sachet affixed as a pressure-sensitive
label to the inside of "lidding" material, as unsightly and
will find this invisible solution much more to their liking.
Many other forms of active packaging systems exist. Desiccants
and other moisture control systems adsorb water vapor from the air or
are in the form of pads that absorb moisture as it drips from the product.
Carbon dioxide generating or scavenging systems also exist and are appropriate
when the maintenance of a high carbon dioxide level is desired.
Intelligent packaging systems
Intelligent packaging systems are sensors that provide information about
the product to the consumer, foodservice operator or other user. The most
widely known intelligent packaging system is the time temperature indicator.
Various types of commercialized indicators have been used as a visual
tool that correlates with the acceptable quality, or lack thereof, of
perishable foods. These indicators track the relationship between time
and temperature and their impact on spoilage or some other end-point of
product acceptability.
New types of indicators are being developed that signal
product quality directly rather than depend on a consumer's inference
of quality from temperature history. Next-generation freshness indicators
are able to potentially detect specific foreign materials in packaged
products, such as bacteria, pesticides and proteins resulting from genetic
modification. Although this technology has not yet been marketed, grocers
and their customers may ultimately be able to determine if a specific
pathogenic bacterium is present in a packaged food.
Other systems under development use an enhanced bar code
format to screen products susceptible to spoilage from the time they are
packaged until the time they are removed for preparation. Bar code readers
at any station in processing or in retail markets will be able to automatically
reject any product that reflects a positive reading for potential or actual
contamination. This system embodies well-established immunochemical techniques,
but provides an innovative delivery system. A membrane impregnated with
antibodies with specificity to selected pathogenic organisms becomes an
integral part of the bar code itself, making the bar code no longer readable
if a particular organism is present.
Just like time temperature indicators, these innovations
in intelligent packaging will need to demonstrate that their activation
correlates with actual temperature abuse or pathogenic contamination.
Nevertheless, these are promising signs of the types of innovations that
will result in an improvement in the safety of our food system.
Editor's Note: Lou Cooperhouse is director of
the Food Innovation Research & Extension Center of Cook College and
the New Jersey Agricultural Experiment Station at Rutgers University.
He has also recently published a comprehensive study entitled, "Retail
Prepared Refrigerated Foods: The Market and Technologies." For further
information, contact Cooperhouse at (732) 537-1901 or at cooperhouse@aesop.rutgers.edu.
© 2003 Columbia Publishing
Growing
Profits Through Packaging
Fresh Cut
June 2003
By Bob Koch
Director - Food Group
Multivac Inc.
When baby-cut carrots were introduced to the market, they
transitioned a vegetable from a packaged commodity to a ready-to-eat snack.
The product offered convenience to customers and new possibilities of
profit for fresh-cut processors and growers. Packaging technology can
help processors make a similar transition with a wide range of fresh-cut
products.
From new options in extending shelf life to offering greater
convenience to consumers, fresh-cut packaging is becoming more sophisticated
to meet evolving needs of consumers. From automated rollstock systems
to high-speed traysealers to compact vacuum chamber machines, understanding
a few key trends in packaging system technology can help processors and
growers use this trend to grow profits.
Extending Shelf Life
Modified Atmosphere Packaging (MAP) is usually referred to as any technique
that alters the air in a package to extend the shelf life of a product.
For fresh-cut products, this can mean anything from oxygen elimination
and gas flushing to using special property films that can breathe and
regulate moisture while protecting products from contamination. MAP offers
tremendous marketing opportunities for fresh-cut brands.
For instance, pre-made leaf salads offer customers an
alternative to both making salads at home or going to an in-store salad
bar. New MAP technology protects the freshness of products longer than
open shelves and also offers peace of mind to customers because sealed
packages are more tamper evident.
Pre-cut fruit, such as melons or even apples, can be sliced
and specially packaged in a modified atmosphere to preserve a fresh-picked
look, feel and taste. Again, this offers consumers a more convenient way
to purchase and eat fresh-cut products, and it also offers an entirely
new perception of the product. Like the baby-cut carrot, a person may
not think about sliced fruit as a convenience store snack until they see
it in a package washed, sliced, protected from bruising, and ready to
eat.
There is a wide range of automated packaging systems that
enable producers and processors to implement a MAP technology solution.
Multivac offers rollstock thermoform systems as well as
automatic and semi-automatic traysealers and vacuum chamber systems. All
of these systems come standard with MAP capabilities and can help processors
incorporate MAP into a packaging line efficiently. Fresh-cut applications
vary, so finding the system that best suits the needs of the product is
key.
Finding the Right Solution
A wide array of options exists to package fresh-cut products. Depending
on product, producers can choose the best solution for branding and re-branding
products. Thermoform Fill and Seal (TFFS) is an example of technology
that allows packagers to efficiently create custom packaging for products.
Virtually any size or shape can be created using the thermoforming process.
Forming dies can be rapidly changed to accommodate different packaging
needs.
For fresh-cut producers, TFFS offers truly unique benefits.
Since the process is so flexible, products can be packaged incorporating
different modifications for entirely new products. Dipping trays can easily
be incorporated into a TFFS package along with a tray to hold vegetables.
Dressing compartments can also be easily added.
Also, unique shapes and sizes can be easily created to
reflect a brand concept. Uniquely shaped packages grab attention on store
shelves and help differentiate brands. A TFFS solution can help make that
statement efficiently and with flexibility.
TFFS systems are not the only solution available, and
finding a manufacturer with an array of machinery is key. An example is
Multivac, which offers systems for large and small operations along with
a wide selection of traysealers and vacuum chamber units in addition to
TFFS systems.
Traysealers now come in a variety of sizes and volume
capabilities, making them ideal for many fresh-cut applications. Traysealing
is very often preferred to TFFS machinery because the product can be put
in the tray at the point where it is cut, and then conveyed to the machine
without damaging the product. Vacuum chamber machines are another option
for smaller volume premium products. All of these options offer their
own unique benefits. Matching those benefits to your needs is key to successfully
packaging fresh cut products.
Selling Convenience
Visuals are only one solution to differentiating a brand and diversifying
a product. Cooking convenience can be a potent tool to attracting attention
to your product and driving sales. Cook-in-tray options and special steam
valves turn a fresh-cut product into an easy-to-prepare and healthy component
of the dinner table.
Resealing options also have become easier to incorporate
into an automated packaging line. Multivac recently developed a system
for incorporating a slider zipper into it horizontal form fill and seal
system, the first ever. The results are that easy to open and close slider
zippers will be easier to incorporate into a packaging line. Customers
can cook, consume and reseal products from the same container. Multivac
also continues to manufacture press-to-close zipper systems that are employed
in similar applications.
Profit margins are higher on these products and for good
reason. Consumers increasingly want to strike a balance between convenience
and health. Offering an easy method of cooking vegetables in a tray with
fresh, great tasting results is just another way packaging can change
consumer outlook on fresh cut products.
Finding Partners
Stepping up to a sophisticated packaging concept may seem like a daunting
task. But, there is good news for both the packaging floor and the marketing
office. These solutions are good for both sides, which rarely see eye-to-eye.
Thermoforming, traysealing, modified atmospheres, and
convenience options are all processes that benefit production with more
automation, less downtime, and greater protection of the product. For
marketing there is great flexibility to alter packaging, add features
and produce different types of products on the same machine.
Both parties also have partners to help design packages
and master the machinery. Training and before sales consulting and after
sales support can help put together a packaging solution for operations
large and small. Multivac University is a free service for Multivac customers,
as well as a consulting service for packaging design, that can help marketing
vision come to life.
Market the Technology
Some producers may shy away from technology because it seems to contradict
the fresh and pure marketing perception of fresh cut. This is a mistake.
There is tremendous marketing opportunity in introducing the technology
behind the freshness.
Educating consumers on the technology behind the freshness
on the package or at point-of-purchase generates interest and differentiates
brands. Branding packages that keep products fresh, articulates the benefits
of packaging and offers another interface with your company.
Consumer buying habits are rarely static, and introducing a new way of
looking at a product can be a great branding technique. First introductions
that are positive often foster long-time loyalty to a brand.
Conclusion
The next baby carrot may not be just one type of vegetable but a kind
of revolution in the industry. As consumers search for easier ways to
eat healthy, the fresh-cut industry can position itself as a healthy,
convenient alternative to fulfill that trend. With the right packaging,
that trend in health and convenience could turn into a convenient healthy
path to profits for fresh-cut growers and processors.
© 2003 Columbia Publishing
Cold
Chain Management Provides Value-Added Tool to Shrink Your Shrink
Fresh Cut
June 2003
By Stephen K. DiRubio
Vice President and General Manager -
Food, Sensitech Inc.
Shrink is an ongoing concern for purveyors of consumable
goods, whether it's theft in the broad world of retail or spoilage in
the world of perishable products. For sellers of produce, it doesn't matter
whether the goods actually spoil and "go bad" or if they simply
lose their key quality attributes and look, smell, and taste bad. The
end result is the same: the produce can't be, or shouldn't be sold and
the retailer loses money.
In general, losses due to shrink in perishable categories
occur for one of the following reasons:
•Theft
•Physical damage to the product
•Code date expiration
•Spoilage (This can include products that are still within the code
date but must be discarded from inventory due to improper temperature
handling which results in quality degradation.)
The last two factors - code date expiration and spoilage
due to temperature abuse - are the primary causes of shrink for the fresh-cut
industry. Fortunately, we can do a great deal to manage the issue of spoilage
due to ineffective cold chain management. In fact, we can increase the
useable life of many fresh-cut products. The key lies within aggressive
cold chain improvement programs where experience shows we can reduce shrink
for key categories as much as 30 percent to 50 percent. That difference
can boost margins significantly for retailers and will drive growth of
the category through improved customer perceptions of freshness. In short,
it improves top line and bottom line performance.
Traditional Approaches to Reduce Shrink
Typically, shrink in the fresh cut industry ranges from 10-20 percent,
but it varies widely stock-keeping unit (SKU) to SKU. For example, shrink
for a high volume SKU, such as a one-pound garden salad, may be 2-3 percent
while for slower moving gourmet produce items it may be as high as 50
percent.
Traditionally, retailers concerned about perishable shrink
attack the problem by manipulating inventory levels downward. By dropping
stock levels and increasing inventory turns for target SKUs the retailer
reduces the risk that the product will pass code or degrade below acceptable
quality levels prior to sale.
However, this often proves to be too blunt a tool for
attacking shrink because it almost inevitably leads to an increase in
out of stocks. It also becomes much more difficult to maintain the variety
in key categories that consumers expect. Lower volume SKUs are, of course,
extremely vulnerable to efforts to reduce inventory levels. Therefore,
it becomes difficult to continue carrying such products.
With this dynamic in mind, it is understandable that those
charged with keeping eyes on supermarket financial performance can be
a bit skeptical about initiatives to substantially cut shrink. Their position
is that the perishable shrink number and the out of stock number sit on
each end of a seesaw. If a retailer aims to bring one of these key metrics
down, the other has to go up, and vice versa. It becomes a sort of shell
game where an undesirable financial metric is shifted from one place to
another and back again.
However, initiatives to control perishable shrink doesn't
have to result in increased out of stocks. There is a very different approach
that attacks the spoilage issue head on. By better managing temperature
and cold chain processes, retailers and their supplier partners can reduce
spoilage or quality loss without having to manipulate inventory levels
and risk out of stocks.
Cold Chain Management
The concept of cold chain management begins with temperature monitoring
- a process that most retailers understand and embrace. However, cold
chain management goes beyond the collection of temperature data on a single
truck trip. It involves identifying where breakdowns in the entire cold
chain occur, so that process improvements can be made - often at a modest
cost - to achieve significant financial benefits.
The cold chain for fresh-cut produce involves a group
of fairly standard processes. It starts with harvesting and cooling, can
include transport to plant, continues on to processing and packaging,
then shipment to customer, on to intermediate warehousing, then transport
to supermarkets or restaurants, and finally to store level storage, handling
and merchandising.
Moving a single case of product from production through
to the supermarket shelf or restaurant kitchen may involve more than a
hundred individuals, dozens of pieces of refrigeration equipment, several
different vendors and multiple facilities. The path to reduced product
shrink and enhanced freshness requires managing each of the key processes.
The nuts and bolts work of measuring and improving each of these key processes
is where retailers and their supplier partners must focus their effort.
Cold chain management remains an industry-wide challenge
despite the fact that reliable mechanical refrigeration is readily available
and has been used widely in food distribution for over 40 years. In general,
the problem is not the refrigeration systems themselves, it is in the
process of managing the cold chain - how we move product through the various
refrigeration systems and how we operate and maintain those refrigeration
systems.
In fact, this is the good news - if improved cold chain
performance were dependent solely on the capital-intensive process of
replacing or upgrading refrigeration systems - meaningful improvement
would be largely out of reach. But, in fact, when the key handling segments
are intensively measured and analyzed, the corrective actions often turn
out to involve much more manageable and cost-effective solutions - adjustments
to procedures, loading patterns, product flows, storage practices - to
name a few.
Cold chain analysis can help retailers identify breakdowns
in the distribution system. It pinpoints what process (not just which
equipment) is involved, and what happens in different distribution segments.
This "process mapping" information goes beyond just transportation
and looks at events such as what happens at product hand off points.
For example, it's useful to examine the process that occurs
when trucks arrive at distribution centers. Proper temperature control
on a 1000-mile truck trip can be undone if the process of unloading the
trailer and moving product in to proper storage conditions is mismanaged.
Other improvements come by more closely managing vendor
performance. One example involves a large national food processor. By
applying techniques of measuring and analyzing cold chain performance
over time, it became clear that one of their contract transportation vendors
had several trailers that always ran a little warmer than the rest of
the fleet (hovering closer to 40 F than to 34 F).
Further investigation revealed that this sub-group of
trailers was among the oldest in the company's fleet. They had damaged
door seals and degraded insulation. Armed with this information, the processor
convinced the vendor that the sub group of trailers should no longer be
used when hauling their product. Immediately thereafter, substantial improvement
in performance was seen in that segment of their distribution chain.
Shrinking the Shrink
In the world of food retailing, there are fewer and fewer ways to produce
more profit out of already tight margins. Reducing shrink is one of those
ways, and making those improvements through non-traditional means, such
as cold chain management. This also offers retailers new avenues to improve
financial performance and also achieve a competitive edge based on an
enhanced reputation for perishable product freshness and quality.
As noted above, our experience points us to potential
reductions in shrink of as much as 30-50 percent for key categories and
SKUs. This savings not only provides direct financial and competitive
benefits to participating retailers, it enhances the financial performance
and relevance of the fresh-cut industry as a whole.
Editor's Note: Sensitech (www.sensitech.com)
is a world-leading independent provider of cold chain information and
analysis.
© 2003 Columbia Publishing
>>
Return to top
Gills
Onions Celebrates Its 20th Anniversary
Fresh Cut
July 2003
To think it all started with salsa - La Victoria salsa,
to be exact. The Gill brothers, Steve and David, were growing peppers
for the salsa giant in 1983 when the manufacturer approached them about
growing onions as well. Soon they found themselves peeling onions for
La Victoria and a business was born.
Fast forward 20 years and you'll find an onion business unparalleled in
the industry. Gills Onions currently ships products - diced, sliced, slivered,
whole-peeled and ready-to-bloom - to the industrial, foodservice, wholesale
and retail markets. Packaging options include resealability, pillow packs
and tray packs in a variety of sizes. Growth strategies include strict
quality standards, innovation and diversification.
"We are getting more and more recognized as a quality processor and
continue to build business," explains Steve, who serves as president
of Gills Onions. "Early on, when learning to process onions, there
was a lot of trial and error, but now we are really proud of the quality
we can ship nationally on a year-round basis."
Focus on Onions
Gills Onions is somewhat unique in the processing world because all it
does is process onions. Yet, sales and marketing strategies, coupled with
exceptional product quality, seem to make it work, according to Susan
Schmidt, director of sales and marketing.
"Strategically, it makes sense for us right now to be the country's
leading supplier in fresh-cut onions," she says. "Our proprietary
technologies give us a competitive advantage. Some 'me toos' are starting
to pop up out there, but we can be more competitive because of the superior
quality and the fact that we can offer national programs."
Other key strategies such as cross docking in a variety of locations -Salinas,
Yuma, Los Angeles - also help make it work, she adds.
According to Gills' customers, doing just one thing and doing it well
is a smart way to go. That seems to be the view of Manny Furtado, vice
president of produce operations for Hallsmith Sysco, Norton, Mass.
"Gills Onions product quality is excellent and consistent,"
Furtado says. "For some reason, its onions are always more fresh
and look and taste better, even compared to the onions I buy locally.
Gills also offer a variety of packaging options, which helps sell my customers.
Some operators like to use a tray pack and some resealable packaging.
Gills has everything we need."
Wrote Their Own Textbook
When the Gill brothers first began processing onions, there was no textbook
to go to, no research papers done by food scientists and no product out
there to copy. Learning through trial and error, it was determination
that allowed the Gills to build both a business and an entire category.
"Fresh-cut onions weren't really done before on a national level,"
explains Steve, "and at first it was tough convincing buyers we could
do it. But the fact is we do it and we do it every day.
"In the beginning, we would recommend that customers start with whole
peeled. Soon, they were moving into different cuts as well. Once they
get started on the products, they get hooked," he smiles.
Gills' onions are processed year-round in a 95,000-square-foot, state-of-the-art
facility in Oxnard, Calif. Framed certificates from a myriad of food safety
auditing companies line the production office walls, all reflecting that
Gills has received their top ratings. The plant is kosher certified, and
a quality assurance staff and onsite laboratory make sure there is strict
adherence to all procedures.
"Our plant features all of the latest technology and food safety
procedures, but we also are proud of our employees," Schmidt adds.
"Many have been with us for 10 to 20 years, so they are onion experts
themselves."
Managing Growth
Managing growth is one of the biggest challenges the company continues
to face. Planning on how to build the next level of the business is a
key role for Steve.
"Plants are expensive to build. You can quickly run out of room,
so forecasting sales growth and planning building projects, which can
take up to two years to get built and into production, is a challenge,"
he says.
Gills Onions also fabricates most of its own equipment, including peelers
and slicers, no small challenge in itself.
But producing the finest quality fresh-cut onions is only part of the
Gills Onions' success story. Getting the attention of buyers and servicing
accounts both large and small is done by a hard working group of sales
and marketing professionals. Their customer roster is a literal "who's
who" of the buying world.
Hallsmith Sysco's Furtado comments: "(Gills') service is fantastic.
They are always willing and ready. They have someone available locally
and they support our food shows and training programs."
Gills Onions is a well-known sponsor of many industry events and an exhibitor
at many leading trade shows. Whether it's passing out tissues, serving
killer fajitas or throwing fun parties, Gills Onions is definitely an
industry player.
Steve is a past chairman of the International Fresh-cut Produce Association
and David previously served as chairman of the Western Growers Association.
He currently serves on the Produce Marketing Association's Foodservice
board of directors. Schmidt is chair of IFPA's Publicity Committee and
recently joined the board of directors of the Produce for Better Health
Foundation. Nivia Santiago is on the IFPA technical committee and Nelia
Alamo has served on an IFPA conference planning committee. This industry
participation is strategic for Gills Onions.
"We think it's important to participate in industry groups,"
says Steve. "It puts us right on the edge of what is going on. We
like to set the agenda. We like to lead."
With a solid track record of quality, innovation and service now spanning
20 years, it's clear that the Gills Onion slogan rings truer then ever.
If you are still cutting your own, it is a crying shame.
© 2003 Columbia Publishing
Rio
Farms: The Sister in the Family
Fresh Cut
July 2003
Gills Onions is a vertically integrated company, somewhat unique in the
processing world. Rio Farms is the growing side of the business.
Rio Farms acreage has doubled over the years, according to David Gill,
partner, and while the crops grown continue to diversify, onion acreage
has increased 20 times over since 1983. Today, onions represent about
20 percent of Rio's overall acreage.
"We plant the majority of the onions in the spring and then we plant
in the fall, so forecasting is crucial," David explains. "We
focus on yields and try to estimate future sales. Sometimes overplanting
is required to ensure availability. Weather and business growth are hard
to predict."
Steve Gill echoes those feelings: "I think having vertical integration
is the only way this business will work. Onions are different because
they are only planted two times per year."
Currently the Gills are looking to source and grow sweet onions on a year-round
basis to meet customer needs.
While processing techniques and packaging technology play key roles, the
Gills don't underestimate where quality assurance needs to start-in the
field.
"Our focus on yield and quality begins with seed selection, followed
by good crop management," David points out. "Our focus on quality
starts in the field."
According to American Vegetable Grower magazine, Rio Farms is the sixth
largest grower west of Colorado with close to 15,000 acres in production.
© 2003 Columbia Publishing
PMA
Foodservice Conference, Tours & Expo Set
Fresh Cut
July 2003
Fresh-cut industry leaders seeking the latest research
on emerging foodservice trends and structural shifts should plan to attend
the Produce Marketing Association's 2003 Foodservice Conference, Tours
& Expo, July 12-14 in Monterey, Calif.
Among those registered to attend this year's proceedings are commercial
and non-commercial foodservice operators, restaurant owners, chefs, menu
developers, buyers, purchasing managers, distributors, wholesalers, brokers,
consultants, processors, grower-shippers, packers and more.
This year's educational program includes a preview of PMA's most recent
Fresh Track research study, the first to examine the foodservice produce
industry. Cornell University researcher Debra Perosio and PMA President
Bryan Silbermann will be sharing findings from the study during the Monday,
July 14, luncheon general session.
Issues to be discussed include changing distribution patterns and market
share, as well as evolving business practices in the areas of procurement,
menu development, vendor alliances and supply chain management.
Following the FreshTrack general session, three concurrent, interactive
workshops have been scheduled. They will focus on:
" Applying FreshTrack Data to Businesses. Led by Cornell's Sandra
Cuellar and Debra Perosio, this follow-up session will take a closer look
at the findings from this year's report.
" Strategic Planning. Led by Julie Krivanek, Krivanek Consulting,
this session will show participants how to analyze the forces and trends
that affect their companies, as well as how to avoid the common pitfalls
of planning.
" Customer Relationship Management (CRM). Led by Don Neal, Rapp Collins
Worldwide, attendees will see actual examples of companies that are using
CRM to transform their organizations from product-centric to customer-centric.
They will also learn how to apply proven tactics to build a foundation
for 2004 that sets them apart from the competition.
The learning aspects of the PMA Foodservice Conference are not limited
to the general session and workshops. On Sunday, July 13, three chefs
will conduct 12 demonstrations of new fruit and vegetable recipes. Attendees
will gain new menu ideas on how they can move produce to the center of
the plate, and learn first-hand how fruits and vegetables can enhance
meals and menu offerings.
On Monday, July 14, four distinct and unique field tours of various growing,
processing and packing operations in the Watsonville and Salinas areas
will be held. While the tours are being conducted, PMA also will be offering
a special leadership session focusing on practical, effective strategies
to use in managing multi-generational workforces. The speaker will be
Meagan Johnson of the Johnson Training Group.
On July 11-12, prior to the 2003 Foodservice Conference, Tours & Expo,
PMA will hold a Fresh Produce Academy education seminar for foodservice
operators and distributors. The Fresh produce Academy is accredited for
16.5 continuing education hours toward certification renewal by the American
Culinary Federation.
Complete event information for the PMA 2003 Foodservice Conference, Tours
and Expo is available in the Events area of the PMA Web site: www.pma.com.
© 2003 Columbia Publishing
Neogen
Playing Key Role in Fresh-cut Food Safety Testing
Fresh Cut
July 2003
With food safety issues a major concern in the United
States today, Neogen Corporation, Lansing, Mich., has been at the forefront,
testing everything from fresh-cut fruits and vegetables to meat products
and grain for possible contaminants.
The company was founded in 1982 by James Herbert and venture capitalist
Herbert Doan, a past CEO/president of Dow chemical Company.
One of the first products Neogen developed was a rapid test for growers
to use to detect aflatoxin (a mold toxin) in grain, according to John
Van Arsdale, director of sales for the company's Commercial Laboratory,
Dairy, Produce and Beverage. For nearly 20 years, Neogen has been working
with growers and processors worldwide to develop easy-to-use diagnostic
tests to improve the safety and quality of food products.
"As the popularity of uncooked, ready-to-eat products steadily increased,
companies in the fresh-cut/value-added arena saw the increasing need to
test for dangerous bacteria, pesticides, food allergens and other contaminants,"
Van Arsdale points out. "Neogen was already well established and
known for its tests for these contaminants in closely related food arenas,
so we were well-positioned to fill the testing needs of companies in the
fresh-cut/value-added business."
A Major Resource on Safety Concerns
Today, Neogen is a major resource to fresh-cut processors with food safety
concerns. Nineteen of the top 20 U.S.-based food companies are currently
using Neogen products to help ensure product quality and safety, Van Arsdale
says.
Neogen's Fruit & Vegetable Group's customer base is evenly split between
foodservice and retail. As a whole, it's Food Safety Division includes
thousands of companies that produce, process or market food or animal
feed of endless varieties.
Neogen currently develops, manufactures and markets rapid test kits and
dehydrated culture media used by companies in the fresh-cut/value-added
industry to help ensure product safety and quality. Its rapid test kits
detect general sanitation problems, pesticides and dangerous bacteria
such as E. coli 0157:H7, Salmonella and Listeria.
The company's general sanitation test, Biotrace's Uni-Lite XCEL, detects
adenosine triphosphate (ATP), a by-product of all living cells, Van Arsdale
explains. In a matter of seconds, the test can determine if a food contact
surface has been cleaned thoroughly enough to minimize the risk of shipping
contaminated product.
A dehydrated culture media is used to grow bacteria to detectable levels,
he explains. Very small numbers of bacteria in food products can grow
to levels that can cause illness by the time they are ready to be consumed.
The speed and accuracy of Neogen's easy-to-use products consistently impresses
customers, Van Arsdale exclaims. Instead of waiting days for feedback
from an outside testing laboratory, they can have the same accurate results
often within minutes.
The use and application of the company's testing products varies greatly.
Its sanitation monitoring products utilize swabs to test the cleanliness
of food contact surfaces of all types. Companies, both large and small,
use these products after a sanitation crew has cleaned equipment to "almost
immediately" verify the surfaces are clean and safe.
"Our tests for dangerous bacteria, such as E. coli 0157:H7, are mainly
performed on product samples either at a small on-site company laboratory
or at an off-site independent laboratory," Van Arsdale points out.
"Food processors we work with use a variety of methods to help ensure
their products are safe and of the highest quality possible."
Customer/Industry Driven Research
The development of new products and services at Neogen has been largely
customer/industry driven. Constant customer contact is maintained to make
sure there is full awareness of food safety concerns.
"Our customers regularly provide feedback about the improvements
to our products that would be helpful to them as well as new products
they could use," Van Arsdale says. "The trend is toward even
faster and easier-to-use, testing products. Our goal is to produce tests
that can by performed by virtually anyone and yet provide instantaneous
results. We're real close to that with some products, such as our test
for ATP. However, we have a ways to go with others."
The company has been highly successful in shortening the time necessary
to obtain results, while improving the sensitivity of its tests. Either
through development or acquisition, additional testing technology has
been added.
Neogen tests are currently used by federal safety inspectors and countless
large, well-known food companies, according to Van Arsdale. "They
are considered the 'gold standard' for the food industry.
"We also offer a 'one-stop shop' of products unique in our business,"
he continues. "A competitor of ours may have a test for this or that,
but none offers the variety of testing products we do. That makes it very
easy for a typical quality control manager in the food industry, for example,
who has a wide variety of contaminant concerns-not just one or two."
Fresh-Cut Industry Is Unique
Part of Neogen's success is attributed to its marketing philosophy which
understands that companies in the fresh-cut industry are much different
than, for example, large meat packers or pet food manufacturers. Each
may buy the same Neogen product, but will have a much different approach
to product testing.
"Our sales representatives are market specialists," Van Arsdale
says. "We require that members of our marketing team become experts
in their markets only. For example, our Fruit & Vegetable Group sells
exclusively to fruit and vegetable producers. We think that sets us apart."
Neogen is currently in the final stages of ISO 9001 certification, expected
by late summer, he adds. With ISO, the No. 1 goal is to ensure that the
company is operating in an organized and efficient manner to produce quality
product and see that customer needs are met.
"The system will help us ensure that we are providing the consistent
quality that our customers expect and that we expect of ourselves,"
Van Arsdale explains. "We are continually working on new developments
with our products, and have new products in development. All of these
efforts have the goal of increasing market share."
As an added bonus to its customers, Neogen provides free training and
24-hour technical support for its products and assistant with the development
of testing programs (e.g., HACCP, SSOPs) utilizing Neogen testing products.
"Since our founding, we've proven to the food industry that our rapid,
on-site testing products are as accurate and reliable as the offsite,
conventional laboratory methods that good companies have relied upon for
many years, says Neogen CEO and president, James Herbert, who has been
with the company since its incorporation in 1982. "We've also proven
that the small expenditure necessary to institute a testing program is
a great investment against the large expenditures, and other consequences,
of a product recall.
"In the future, we want to be an even more important supplier to
our customer base," Herbert emphasizes. "A quick review of food
industry news shows there are still far too many product recalls that
could have been prevented through more, or better, testing. It's clear
there is more work to be done in the field of food safety testing."
© 2003 Columbia Publishing
New
Developments in Fresh-cut Produce Packaging
Fresh Cut
July 2003
By Jeffrey Brandenburg
Since the beginning of the fresh-cut produce industry
improvements in packaging and packaging technology have kept pace with
the industry's desire to provide an ever-increasing array of fresh-cut
vegetables and fruit. This has been driven by the consumer need for convenience
and a push towards healthier eating.
The present is no exception. By the end of this year the industry will
see new products from resin suppliers, film manufacturers and packaging
converters. These new technologies will allow longer shelf lives for existing
vegetable items as well as new items in both the vegetable and fruit markets.
This trend is especially true in the fresh-cut fruit market, where many
of the new technologies will be applied. These technologies have been
detailed in both the IFPA's fall technical seminar and spring conference,
and will continue to be discussed during upcoming events.
Need for Effective Communication
The most significant factor in developing new packaging technology is
not, however, as widely discussed. That development is communication.
As packaging complexity increases, the need for effective communication
between all involved parties increases exponentially. In today's world
of fresh-cut produce packaging the old saying, "Just give me your
salad bag," is gone. Processors are realizing that there is no such
thing as a "one size fits all" salad bag, or any other produce
item for that matter. Today's fresh-cut produce packaging is a complex
combination of resins, film manufacturing techniques/processes and converting
steps. Any number of seemingly insignificant details can significantly
affect the final outcome, properties and "run-ability" of a
fresh-cut produce package.
When designing a fresh-cut produce package different design disciplines
are required. Disciplines can include:
" Plant physiology/post-harvest technology
" Polymer engineering
" Plastic film manufacturing
" Converting (the science of printing, laminating, coating, slitting,
perforating)
" Packaging equipment engineering
Knowledge of Disciplines Needed
A fresh-cut produce packaging designer must have at least a working knowledge
of these disciplines, because it the knowledge of how to best combine
the raw materials, technologies and equipment that will lead to a package
that has all of the desired properties.
For example, a typical retail "salad kit" structure is comprised
of two separate films laminated (glued) together with an adhesive. Inks
used for printing are also often sandwiched between the layers of film.
In order to calculate the proper package oxygen transmission rate (OTR),
one must know and understand the respiration rate of each produce item
to be packaged and all of the resins used in each film as well as how
the inks and adhesives affect the overall transmission rate of the package.
In addition the process of making the resins and films as well as the
converting processes, which combine all of the raw materials, can affect
many of the physical properties, including OTR. The impact on OTR can
even be felt by going from one piece of manufacturing equipment to another
not to mention different manufacturing locations. Even something as benign
as ambient air temperatures at the time of manufacture can have a significant
affect on a film's OTR.
As packaging becomes more complex - to meet the requirements of different
produce as well as a demanding public - the design process increases even
further. For example, many of today's fresh-cut produce packages contain
anti-fog, peel-able properties, re-seal attachments, patches and perforations
(either macro or micro), all of which impact the design process from resin
selection through converting to filling. In addition, incorporating additives
such as antimicrobials, gas scavengers, etc., are being explored.
More Factors than OTR
With fruit packaging monitoring and controlling, OTR is not enough. Carbon
dioxide transmission rates are critical. Therefore, knowledge and understanding
of the beta value (ratio of CO2 transmission rate to O2 transmission rate)
of a resin, film, structure is imperative. Often the raw materials needed
for optimal OTR are not necessarily the same for optimal CO2TR.
In addition the resins, films, processes needed to optimize gas transmission
are often the exact opposite of the materials/processes desired for manufacturing,
filling and aesthetics. A case in point, the higher the OTR in many polyolefins
the softer and more extensible the feel. Therefore the higher the OTR
the further the film's properties are to the marketing mantra of "stiff
and crinkly". Resins can be blended. Processes used to compensate
for this but the designer must be able to understand what impact these
changes in blends will have on the other required properties. In other
words, you do not get something for nothing.
There have also been improvements and advancements in the filling equipment
used to run these structures. One such advancement is increases in filling
equipment-running speeds. This will impact resin and film selection so
that the package can still be effectively sealed at the higher line speed
without increasing "leakers." It can also cause structure properties
not previously an issue or in some cases even known to suddenly become
very critical. For example, as the filling equipment line speed increases,
the coefficient of friction, COF (how slippery a film/structure is) becomes
a very critical parameter. At slow speeds filling equipment can often
overcome if a structure is too slippery or not slippery enough. But as
line speed increases designing and controlling the correct COF into the
package becomes critical. Quality issues stemming from improper COF can
include "leakers," wrinkles, fold-overs, improper package dimensions,
shorter shelf life due to "leakers" and appearance.
Increasing Complexity
Many of the challenges and issues are not new to the packaging industry.
What is new is the increasing complexity and demands being placed upon
the package in order to achieve the ultimate goal(s). If these demands
are to be successfully met the single biggest requirement and advancement
must be the continued increase in effective communication between the
different industries and disciplines. This, although on the surface a
simple notion, is complex when one considers that each industry/discipline
has its own language and jargon. Just getting all of the parties involved
to speak the same language can be a daunting task. There is, however,
an ever-increasing awareness within the fresh-cut produce industry that
if we are collectively going to be successful then this communication
must take place. Effective communication will lead to a better understanding
of all of the parameters affecting a package. Hence, as technical advancements
are made in each of the respective disciplines and industries, they can
be fully utilized to create a fresh-cut produce package that will meet
the needs of both the Industry and the consumer.
Editor's Note: Jeffrey S. Brandenburg is president
and primary consultant for The JSB Group, Greenfield, Mass. The company
provides technical and business consulting for the fresh-cut produce,
flexible and food packaging industries. Brandenburg started The JSB Group
five years ago with a mission to be the leading technology resource for
the flexible, produce and food packaging industries by providing participating
companies with technical, sales, marketing, market research, training
and management support. This is accomplished through expertise in a wide
variety of packaging and equipment technologies, including fresh-cut produce,
MAP, barrier packaging, peelable lidding structures, forming materials,
microwave, stand-up pouch technology and rigid containers. A chemical
engineer, Brandenburg holds a degree from Iowa State University emphasizing
bio-medical engineering.
© 2003 Columbia Publishing
Salads
Still Hot after All These Years
Fresh Cut
July 2003
By Ken Hodge,
IFPA Director of Communications
Chalk it up to convenience or perhaps the national uproar
and debate over obesity-or perhaps to baby boomers' growing concerns about
healthy eating-but fresh-cut salads have been in the spotlight recently
in both foodservice and retail arenas.
Currently, about 31 percent of Americans-59 million-are obese, a condition
defined as being 30 or more pounds overweight. Almost 65 percent are either
obese or overweight. USA Today recently reported nearly four of 10 Americans
will be obese in five years if people continue gaining weight at their
current rate-an average of one to two pounds per year.
While Americans don't seem to be getting the message fast enough, salads
and vegetables represent a solution to America's obesity problem while
also offering a litany of health benefits for those who eat them.
In the face of lawsuits and other forms of finger pointing, however, fast
food chains such as McDonald's, Burger King, Jack in the Box and Carl's
Jr., are now adding premium salads to their menus as well as fresh fruits
in some cases.
A recent article in the Sacramento (California) Bee rated premium salads
at Jack in the Box, Wendy's, Carl's Jr. and McDonald's for flavor and
size, also comparing total calories, calories from fat, total sodium and
price.
In an effort to add flavor to their salads, McDonald's also struck a deal
with Newman's Own brand all natural salad dressings to improve the image
of its offerings. McDonald's was the last of the major fast-food chains
to add quality entrée salads to its menu.
Concerned Over Health Issues
Health and obesity are obviously on consumers' minds. Witness the exciting
growth trend in quick casual restaurants reported recently by MSN Money.
These chains, noted for more vegetable offerings, enjoyed double-digit
growth last year that was nearly five times greater than traditional fast-food
outlets.
"The public's tastes are changing," according to the MSN Money
writer. "Burgers and fries may be tasty, but a growing number of
customers want more vegetables and more variety along with the convenience
of traditional fast food."
In the retail arena, too, salad sales are still growing at a healthy clip,
according to an article in the June 2003 issue of Grocery Headquarters
magazine. Quoting ACNielsen figures, the publication reported growth for
branded packaged salad products was about 11.5 percent in 2001 and fell
off slightly to about 8.8 percent in the 52-week period ended April 19,
2003.
Private label packaged salads, however, are growing at a faster rate,
14.8 percent in 2001 and 11.7 percent during the same 52-week period cited
above. Total sales figures for "pre-cut fresh salad mix" were
$1.94 billion in 2001 and climbed to $2.11 billion in the period ending
April 19.
According to the Grocery Headquarters article, fresh-cut produce is still
the hottest trend in supermarkets and fresh-cut salad sales continue to
grow at double-digit rates.
As the salad category matures, more grocers are experimenting with private
label salads as a way to reach additional shoppers. In one study conducted
by the Perishables Group, private label salads were introduced into nine
test stores belonging to a single retail supermarket chain.
Study findings indicated that average weekly volume, dollars and gross
profits increased in the salad category for the nine stores in question
after the introduction of the private label items. Unit volume went up
28 percent and dollar volume increased more than 22 percent. The private
label garden salad became the top-selling item in the packaged salad category.
Canadian Salad Craze
Even Canadian retailers are experiencing the "salad craze,"
according to a recent article in the National Post, a nationwide Canadian
newspaper headquartered in Winnipeg. Quoting more ACNielsen data, the
author pointed out that refrigerated and ready-made meals grew by 46 percent
to $29.7 million during the 52-week period ended in July of 2002. Sales
of bagged salads grew 21 percent to $166 million during the same period.
The Post reported salads are such a hit they are quickly gaining market
share held by dry-packed dinners such as noodles and sauce whose annual
sales declined during the year to $181.6 million.
Convenience, health, freshness and flavor are the major drivers of this
continuing growth trend for packaged salads. As long as Americans are
on the go, yet still concerned about getting a healthy, nutritious diet,
that growth will continue.
One recent article in the New York Times pointed out that sales of salads
have "soared in the last decade," noting that consumption of
greens such as "green leaf and red oak has more than doubled since
the early 1990s." Iceberg now represents 73 percent of all lettuce
grown in the United States, compared to 84 percent in 1992, according
to the article.
Creativity is the only limit to what salads can become in the future,
according to another writer in the Los Angeles Times, who noted, "salad
is the most pervasive contribution California has made to the world."
"To the outside world, Californians look like fanatical salad nuts,"
he wrote. "We are salad nuts. We've been salad nuts for a century
or more. What's next? Grilled salad? Italo-Asian fusion? Genetically engineered
micro-greens to go with your micro-brew? Whatever it is, chances are [Californians
will] still be the kings of rabbit food."
© 2003 Columbia Publishing
>>
Return to top
Fresh
Logo a Perfect Fit for Company's State-of-the-Art Facility
Fresh Cut
August 2003
Aunt Mid, the wise looking lady with her grey hair in
a bun, may well be on her way to becoming the Betty Crocker or Aunt Jemima
of the fresh-cut fruit and vegetable industry.
Phil Riggio, president of Aunt Mid Produce Co., Detroit, Mich., couldn't
be happier with what's been happening in the marketplace, particularly
with in-store product demos in food stores in the Detroit metropolitan
area. Whenever and wherever they are staged the feedback is highly positive.
Regardless of the particular product featured, sales increases up to ten-fold
are being reported.
"Our goal is to spread our wings throughout the Midwest, and even
into parts of Canada," Riggio says. "We wanted to improve our
name recognition and have more people saying, 'Oh, that's Aunt Mid's product.
It's fresh, the quality is always good and we love that!'
Memorable Face
"We're fortunate that our company logo is in the form of a person,"
he smiles. "We've hired several ladies to do in-store demos. They
look and dress up like Aunt Mid. They have the appearance of a friendly
aunt and don't scare away the little kids. Our demos have been so successful
that we're actually booked up for more than a year. We've tripled our
demo staff and we're excited about the future."
Working with nationally known chefs, Riggio has come up with a series
of new recipes printed on the back of all Aunt Mid packaged products.
These range from the company's flagship, classic and baby leaf spinach,
to celery hearts and sticks, baby peeled carrots, cauliflower, broccoli,
red and gold potatoes, onions and more.
When Aunt Mid was founded in 1948, there were 25 employees and the company
was processing only four or five items. Aunt Mid was more of a terminal
market wholesaler than a vegetable processor. The only fresh-cut items
were spinach and coleslaw. The main appeal of the spinach was that it
was clean and washed.
Today, Aunt Mid is a household word in the region, enjoying wide recognition
in both the retail and foodservice arenas.
"We're doing about 150 items out of our Detroit plant and have 125
employees," Riggio says. "Over the past five years, we've expanded
our plant twice. We've increased our floor space from about 45,000 to
70,000 square feet and are looking to expand again."
While the company is primarily involved in fresh-cut processing, it also
repacks potatoes, onions and other vegetables, and is a terminal market
receiver on the Detroit Produce Terminal, where it has an addition 17,000
square feet of selling and cooler space.
On the value-added side of the business, the company hangs its hat on
product quality and freshness.
"People really like our product, and they like it because it's fresh,"
Riggio stresses. "Our goal is to cut it for same day/next day freshness.
We strive for same day/next day delivery. Our turnaround time is tremendous.
Our customers like the fact that our products are really fresh, because
they are sourced out within our regional location. We have deliveries
on virtually every item every day. Anything you see being processed today
is either shipped immediately that day or no later than the next morning."
While the exact number of pounds turned out per week remains a proprietary
secret, it is considerable and continues to grow. The Aunt Mid plant is
currently operating at about 70 percent of capacity, right where management
wants it to be. Should an opportunity come along, there must always be
room for growth.
Both Retail and Foodservice Business
Today, Aunt Mid's fresh-cut business is equally split between retail and
foodservice customers. The foodservice sector, including restaurants,
hospitals, schools and other institutions, is much more important to the
bottom line than it used to be. Customers recognize the Aunt Mid logo
and are associating it with freshness, convenience and quality.
What sets Aunt Mid Produce apart from many of its competitors is its diversification,
flexibility and attention to customer service, Riggio feels.
"We're hands-on owners," he points out, "and above everything
we are customer, quality and service driven. When we approach a new customer,
our focus is on what he can't get done, what he is having trouble with,
or what he can't get his supplier to do for him. To us, that's much more
important than what he is doing now. We start there and then try to come
up with ways in which we can provide solutions."
Riggio expects the same from his suppliers, which include both growers
and brokers. Supplies come from growers in Michigan, Idaho, California,
Arizona, Texas, Colorado, New Jersey, Florida, Georgia and elsewhere throughout
the world.
"When the commodity markets are down, we have people calling us wanting
to sell lettuce, potatoes or any commodity every single day," he
notes. "But when the markets are tight and there is not a lot of
product available in California or anywhere you may never hear from them.
On the other hand, even under such situations, occasionally
there will be somebody that comes through and says, 'I have lettuce, or
red potatoes or whatever it be, if you want them.' That's the kind of
supplier we're interested in, someone willing to do something for our
company that nobody else is willing to do. He's the one who will get our
business."
Got the Business
Recently, Riggio says a problem with lettuce bins coming in from California
illustrates his point. Poorly designed, they were collapsing on each other
while waiting for processing. When he asked for a hexagon-type bin, certain
suppliers were reluctant, or unable, to meet his request. The one who
complied with his request got the business.
"We work closely with our suppliers and have a good
relationship with all of them," he says. "The fact that we partner
with them somewhat has helped tremendously. We don't look at it like,
well, we're the customer. Our philosophy is, 'Look, you're selling us
product but it still has to go to our customers. If you don't see our
customers as yours, we don't really have any common ground.'
"I try to think like I'm a consumer and I'm buying a certain product,"
Riggio explains. "What do I want? Is what's being offered a help
to me, and is it a value? If it is difficult or inconvenience to do at
home and you have to cut it with a knife, what would I be willing to pay
for this value-added service? Using this thought process, I then factor
in what I am paying for the raw product and processing considerations
and how much our customer needs to make. I work backwards to see if there
is a fit."
State-of-the-Art Facility
In addition to its strong customer relationships, Aunt Mid Produce has
invested heavily over the years in its processing facility. It is truly
state-of-the-art. It also has a HACCP plan, a third-party auditing program
and a quality assurance staff in place to help assure its customers that
its fresh-cut products are safe and wholesome.
Occasionally, Aunt Mid's quality assurance lab personnel are asked to
help answer other customer questions and concerns.
"Often, we'll talk with restaurant chefs or produce department backroom
managers," Riggio point out. "We have them actually visit our
packing and processing facilities so they can see how everything is done
from the ground up. If there are concerns about food safety or if they
have a problem with understanding what to do under certain situations
our QA people will sit down with them and discuss each concern.
"On one occasion, we had a customer, a casino in Detroit, who needed
help with its HACCP plan. Its management team wanted to initiate a plan
and requested some guidelines for handling produce. Our QA people were
able to provide the assistance needed and further strengthen our relationship."
All three of Riggio's sons are currently heavily involved in the day-to-day
management of the business. Vince and Philip, Jr. manage the plant operations
while Dominic supervises the terminal market facility. Working together
in a family business, this father and three sons appear to be a perfect
fit for a family of fresh quality produce that have continued for more
than 50 years.
Aunt Mid Produce Company is located at 7939 West Lafayette, Detroit, MI
48209. Riggio can be contacted at (313) 841-7911; fax (313) 841-6220.
The company Web site is: www.auntmids.com.
© 2003 Columbia Publishing
China's
Blossoming Fresh-cut Vegetable Industry
Fresh Cut
August 2003
While still in its infancy and limited to a single processor,
China's fresh-cut vegetable industry is off and running and is growing
at a spectacular rate. A new generation of busy Chinese consumers with
money in their pockets, concerns about their health and a willingness
to spend is beginning to emerge. The country's fresh-cut processing industry
already has its eyes on Japan and other Asian markets where there is proven
demand for all kinds of fruit and vegetable products.
Last year, Creative Food China, also known as Chinaveg, did $5 million
in sales. Founded in 2000, sales for the fresh-cut vegetable processor
were up 40 percent over 2001. Creative Food officials project the company
will market 10 million packs of value-added produce in 2003 and an additional
500 tons of produce, most headed in traditional packs, for export markets.
With Creative Food's success, others are looking at the fresh-cut market
although no national competitors have yet entered the scene. On the domestic
side, most consumers are accustomed to ultra-cheap produce and remain
hesitant to pay the additional costs associated with value-added products
- maintaining the cold chain and assuring a safe processing environment
meeting HACCP standards.
One positive consequence of the SARS outbreak is that it has radically
changed the mentality of many Chinese and they are beginning to ask questions
about growing and processing methods. They are concerned with their health
and want guarantees on food safety. Given the fact that the Chinese like
fresh, rather than frozen, vegetables, the fresh-cut market is expected
to grow.
Took Root in 1997
The idea for the creation of Creative Food took root in 1997, when KFC
Shanghai asked the Compass Group PLC China, a major world contract foodservice
player, to process shredded lettuce for its restaurants. Three years later,
in 2000, Compass Group China's CEO, Xavier Naville, and Interasia Venture
Management, a venture capital firm from Hong Kong, entered into a business
agreement to create a separate company dedicated to marketing fresh-cut
vegetables in China. Later that year, Creative Food China was born.
Today, the company markets to both retail and foodservice customers and
exports fresh-cut lettuce, cabbage, broccoli florets and other patent-pending,
loose-leaf iceberg lettuce to various Asian ports. On the home front,
its major customer is KFC, China's largest and most successful fast food
chain.
Born in Marseilles, Creative Food's Naville heads a wholly foreign-owned
enterprise with processing plants in Beijing, Shanghai and Guangzhou.
These three facilities enable the company to deliver fresh-cut product
to both domestic and export markets. Naville has put together a team of
local managers to help the company sort through the challenges associated
with doing business in a foreign country with a difficult language and
unique ways of doing things.
The bulk of China's farm land is worked by hundreds of farmers, most with
less than a tenth of an acre. Lining up contracts and meeting the production
standards of customers such as KFC has been no small task. Creative Food
officials have had to supply the right kind of seed and convince locals
to use pesticides acceptable to the U.S. Department of Agriculture. In
the beginning there were challenges with growers accepting the pesticides
and then selling them off to others for a quick profit. Sometimes highly
toxic replacements were substituted and the produce could not be used.
Not any more. After establishing business relationships using local farmers
as middlemen and watchdogs, improvements have come steadily. The company
no longer has to station rings of police around contracted fields to protect
them from nearby residents. Highly functional fresh vegetable supplier
networks have been established, ensuring field-fresh quality vegetables
year-round.
Post-harvest Handling Procedures
"At Creative Food, we have established and enforced proper post-harvest
handling of all raw materials," Naville claims. "This includes
cooling products as quickly as possible. Vacuum coolers are kept close
to the fields for pre-cooling, contracts have been worked out with third-party
refrigerated logistics companies and the company maintains its own fleet
of refrigerated trucks for end user fulfillment. In support of our supply
cold-chain, we have our own vacuum coolers and specialized, icing equipment.
From harvest to delivery, our staff works to ensure a consistent cold-chain
to promote the best quality and shelf-life possible."
Creative Food officials are now working on the next step of their plan
- boosting yields and quality by introducing tractors and other modern
equipment. There is still a long way to go.
"The opportunity with KFC in China led us to look at the market for
fresh-cut products in Asia," Naville says. "Japan is importing
more than $900 million of vegetables each year, many coming in raw form
from California and China. Given the high level of labor cost in Japan
and the proximity of China, we believe the Japanese will gladly look into
fresh-cut products exported by a professional and reliable supplier from
China."
At the same time, Naville believes that many of China's growing middle
class, who shop in retail stores, are searching for safer and more convenient
products such as fresh-cut vegetables. In the earlier years of the venture,
when that market niche was only beginning to materialize, the emphasis
was on export markets.
"Beginning in 2001, we entered the emerging retail market here with
our first Carrefour store in Shanghai," Naville explains. "We
now have product in 150 Hypermarkets and Supermarkets and in 15 Carrefour
stores and piggy back on other giant developments, including Wal-Mart,
Seven Eleven and C-Stores. These are springing up at an amazing pace all
over China. Currently, approximately 70 percent of our customer base is
foodservice, while 30 percent is retail."
Fresh-cut Product Offerings
Creative Food's initial product offerings included shredded lettuce and
coleslaw, cut especially for KFC. Later, using patent-pending technology
from the U.S., the company added cut and loose-leaf lettuce with improved
shelf life to its offerings, hoping to better penetrate the Japanese market.
Today, Creative Food products fall into two basic categories: (1) ready-to-eat
salads that bring a western flair to China and its growing number of middle-class
consumers, and (2) ready-to-cook products that use Asian mixes but bring
convenience and safety to consumers.
All processing operations are conducted with strict adherence to tough
Creative Food's operating practices, "among the most stringent in
the world," according to Naville. These meet, or exceed, the Chinese
government's regulatory requirements, ISO 9000:2000, HACCP and SQF 2000.
"In China, at least at this stage, there is no need to become too
fancy or creative," Naville believes. "With SARS and other concerns,
the emphasis is on quality and consistency. These are what Chinese consumers
want."
Each of the three processing facilities - located in Beijing, Shanghai
and Guangzhou- has 1,000 square meters of refrigerated storage and processing
floor space. The combined workforce varies from 400 to 600, depending
upon the time of the year. Creative Food began operations with approximately
60 workers. Each facility is equipped with modern processing lines and
a double wash system.
The company's pilot processing plant, opened in the beginning at Shenzhen,
has since been closed to open a new state-of-the-art facility in Guangzhou.
"Our 'double wash' processing lines are unique in China," says
Naville. "Other equipment is purchased overseas or is put together
locally according to specific needs. In developing countries, such as
China, basic quality and consistency are essential in winning customer
acceptance. We need better and faster processing equipment but at the
same time have to be aware of what the market can take at this time. We
therefore develop much of the equipment needed ourselves."
Huge Middle Class Developing
As for the future, China is building the largest middle class in the world,
the CEO points out, adding that just as those in other countries Chinese
consumers want convenience.
"And convenience is what we intend to provide," he smiles. "Safe
and healthy food is important, but convenience is what drives markets."
At present, few Chinese eat salads, according to Naville. In general,
salads remain a western-type product, although change is in the air. Office
ladies in Shanghai, for example, are now asking for fresh-cut salads when
enjoying their coffee at Starbucks. There is growing demand for Starbuck's
coffee blends, pizza, cheeseburgers and KFC fried chicken products. As
elsewhere around the world, Chinese consumers are thirsty to experience
new tastes and experiences, even though today most fresh-cut vegetables
are used in stir-fry dishes.
Another positive plus for the fresh-cut industry is the Chinese traditionally
consume large amounts of fresh produce. Whether produce or fish, the emphasis
is on freshness. All Chinese restaurant entrances, for example, display
aquariums filled with live fish, and a visitor will not order a fish dish
until he has personally inspected and picked out his meal while it is
still alive.
"The Chinese (and other Asians) look at frozen and canned vegetables
as belonging to the past," Naville emphasizes. "Foreigners may
eat them, if they desire, but not the Chinese."
Since the technology for guaranteeing consistent fresh-cut product quality
has matured, the Creative Food executive is banking on his belief that
the Chinese will opt for fresh-cut fruits and vegetables without first
turning to canned and frozen foods as an intermediary step (as has been
the case in western countries).
"Look at the telecom market here," he stresses. "There
currently are 100 million mobile phone users. Most do not have a fixed
line connected to their homes."
Today, the newest and fastest growing market in China is fresh traditional
packs. Quality is better assured through use of the cold chain and everything
is packaged with modern methods. Over the past few years, growers have
been making significant improvements, investing in pre-cooling equipment
to meet the needs of their export clients. China is now marketing acceptable
iced-broccoli to Japan, for example. While it still lacks consistency,
the price is very low and market share has been increasing dramatically.
For fresh-cut products, shelf life is a critical element in the Japanese
market. Customers want product with at least a 14-day shelf life and are
demanding consistency throughout the year.
Creative Food's Business Focus
From its inception Creative Food has focused on determining client needs
and then has worked backwards to develop products and supply channels
to meet those needs.
"Believe me, this is not a given in China," Naville explains.
"Traditionally in China, growers are confident to grow one of two
crops and compete with each other to 'push' it, or them, to the market.
The only differentiation is cost. On the other hand, we spend a lot of
time identifying our target markets and engineer products to fill the
needs of the new China."
Meanwhile there are business opportunities for U.S. growers, according
to the Creative Food's CEO. The company, he says, is looking for growing
partners willing to come to China and establish a base.
"Our platform makes it easier to come here and avoid all of the usual
mistakes made by foreign companies trying to do business in China,"
Naville says.
© 2003 Columbia Publishing
Quiznos
Considering the Use of More Fresh-cut Products
Fresh Cut
August 2003
Quiznos, a national quick-service sandwich shop with
around 2,300 stores, is looking at using more fresh-cut vegetables in
the future.
The company is now number two in the sandwich segment. Subway, with a
little over 18,000 units, leads the pack. Blimpies and Schlotzsky's Deli
are battling for third and fourth positions.
Bob Santilli, senior quality assurance director for the Denver-based company,
says the company hopes to double the number of it stores over the next
three years and, like its competitors, is striving to improve quality
and cut costs.
Most Quiznos shops are located in the United States and Canada, although
the company also does business in 15 countries.
"We are at a size level now where management is thinking there may
be some potential labor savings," Santilli says. "That may,
or may not, be the case. I worked for a previous chain some time back,
and to be honest, the labor savings was not what we had projected. There
was some, but it was not the windfall we had hoped to see. A reduction
in food preparation time won't necessarily provide meaningful savings
in operational costs."
Vistar, a national food distributorship, currently supplies most North
American Quiznos shops with needed vegetable products, including shredded
lettuce, used in making up the variety of sandwiches offered. Tomatoes,
peppers, red and yellow onions, cucumbers, mushrooms and lemons are prepped
daily in the respective stores.
Some shops also procure vegetables from area growers and processors.
Considering a National Program
"We've been looking at a national program that would expand our pre-cut
program," Santilli says. "While still being studied - no decisions
have been made yet - pre-cut onions and peppers could certainly be done,
and we're even looking at tomatoes."
Among the advantages of moving in that direction would be improved product
uniformity, important in making favorable customer impressions, he says.
Consistency in the way products are cut has a certain pleasing effect
on the eyes.
On-going concerns over food safety may also be a plus for the fresh-cut
industry, he says. Most sandwich shops entrust their day-to-day operations
to a young workforce, which may, or may not, be as conscientious as older
adults in following strict sanitation practices.
"With in-store handling in any restaurant, there is potential to
incubate some form of problematic concern if good hygiene practices are
not maintained," Santilli says. "By and large, our store operations
are very good in that respect but no one can ever guarantee 100 percent.
On the corporate side, we are continually monitoring our stores to verify
their competency and compliance with our safety standards."
The use of more fresh-cut vegetable items, however, is seen as a possible
way to reduce contamination risks.
"My opinion of the pre-cut industry is that it has grown tremendously
over the past 10 years or so," the quality assurance manager explains.
"Equipment technology has improved and the industry has established
high standards for both product quality and safety. To my knowledge, the
industry has yet to be investigated by the regulatory agencies, but it
knows that is coming and has voluntarily raised its safety standards.
Generally speaking, most fresh-cut businesses today are no longer the
simple, garage-type setups that once existed. They are sophisticated with
state-of-the-art equipment and rigid safety standards."
Cost and shelf-life factors also are expected to play a role in the company's
future determinations, Santilli says.
Most quick-service restaurants design their core menu lines to be "idiot
proof," Santilli points out. Adding fresh-cut products could complicate
things until handling procedures are clearly understood.
"As sensitive as these products are, proper rotation would be a must,"
he explains. "Mistakes tend to show if recommended practices are
not understood and implemented."
Food safety is very important to the company and its future, Santilli
stresses. The Quiznos quality assurance team regularly inspects the operations
of all company suppliers, both processors and distributors. These inspections
occur at least once each year and, depending upon the need, may be even
more frequently.
"If new products are being rolled out, invariably we are onsite at
the plant for the initial production to make sure they meet Quiznos standards
and specification limits," Santilli points out.
© 2003 Columbia Publishing
>>
Return to top
Stretching
a Foodservice Budget - Behind Bars
Fresh Cut
September 2003
While paying their debt to society, inmates throughout
the country still participate in a daily ritual, namely dining. In their
case, however, "dining in" is the only option.
As the nation's prison population steadily expands, so too grows the foodservice
industry providing fresh fruits and vegetables to the nation's nearly
2 million inmates. According to the Bureau of Justice Statistics, state
prison foodservice expenditures for the year 2000 were $1.46 billion.
"Cost has been, and always will be, the driving force in our foodservice
budget," says Santos Lamas, foodservice manager at the Washington
Corrections Center for Women in Gig Harbor, Wash. "In trying to reduce
the foodservice costs at our facility, we try to consider things that
are beneficial to the individual's health. It's always a challenge to
try and maintain a good balance in the food items we serve."
One of those food items that is gaining in popularity is fresh salad.
"Due to budget restraints, we only purchase fresh-cut lettuce,"
says Lamas. "Once a week we purchase fresh produce - including large
bags of pre-cut lettuce - from Charlie's Produce in Seattle. Over the
last few years, they have been a steady supplier for our foodservice needs."
"Regarding the vegetables that go on our fresh-cut salads, we do
our own cutting in-house," explains Lamas. "We're very careful
to use exactly what we order. In fact to make things go a little further,
we will add fresh-cut cabbage to our bagged lettuce. Cabbage is a little
less expensive and doesn't wilt as fast as lettuce. A plain lettuce salad
will cost us about 38 cents per serving whereas a mix with cabbage will
take the cost down to about 20 cents. Our food budget goal is to stay
at 97 cents per inmate per meal. That includes the entire meal."
Never a Leftover
Lamas uses his 35 years experience in the foodservice industry to determine
the exact amount of product needed on a weekly basis. Very seldom do they
have leftovers. "If it's leftover, it's discarded," says Lamas.
"The inmates get a little upset with me on those occasions when we
run out of food. But, I'd rather run out of food than have uneaten food
to throw out."
Another approach to cutting down on wasted food items is in the preparation
of salads. Inmates are allowed to order individually-prepared salads made
to order by foodservice personnel on a daily basis. (Yes, this is a prison!)
"If an inmate orders a salad but fails to pick it up during the scheduled
mealtime, they no longer can order individual salads," explains Lamas.
"We regard this as a privilege, not a right." Of the 930 inmates,
380 have special diets and meal requirements. "We stay busy trying
to prepare the right meal for all of these individual requests and in
keeping with health status reports," says Lamas.
According to prison administrator June Johnson, the Revised Code of Washington
is the guideline we use to maintain healthy nutritional standards. "We
have a consultant on staff who reviews the menus and ensures that they
meet the standards set by the state for nutrition and calories,"
says Johnson.
Though each state offers a different set of nutritional health guidelines,
most average between 1,800 and 2,400 calories per day per inmate for females.
The male population averages 3,200 to 3,400 calories per day. At the Washington
Women's Correctional Facility, 2,400 calories is the goal used by Lamas.
In addition, Lamas uses information from other in-state institutions as
a guideline to determine where he can improve on his overall foodservice.
He routinely contacts his peers to try and improve or apply best practices
for his operation. In fact, implementing the individually-ordered salad
was a suggestion he picked up from a fellow foodservice manager at another
correctional facility.
Pre-cut In-house
With 142 inmates working in the Washington Women's Correctional Facility's
foodservice department, meal preparation is a non-stop venture. For the
first three months of 2003, nearly 240,000 meals were served at the facility.
Since purchasing pre-cut fruits and vegetables is more expensive, most
items at the prison are fresh-cut in-house. According to Lamas, cutting
vegetables is a time-sensitive job that requires a great deal of coordination.
Due to the potential danger, there are only four inmates allowed to cut
fruits and vegetables. As such, the knives they use are tethered to the
wall with a steel cable. And at 42 cents an hour for labor, using inmate
labor is cost-effective.
Food safety is also well-monitored and well-documented during food preparation.
"We have a HAACP program in place and follow the rules to a tee,"
says Lamas. "We have documentation for everything, including refrigeration,
temperatures for hot water, dishwashers and a 24-7 monitor of our refrigeration
system." Lamas adds, "We monitor how our produce is washed and
cleaned before being prepared. Safety is a big deal here."
With the steady increase in prison populations, the foodservice industry
will continue to grow as well and keep companies like Seattle-based Charlie's
Produce in business for years to come.
© 2003 Columbia Publishing
Moving
Forward One Step at a Time
Fresh Cut
September 2003
By D. Brent Clement
Managing Editor
With the opening of a new, state-of-the-art, fresh-cut
produce food processing plant last year in Bradford, Ontario, Canada,
Henry G. Beben took another important step forward in his quest to see
Kitchen Express become a dominant player in the fresh-cut produce industry,
particularly in the eastern half of North America
Born and raised in Toronto, Beben is President and CEO of EarthFresh Foods
Corp., a multimillion dollar conglomerate with three divisions: (1) MacKay
& Hughes, one of Canada's largest growers, packers and distributors
of fresh potatoes; (2) Gemini Farms, among the country's largest growers,
packers and distributors of carrots, onions, parsnips, beets and greens;
and now (3) Kitchen Express, commissioned last year to process fresh-cut
carrots and potatoes.
Set to Becoming a Dominant Player
The opening of the fresh-cut vegetable processing plant in 2002 signals
the latest in the company's overall objective of becoming a force in the
produce trade in both Canada and United States. Beben and other investor
partners purchased MacKay & Hughes and Gemini Farms in 2001 and, as
the new owners, see their fresh-cut vegetable processing venture as a
natural next step in a long-term plan to provide busy produce consumers
with more of what they want.
"Our goal is to remain with the core businesses that
have been successful in the past but also venture out into the new world,"
Beben explains. "We want to be on the leading, if not bleeding, edge
of the new (fresh-cut) thrust. Ultimately, we believe there may be one
additional step and that is to provide fully prepared food. We've been
providing washed, fresh produce in the past and have now added fresh-cut
produce to that line. Somewhere down the trail the next logical step is
to provide fully prepared food products."
Over the past two years, Beben says his team has been
"setting the foundation" and is now prepared to "put the
pedal to the metal." "We've done the spade work and now is the
time to get out there and really start selling," he adds.
EarthFresh Foods Corp. both imports and grows its own
basic vegetables. The end products are shipped throughout North America.
The company is versed in all aspects of cross-border customs requirements
- USDA certification, phytosanitary requirements, NAFTA certification,
certificate of origin and confirmation of sale documentation - and is
prepared to compete. Its fresh-cut vegetable products are generally delivered
within two days of being processed.
"We are supported by state-of-the-art computer systems and utilize
the most current logistics and Internet applications," says Geoff
Silva, the company's Vice President of marketing. Transportations modes
include over-the-road, rail intermodal, truck on rail, traditional boxcar
and marine services. The company also boasts of a strong pallet inventory
management capability.
Set to Compete
With the Kitchen Express fresh-cut foods division now coming into its
own, Silva says EarthFresh Foods Corp. is set to compete with the best
of the best in the industry. The Ontario plant is a high tech processing
facility located in the heart of Canada's richest growing region. A HAACP-based
quality assurance program ensures that hygiene and sanitations practices
are among the best in the industry. Operations will be independently audited
and reviewed by the American Institute of Baking (AIB). A thermal processing
and automated vision inspection system and size grader optimize product
quality and consistency. Every attempt is made to deliver nothing but
the best fresh-cut vegetables to the company's growing list of satisfied
customers.
"Our promise is in our name, 'forever fresh, forever ready,'"
Silva proclaims. Fresh-cut products include carrots (baby peeled, tiny
baby peeled, jumbo baby peeled, sliced, crinkle sliced, diced, shredded
and sticks) and potatoes (shoe strings, diced, sliced -- "any way
you want them").
Approximately 60 percent of Kitchen Express fresh-cut products will be
sold to foodservice customers, with 40 percent going to the retail trade.
Beben and Silva forecast double digit growth each year over the next three
to five years.
For the company's foodservice customers products are available in Chef
Quik™ brand. Brand names for retail customers are Mother Earth™
and Beatrix Potter's Peter Rabbit™.
"We are a sales and marketing driven organization committed to bring
strong branding to an industry where this has been lacking," Silva
says.
Branding Innovations
One such success story has been the recent launching of Beatrix Potter's
Peter Rabbit fresh-cut carrots, which exemplifies the company's approach
to unique and exclusive products and branding.
"In an age when licensed properties go in and out of the spotlight
in the blink of an eye, there's a certain sense of security, from the
standpoint of both the consumer and retailer, in those classic, timeless
character brands with proven longevity," Silva explains. "Beatrix
Potter's Peter Rabbit is one such property. We are proud to have the exclusive
rights in Canada to this much-loved, 100-year-old, literary phenomena."
Kitchen Express is the first produce company in Canada to have the Beatrix
Potter's Peter Rabbit brand identity on its fresh vegetables. The Tale
of Peter Rabbit is the bestselling children's classic of all time, with
more than 32 million copies in print, Silva hopes to create a memorable
link that will translate into increased sales.
Because Kitchen Express is tied in with EarthFresh Foods
Corporation's other two divisions, Gemini Farms and MacKay & Hughes,
there are additional advantages to be found- " access to products
from our own farms improves product quality, freshness, flexibility, supply
and pricing Silva concludes.
Gemini Farms and MacKay & Hughes
Gemini Farms, which has been around more than 25 years, is located in
the heart of Bradford, Ontario, Canada's richest growing farming area.
Much of the land there is rich, black dirt known as "muck."
It is there where a heavy percentage of the carrots, onions, greens, parsnips
and beets are grown. On-the-farm packing and vacuum cooling ensure that
Gemini products are delivered with maximum field freshness.
Gemini Farms' brands include Garden Rich™, Gemini™, Canadian
Gold™, and Honey Bunny™ .
Founded 38 years ago by David MacKay and Tom Hughes, Sr., MacKay &
Hughes is one of Canada's largest distributors of fresh potatoes. Products
sold through this division are either grown on its own farms or contracted
with other producers in Ontario, Prince Edward Island, Alberta and the
U.S. Among the varieties offered are Klondike Rose, Cherokee, Norkotah
Russet, Russet Burbank, Superior, Agria, Shepody, Yukon and Frontier.
Lessons from the Meat Industry
As President and CEO of EarthFresh Foods Corp., Beben sees tremendous
potential for the fresh-cut vegetable industry in the future. While most
of his working career has been in the meat industry, his learning curve,
although very much a reality, has not been as pronounced as imagined when
he was first approached to cross over into produce.
"I see in EarthFresh Foods a major opportunity for two reasons,"
he says. "First, it allows for fresh new thinking, and second, it
soon became obvious that I could bring over some of what I had already
learned from past experience in the meat industry. I envision fresh-cut
produce, as an industry on the verge of major change and that there are
helpful parallels that can be drawn from my past experiences in the meat
industry.
"There was a day when meat packers shipped a lot of whole carcasses.
Restaurants generally had someone trained as a butcher that could take
a carcass apart, portion out steaks and do all of that. And then as the
years rolled by, things began to change. More of the cutting and portioning
was done offsite from the supermarkets and/or restaurants. And while equating
produce to a beef carcass may not be the greatest analogy, more of the
washing, peeling and portioning is now being done offsite. There are new
entrepreneurs who can do that sort of thing very efficiently and distribute
it to the end users clean and efficient in terms of portion, health and
safety. We are equipped to provide that kind of service.
"I see packaged salads as a great example of what is happening,"
Beben points out. "Over the next 15 to 20 years, or whatever the
horizon is, I suspect we're going to see more and more food preparation
taking place offsite. Gone will be the need to go through the drudgery
of washing, peeling and cutting vegetables. We will be able to reduce
labor costs and cut health and safety risks, and do it cheaper than the
end user can do it himself or herself.
"In my opinion, there are striking similarities," Beben says.
"In the meat industry we used to say, 'You either sell it or smell
it.' Likewise, to avoid trouble in the produce industry, everything must
be done as efficiently as possible under clean, pristine conditions. Like
meat, produce requires refrigeration and shelf life is an issue. I believe
the fresh-cut industry will be working at improving shelf life considerably
over the next few years. We are excited about the future and intend to
become a major player."
Company headquarters for EarthFresh Foods Corporation is located at 131
Browns Line, Toronto, Ontario, Canada, M8W 3S2. Beben and Silva can be
reached at (416) 251-2271.
© 2003 Columbia Publishing
Innovations
in Modified Atmosphere Packaging
Fresh Cut
September 2003
By H. Louis Cooperhouse
Modified atmosphere packaged products occur in almost every aisle of the
supermarket today, and fresh-cut produce represents the fastest growing
segment in which this technology is being applied. This promising technology
greatly improves the potential marketability of value-added produce, but
it must be utilized in combination with other barriers and employed as
part of a comprehensive HACCP system.
Rapid Growth of MAP in the Fresh-Cut Marketplace
Billions of packages of refrigerated, frozen and shelf stable foods are
sold worldwide every year that are packaged with modified atmosphere packaging
(MAP). This array of food products includes potato chips and other snack
foods; ready-for-display fresh meats; hot dogs and other processed meats;
pizza dough and other bread and bakery products; and items as diverse
as coffee and cheese. Although the application of MAP in the fresh-cut
produce category was virtually non-existent some 15-20 years ago, it is
estimated that over one billion packages of fresh-cut produce products
have been sold to date.
The initial application for MAP in the value-added produce segment was
the foodservice market, in which pre-cut lettuce was sold to salad bars
and to the quick service restaurant industry. This was followed by prepackaged
iceberg lettuce salads that were developed for the retail market, which
subsequently evolved to include a wide variety of lettuces, cabbages,
carrots and other vegetables. Meat ingredients, such as precooked pieces
of chicken and ham, have recently started to appear in salads too, either
in a separate MAP pouch or actually integrated into the salad. As a result,
salads which have become quite popular in restaurants, such as Chicken
Caesar salad, Chef Salad, and Cobb Salad, are now appearing for the first
time in the retail marketplace. Cut fruit, such as honeydew and pineapple,
and cut vegetables, such as baby carrots and broccoli, are rapidly growing
markets as well.
Process Overview
In the MAP process, product is packaged in an atmosphere that is different
from air. Air normally contains 78.08 percent nitrogen, 20.96 percent
oxygen and 0.03 percent carbon dioxide. A typical objective of MAP in
fully-cooked products is to minimize the amount of oxygen that is left
in the package. This process can replace the level of oxygen, typically
with nitrogen and/or carbon dioxide, which serves to extend the product's
shelf life.
MAP is a process in which the composition of gases in a package of known
permeability is altered after the food is filled, but before the package
is sealed. Frequently, MAP is a two-stage process. It begins when a vacuum
is first pulled on the product so that as much oxygen as possible is removed
from the system. This is then followed by a "back flush" of
nitrogen and/or carbon dioxide.
Nitrogen is used as a sterile filler gas to dilute the concentration of
carbon dioxide and oxygen in the package, thereby reducing the onset of
oxidation and helping to ensure package stability. Carbon dioxide has
bacteriostatic and fungistatic properties and its effectiveness is probably
due to its ability to penetrate the cellular membrane. This penetration
causes intracellular pH changes and disrupts internal enzymatic equilibrium.
The gas selectively inhibits the growth of Gram negative bacteria, such
as pseudomonades and other related psychrotrophs, which otherwise grow
rapidly and produce off-odors and off-flavor. Lactic acid bacteria, such
as streptococci and lactobacilli, are less affected by elevated levels
of CO2.
Accordingly, the predominating flora of products stored in modified atmospheres
consists of these organisms, which develop more slowly than pseudomonades
and related Gram negative bacteria.
Optimal gas mixtures vary widely by species. Produce commodities are often
classified according to their respiratory requirements. Potatoes, radishes
and tomatoes are generally considered low respirers while asparagus, broccoli
and mushrooms are considered heavy respirers. Once commodities are cut
and handled, product deterioration accelerates as the respiration rate
is increased, the tissue becomes more susceptible to oxidative discoloration
and microbial growth is enhanced. It is critical to match the oxygen transmission
rate (OTR) of the packaging material with the respiration rate of the
product.
By no means is MAP a "magic bullet" that will individually provide
for product safety and shelf-life extension. Clearly, raw material control
and superior agricultural practices are critical to the successful development
of value-added produce products. Variety, source, season, initial maturity,
processing maturity, slicing and cutting equipment, chemical or other
treatments and dips, packaging environment, shipping and handling all
affect the sensory acceptability and attainable shelf life of fresh-cut
produce - and impact product safety. Temperature management from "farm
to fork" is critical.
Safety Concerns
MAP via reduced-oxygen may be a technology chosen to help a fresh-cut
processor achieve a much longer shelf life. However, because MAP results
in a dramatic change in the time it takes for product to spoil, and the
type of bacteria that will cause this spoilage, it creates significant
additional risk as well. This is due to a number of factors such as extremely
low oxygen levels, lack of bacterial competition, prolonged shelf life
and potential for temperature abuse - conditions that can favor the growth
of pathogenic organisms, which are otherwise quite fastidious and less
likely to grow.
MAP and other forms of reduced oxygen packaging minimize the activities
of spoilage organisms that normally give warning about potentially unsafe
conditions. MAP concerns are well founded because of the potential for
growth of anaerobic or facultative anaerobic bacteria, such as Clostridia.
These can cause food poisoning before food spoilage is organoleptically
detectable. Reduced oxygen packaging contributes to botulism potential
of botulism (caused by Clostridium botulinum) and other pathogens by providing
greater time and opportunity for outgrowth.
FDA Assessment of Produce Safety
The Food and Drug Administration (FDA) of the U.S. Department of Health
and Human Services has been working in concert with the Institute of Food
Technologists (IFT) to provide scientific review and analysis of issues
in food safety, food processing and human health. This group has published
a report entitled, "Analysis and Evaluation of Preventive Control
Measures for the Control and Reduction/Elimination of Microbial Hazards
on Fresh and Fresh-Cut Produce". In this study, it is noted that
although only two MAP produce products (coleslaw mix and ready-to-eat
salad vegetables) have been implicated in food-borne illness outbreaks
to date (botulism and salmonellosis), the potential for pathogen growth
is quite significant in the fresh-cut produce industry.
Currently, there is concern with psychotropic food-borne pathogens such
as L. monocytogenes, Y. enterocolitica and A. hydrophila, as well as non-proteolytic
C. botulinum, Salmonella spp., E. coli O157:H7 and Shigella spp. These
represent potential health risks when present on MAP produce. Because
reduced micro flora exist in MAP products, L. monocytogenes, for example,
can grow at low temperatures to potentially harmful levels during the
extended storage life, while remaining organoleptically acceptable. Because
many of these bacteria in addition to enteric viruses such as hepatitis
A have been implicated in produce outbreaks, there is concern about their
behavior under modified atmosphere conditions. Incorporation of other
barriers is critical, and microbiological challenge studies are necessary
to minimize such risks.
The concern when using MAP for fruits and vegetables arises from the potential
for food-borne pathogens which may be resistant to moderate to high levels
of CO2 (< 50%) and outgrow spoilage microorganisms, which may be sensitive
to the modified atmosphere. It is generally believed that with the use
of permeable films, spoilage will occur before toxin production is an
issue; MAP of produce, however, should always incorporate packaging materials
that will not lead to an anoxic package environment when the product is
stored at the intended temperature. Spoilage of fresh produce is mainly
due to the background microorganisms that can vary greatly for each product
and storage conditions. The FDA/IFT report recommends that the elimination
or significant inhibition of spoilage microorganisms should not be practiced
as their interaction with pathogens may play an integral role in product
safety. This report further recommends that the percentage of O2 in a
modified atmosphere for fruits and vegetables (for both safety and quality)
fall between one and five percent.
Areas of Promise Identified
Over the past few years, a number of packers of fresh prepared green vegetables
in the United Kingdom have begun experimenting with oxygen levels that
are between 70 and 100 percent. This "oxygen shock" treatment
of super atmospheric oxygen levels has been found to be very effective
in inhibiting enzymatic discoloration, preventing anaerobic fermentation
reactions and inhibiting aerobic and anaerobic microbial growth since
the optimal oxygen level for growth (21 percent for aerobes, 0-2 percent
for anaerobes) is surpassed. As with most MAP gases, super atmospheric
O2 has varied effects depending on the commodity. Further research will
be required to understand the application of this technique in the fresh-cut
produce industry.
Another area of promise is the use of edible films where
antimicrobial compounds are incorporated directly onto the product, and
in which the product is packaged under MAP conditions. There have been
many studies investigating the migration of antimicrobials such as sodium
benzoate, benzoic acid, prop ionic acid, and potassium sorbate from coatings
into food. The FDA/IFT report concludes that the most advantageous use
of these films for antimicrobial properties would be the formation of
a monolayer lipid and sorbic acid film, or a bi-layer film composed of
a hydrophilic base layer coated with a thin layer of lipid containing
sorbic acid. Research is needed in order to produce coatings with good
surface tension that will stick to produce.
Areas of Further Research Identified
The FDA/IFT report identified the need for further research so that industry
will be better able to safely apply MAP principles. These areas included:
• Investigation of the antimicrobial effect of super atmospheric
oxygen levels.
• Study of interactions of background micro flora with food-borne
pathogens in various modified atmospheres used for produce, as well as
the effects of different gaseous environments on the survival and growth
of bacterial food-borne pathogens on whole and fresh-cut produce.
• Examination of the potential for growth of C. botulinum in a wide
variety of modified atmosphere packaged produce stored at mildly abusive
temperatures such as 7-12°C. Evaluation of other hurdles besides temperature
to prevent botulinum toxin production.
• Examination of the influence of different atmospheres, background
micro flora and storage temperatures on the survival and growth of L.
monocytogenes on MAP fresh-cut produce.
• Investigation of the behavior of verotoxin-producing E. coli on
fresh and fresh-cut product, both under MAP and without MAP.
• Exploration of the survival of the enteric pathogens Y. enterocolitica
and Campylobacter spp. and the behavior of food-borne viruses and protozoan
parasites on MAP produce.
• Examination of hurdle technology, or the combination of novel methods
of food treatment and packaging; i.e., irradiation used with MAP and antimicrobial
films used in combination with MAP.
• Evaluation of the use of intelligent packaging systems.
Suppliers of MAP Process
The BOC Group is believed to be the world's largest supplier of gases
used for MAP purposes. Other companies include Air Liquide, Praxair, Linde
and Air Products. These companies can serve as excellent resources for
further information on MAP applications.
Other suppliers involved in MAP include companies whose packaging equipment
incorporates gases just prior to sealing. The sealing of the primary package
can occur in an in-line vertical or horizontal form-fill-seal machine,
in a tray-sealing machine that uses preformed trays, or in a horizontal
or vertical chamber or snorkel machine that seals preformed bags. Many
companies, including Multivac, Robert Reiser & Company, Convenience
Food Systems, Ilapak, Orics, Hayssen, Harpak and CVP Systems, supply such
sealing equipment.
Film and resin suppliers such as Cryovac Sealed Air, Dupont and Eastman
have tremendous capabilities as well. Companies that supply analytical
equipment utilized to verify gas amounts are also a critical part of the
process and include PBI-Dansensor and Mocon.
Editor's Note: Lou Cooperhouse is director of
the Food Innovation Research & Extension Center of Cook College and
the New Jersey Agricultural Experiment Station at Rutgers University.
He recently published a comprehensive study, Retail Prepared Refrigerated
Foods: The Market and Technologies. He can be contacted at (732) 537-1901
or at cooperhouse@aesop.rutgers.edu.
© 2003 Columbia Publishing
>>
Return to top
New
Super Premium Produce Label Expected to Boost Market Share
By D. Brent Clement
Managing Editor
Fresh Cut
October 2003
SALINAS, Calif. - Hoping to grow its market share even
more, Tanimura & Antle, Inc., has introduced a new brand of super
premium produce. Reflecting the name of the family partnership, the new
Tanimura & Antle™ brand offers consumers the highest quality
produce available at retail and in the years ahead is expected to help
take the million dollar business to an even higher level of performance
in terms of market share.
While branded produce may be common in bagged salads and pre-cut vegetables,
it is a relatively new concept for other fresh vegetables, according to
Rick Antle, Tanimura & Antle president and principal. The company
has a complete line of branded and unbranded fresh vegetables, packaged
salads and fresh-cut vegetables.
The new Tanimura & Antle label will not replace the current T-A®
brand, but will create a produce line that falls within the strict specifications
of super premium quality, Antle explained, speaking during a field harvest
tour for members of the press held Sept. 4 and 5 in California's Salinas
Valley.
"If produce doesn't meet the standards, we won't pack it under the
Tanimura & Antle brand," added Mike Kenter, vice president of
sales and marketing. "When customers purchase Tanimura & Antle
produce they expect to consistently receive the same premium product,
each and every time. This is the promise we make to the retailer and they,
in turn, can make to their customers."
One "Power" Brand
"We are consolidating our brands under one power brand to help grow
our sales across the fresh vegetable and packaged salad categories,"
explained Kenter, hired in October 2001, to put together a new marketing
plan based on feedback from customer and consumer research.
Under the direction of Tanimura & Antle executive management, Kenter
went to work implementing a series of research efforts to help decide
where and how to take the next step. A National Consumer Produce Poll™
was initiated to better identify what consumers really value and want
in their produce.
Among the findings were:
" Consumers view fresh vegetables and packaged salads similarly.
It's all "fresh produce." Packaged salads are just a convenience
form. They expect the same benefits - freshness, quality and taste - from
all of the products.
" Consumers preferred the brand name, Tanimura & Antle, over
the company's other brand names by a wide margin. Consumers surveyed in
the study were highly supportive. They expressed more of a personal connection
with a family-run business versus a large corporate conglomerate.
" Consumers found the Tanimura & Antle brand/company appealing.
They seemed to recognize that for the partnership, fresh produce is their
life's work and their only business. The business is family run. Family
members are involved in the growing, harvesting and shipping and guarantee
the quality of their products with their name.
" 95 percent of consumers expressed positive purchase intent for
the Tanimura & Antle brand.
" Tanimura & Antle was selected as their pick for the "highest
quality brand." When more than 2,000 consumers were asked what the
most important brand attribute was in making a purchase decision on lettuce
or packaged salads, the No. 1 response was: "Highest quality brand
available." The Tanimura & Antle brand was most often selected
as being that type of quality.
Based on that study and other research, the new Tanimura & Antle brand
of super premium produce was born. With the help of packaging designers
and others, a new brand identity--a logo depicting two farmers gazing
out over the fields and carrying the company slogan: "Grown with
Family Pride for Three Generations"-- was created.
Special Field Tour
To help kick off the new marketplace identity, a special field harvest
tour, hosted by Tanimura & Antle executives, took place. Fresh Cut
magazine was among four publications from throughout the United States
and Canada invited to participate. The tour included a walk-through of
the company's headquarter facilities, salad processing plant and distribution
center, all in Salinas.
Guests were able to see first hand how the company's Tanimura & Antle
brand packaged salad products are put together. Donning netted hats, white
gowns and booties, editors watched high tech equipment and a skilled workforce
at its best processing raw produce into the attractive, finished product
recognizable in retail and foodservice outlets today.
Unique to the company's salad processing plants, both crew and equipment
head down the road at the end of each harvesting season. As the harvest
winds down in Salinas, for example, the crew dissembles row after row
of processing equipment there, loads it onto 22 trucks and makes the long
move to a second company plant in Yuma, Ariz. Once there, everything is
quickly reassembled on a weekend in time for processing to begin first
thing on Monday morning. From tear down to restart only 50 to 60 hours
are involved.
Following the Salinas season, the processing equipment is torn down and
trucked to Yuma, Ariz., for the winter harvesting cycle. Once completed
there, it is loaded again and trucked back to Salinas, where the cycle
begins all over again.
Many Tanimura & Antle workers are employed year-round and follow the
harvesting circuit, according to Kenter. Retention is well above the industry
average, as all full-timer employees receive a wide range of benefits
and participate in various incentive programs. Whether working in the
plants and warehouses or in the fields harvesting celery, broccoli, lettuce
and other vegetables, worker pride and enthusiasm is apparent on almost
every face.
Long History of Quality
Believing that higher quality produce translates into higher profits for
retailers and the company itself, Tanimura & Antle management has
long recognized the value of marketing only premium produce. The Tanimura
family, descendants of Japanese immigrants and interred with other Japanese
citizens during World War II, focuses on farming the company's approximately
45,000 acres of prime farm land. The family and company are widely honored
as being among "the best of the best" Salinas Valley vegetable
growers. George Tanimura was instrumental in bringing eco-friendly drip
irrigation to the fields that the company now farms. And today, at 88,
he continues to monitor the fields and refine this technology.
The Antle family migrated to California from the Dust Bowl of Oklahoma
in the 1930s and after years of struggle established itself as a prominent
produce shipper. In the earlier years, Bud Antle worked with his father,
Lester, in various lettuce packing sheds, before establishing a family
business of their own. Involved in the business was Lester, Bud and Bud's
sister, who worked as the accountant and bookkeeper.
To Bud, employees were part of his family and he treated them that way.
He knew all of them personally. Even after the company grew from 60 to
300 employees, Bud still traveled the fields every day to visit with the
workers. His son, Bob Antle, who serves with George as co-chairmen of
the board today, continues the legacy by encouraging all involved in day-to-day
management to read John Steinbeck's Grapes of Wrath at least once each
year. His purpose is to keep things in perspective and remind his family
of its history and goals.
World War II brought a shortage of wood and other materials needed for
packing and processing iceberg lettuce and the available materials were
very expensive. This led Bud to explore a new process of cooling and packing
iceberg lettuce for shipment - vacuum cooling. Ultimately, his introduction
of vacuum cooling revolutionized the produce industry.
Meanwhile, by the 1950s, the Tanimura brothers-George, Charlie, Tommy,
Ben, Bobby and Johnny-were growing lettuce exclusively for Bud Antle,
Inc., and George and Bud were trusted friends. That legacy of respect
and cooperation has continued through the generations.
The new Tanimura & Antle logo appears to represent George and Bob,
two long-time friends and business partners, whose friendship during those
earlier years led to the formation of Tanimura & Antle in 1982. George
and Bob and their respective families combined their more than 50 years
each of produce experience and knowledge to go into business together.
The company was incorporated in 1988 and today includes a full line of
fresh vegetables and value-added products shipped throughout the United
States and to other international customers. Tanimura & Antle has
become an industry leader and dominate force in the produce industry today.
© 2003 Columbia Publishing
Skilled
Field Crew Plays an Important Part
Fresh Cut
October 2003
If you want to see a work of art in motion, visit a Tanimura
& Antle celery field during harvest time. It can be an eye-opening
experience, as I learned during a Sept. 5 harvest tour of a few of the
company's immaculate and well-kept fields in California's Salinas Valley.
Most of us have seen work crews before, but there is something extra special
about witnessing a highly specialized celery crew given an incentive that
rewards them for quality and speed. What I saw there was incredible speed
and precision. Every cut, every movement was a work of art. More important
was the end product. Perfectly uniform in every dimension each stalk going
into the packages was close to perfection. This was a testimony of the
value and skill of a hard-working Tanimura & Antle team whose services,
value and contributions speak for themselves.
"These workers are so specialized they harvest only
celery fields," noted Jed Murray, the company representative conducting
that segment of the tour. "Most average $14 to $16 per hour, have
a full package of benefits and are worth every penny of it. Do any of
you think you can match their skills?"
Shifting his gaze in my direction, he handed me one of the specialized
cutting knives used and challenged: "Come on, Brent, give it a try!"
My first swoop at the base of a celery stalk was not that bad-the cut
was actually surprisingly close to accurate, I thought-but then I ran
into trouble trimming the branches to industry standards, especially in
the amount of time required. While I cut and trimmed one celery stalk,
the worker nearest me had completed at least three and was working on
his fourth.
"Try again once more," Murray encouraged. "You'll
do better this time."
Not so, as my second effort proved. The end product was
worse and even slower to complete than the first. My base cut was too
high, and the celery stalk came apart in my hands. Holding it together
in one hand, I trimmed the top anyway, but that, too, was not up to packaging
standards. The celery stalk was at least four inches too short. This one
would be left in the field.
"Want to try once more?" Murray asked.
"I'll pass," I returned, resolute in my decision to avoid further
embarrassment. "This crew has my deepest respect!"
© 2003 Columbia Publishing
Fifteen
Years of Solid Growth with More to Come
Fresh Cut
October 2003
SIDNEY, Ohio - While much has changed at Freshway Foods
since the company was founded in 1988, the desire to provide the highest
quality and safest fresh-cut produce available remains its No. 1 commitment.
Over the years, Frank and Phil Gilardi, Freshway Foods co-founders, have
not forgotten their cultural roots and humble beginning. Both attribute
the success of Freshway Foods, their Sidney, Ohio-based company, to lessons
from the past.
2003 marks the 15th year anniversary for the company, which has come a
long way from its humble beginning.
Lessons from the Past
"Part of our education came from cleaning vegetables for our father's
company when we were kids," Frank remembers, recounting the days
when he and brother, Phil, worked for their father, Frank Gilardi, Sr.,
a wholesale produce distributor. "In that family owned business we
all worked hard to take care of our customers needs. We did everything
from filling orders ourselves to driving the deliveries to the customers."
It was through such experiences that Frank, Jr., and Phil realized how
important quality, safety, and meeting customers' needs are to any business.
This tutoring and training from any earlier part of their lives helped
prepare them for the multi-million dollar fresh-cut business they operate
today.
Led today by Frank Gilardi Jr, who serves as CEO, and Phil Gilardi, as
President, company sales volume continues to climb. An expansion of their
3-year-old state-of-the-art processing and distribution facility is currently
in the planning stages.
"Over the past few years, we've added more sales people in the field
and now service practically the entire eastern U.S. with our company-owned
logistics and distribution fleet," says Dan Purdy, vice president
of sales and marketing. "We now service a 17-state area."
The Gilardi brothers have worked hard to maintain and expand market position,
working closely with vendors and installing cutting-edge wash, packaging
and processing equipment and systems.
"From top management down, everyone is focused on doing those things
that ultimately will help the customer," notes Bill Oda, director
of technical services.
The current Freshway Foods facility features some of the most efficient
equipment available on the market today. Every effort is made to ensure
the quality and safety of all fresh-cut produce shipped to the company's
growing customer base. In 2003, additional new, state-of-the-art processing
and packaging equipment has been added.
"We have an excellent environment and are proud to be using the finest
fresh-cut produce processing equipment available in the industry today,"
says Phil.
Freshway Foods works hard to obtain timely feedback from its people on
the floor, according to Ken Baptist, vice president of operations. "They
know their customers and take great pride in delivering safe and fresh
product for every order. They understand our commitment to food safety
and food quality."
Today, Freshway Foods is a leading U.S. fresh-cut produce processor. Early
last year, the company was awarded the prestigious 2002 Fresh-Cut Produce
Award, sponsored by the International Fresh-cut Produce Association (IFPA)
and The Produce News.
Foodservice, Retail Trends
Looking to the future, Freshway Foods management is aggressively involved
in new product development, according to the Gilardis. The company continues
to work on achieving its goal of helping meet the needs of both foodservice
and retail customers.
"We see an ongoing need for further convenience in food preparation."
Frank notes, pointing out time constraints facing restaurants and foodservice
operators as well as busy families. "We are positioning ourselves
to meet their needs."
Freshway Foods management is currently marketing a series of products
offering convenience for both the foodservice and retail sectors. Included
are toppers, ready-to-go salad kits, blooming onion cuts, salsas, variety
items such as tomatoes and squash, as well as other customized cuts.
"Basically, if it grows, we are trying to find a way to add value
to it and get it safely to the end-user," grins Purdy.
Among the value-added benefits fresh-cut produce offers are: 100 percent
usable product, consistent quality, time and labor savings, reduced risk
of cutting injuries, and reduced need for costly storage space, Purdy
points out. On-site cutting operations also find it difficult to match
food safety standards and the quality and consistency of cuts made at
processing facilities such as Freshway Foods.
Because of this, the market is moving more and more toward fresh, pre-cut
produce, adds Frank. "People are getting smarter about what they
eat, food safety and the areas of nutrition. This is driven by the consumer,
and ultimately, by foodservice and retail buyers who are demanding this
from the entire supply chain."
The Full Package
Part of the Freshway Foods' success is attributed to its first-class fleet
of company owned trucks. The company can deliver fresh-cut products to
any of its customers in 12 hours or less. Sales people also have been
strategically placed throughout the marketing area to help with customer
needs.
"With product moving all over the country to various points in the
17-state area, Freshway Foods knows the importance of cultivating our
relationships with customers and of being there when a need arises,"
Purdy points out.
.
Full Line of Products
Today, Freshway Foods offers a full line of fresh-cut produce, including
lettuce, onions, cabbage, romaine, carrots, celery, tomatoes, fruits,
deli salad kits, Topper products (salsas, diced roma tomatoes, diced onions,
three-way onion dice, diced yellow onions, diced red onions, diced green
peppers), gourmet stuffing mixes, relish and vegetable trays, cranberry
relish, cauliflower, peppers, cucumbers, radishes, broccoli, and more.
Freshway Foods also offers customized cuts in various shapes and sizes
and with a variety of packaging options, according to Frank. All products
have been processed and packaged so that they are easy and simple to use.
One success story, according to Frank, is a satisfied customer from Bermuda.
They use the company's salad kits. Product is shipped twice a week to
a distributor on the East Coast, who then put it on a boat bound for the
tiny island. Eventually it is distributed throughout Bermuda.
"The customer is one of our biggest salad kit fans," Frank smiles.
Commitment to Food Safety
From day one, Frank and Phil have stressed the importance of both food
quality and safety.
"It all starts there," Phil stresses. "Our food safety
trend is moving in the right direction. We want professionals doing this
type of work, all of the way from when the seed is first planted to when
product is distributed to the end user. Everyone along the way is involved
in our food safety program, and we work together to provide the highest
quality and safest fresh-cut product available today."
Freshway Foods has adopted a Qualified Through Verification, or QTV, program.
Under QTV, USDA inspectors check and monitor how well the company food
safety program is working.
Oda explains. "The inspectors can come to our facility at any time,
during any shift," Oda explains. "They are unaccompanied and
unannounced. Everything we do is expected to meet QTV specs. Only a limited
number of processing plants in the U.S. are QTV certified. The reports
have been excellent, but we are continually trying to raise the bar."
Freshway Foods also has a HACCP program and GMPs in place. The purpose,
of course, is to ensure that food safety comes first and is a continual
process.
Bright Future
Looking ahead, the Gilardis also recognize the importance of the Freshway
Foods workforce in maintaining a bright future.
"We want our employees to be happy with what they do and with what
they have accomplished," says Phil. "Many of our employees have
been with us all of the way through. There is a deep family feeling around
Freshway Foods. Our people are the beginning and the future of our company
and we remain committed to helping them achieve their goals and enjoy
a better life."
For more on Freshway Foods' full line of fresh-cut produce, visit the
company Web site at www.freshwayfoods.com or call 1-800-497-1566. The
company is located at 601 N. Stolle Ave., Sidney, OH 45365.
© 2003 Columbia Publishing
Gills
Onions Displays 'Best Booth' at PMA Foodservice Expo
Fresh Cut
October 2003
One of the highlights of the recent Produce Marketing
Association Foodservice Expo in Monterey, Calif. was the selection of
the best booth award. In its first-ever contest, PMA judging officials
selected Gills Onions of Oxnard, Calif., "best of show."
According to contest judge Darby Mason, Gills incorporated several visual
elements that warranted the selection. "They made great use of one
clean image to communicate what they do, namely onions," said Mason,
executive programs manager for Xilinx, Inc. "Other outstanding aspects
of Gills' booth included the company logo being prominently displayed
and well lit; the logo was also used on the giveaway pedestal which heightened
name recognition. Also, using the product in a way so that visitors could
personally experience it was innovative. As such, Gills' employees prepared
a memorable sweet onion cake."
Gills also took advantage of its booth location. "Gills had a corner
booth which allowed them to display their new product sign toward the
front and also on the open side area," said Mason. "There were
no barriers to the entry which helped with the flow of visitors. The openness
was very inviting."
Booth staff played an important role, too. According to
Mason, Gills' staff were engaging with visitors, presented an open and
inviting attitude, showed approachability with body language, listened
intently to visitors, asked qualifying questions and did not eat or drink
while in the booth.
As the winner, Gills Onions will receive first choice of booth space for
the 2004 Foodservice Produce Expo, a "best of show" plaque and
other benefits. "We are very excited to be the winners of this year's
contest," said David Gill of Gills Onions. "This show is one
of the best we participate in all year because many of our customers and
potential customers are at the show or in town. To have our hard work
in setting up, booth design and staff training recognized and rewarded
is a great honor. We are already thinking about how we can improve upon
this year's effort for the 2004 Foodservice Produce Expo."
The 2004 PMA Foodservice Conference, Tours & Expo will be held July
24-26 in Monterey, Calif. The Foodservice Produce Expo will be held July
25, 2004.
© 2003 Columbia Publishing
Darby's
Ideas For Designing, Updating Your Booth
Fresh Cut
October 2003
Here are Darby Mason's additional recommendations for
designing a trade show booth.
Designing a New Booth:
• Take time to look at other booths at trade shows - in your own
industry and in others.
• Look at trade show industry Web pages and magazines for latest
design trends and functionality in all different size and types of booths,
e.g., pop-up, modular, custom modular and custom.
• Develop a comprehensive request for proposal (RFP).
• Select top booth design companies that you want to meet with to
review the RFP. Base your decision on references from other companies,
style of work, range of cost, company philosophy/personality and other
elements that would be important for a long-term relationship (if that's
what you are looking for) such as location, account management, manufacturing
locations, etc.
• Thoroughly review the RFP with those potential vendors you have
chosen (no more than three).
• Meet with designers and review proposals keeping to budgets and
required timelines.
Elements to Include in Your RFP:
• Identity of your company: It's history, philosophy, values, organization,
what the company does, its audience and market.
• Specify objectives of the booth: Brand awareness, product demonstrations,
flexibility for multiple sizes or styles, etc.
• Define clear likes and dislikes in booths that you have seen: Materials,
fabrics, colors, shapes, etc.
• Be specific about what type of booth you are looking for: Pop-up,
modular, custom modular, custom, etc.
• Give lists of the number of items you require: Number of demo stations,
graphic panels, theatre stages, storage, audio/visual, registration desk
areas, seating, and configurations for the booth.
• Define the budget range you have to work with. This will allow
vendors to give you proposals that you can afford.
• Specify a timeline for completion and who the main contact and
final decision-maker will be.
Specific Design Elements to Consider:
• Clear company name recognition, i.e., visible logo, large enough
to easily read.
• Messaging: Position company identity/logo and tagline/key message
high and visible in order to communicate it to the audience within 30
seconds (so they remember your company and what you do). What is the one
key thing you want them to remember when they walk away?
• Graphics: Positioned and designed to communicate messages to audience
in right size and at right eye levels to be effective.
• Space: Create an open environment that is inviting for the audience.
Do not blockade your staff behind walls. Trade shows are face-to-face
opportunities. Design the space to allow for this.
• Structure: Design with materials that communicate the identity
and image of the company (Conservative vs. modern, wood vs. chrome or
fabric, etc.)
• Product/technology Demonstrations: Have space designed for easy
access and flow of audience in and out of demo areas. Design for proper
storage or refrigeration, computer systems, etc.
• Interactivity/Applications: Design space in your booth to allow
for interactivity with the audience. Maybe have product tasting, computer
activity, games, etc. If possible, find a way for attendees to use your
product or a product that has your product inside. Many attendees will
remember because of the experience they had more than a sign they read.
• Lead Capture: You should always design an area that is specified
for lead capture - to capture cards or run attendee badges - with enough
space to do so without being cluttered.
• Hospitality/Information: Design an effective way to host guests
into your booth without a barrier, if possible. Have literature available
in a portable or built it rack/shelf to save space and look organized.
Set aside space or storage for any incentives or giveaways.
Ideas for Updating a Current Booth:
" Define what budget you have available.
" If the budget allows, go to a booth design company for ideas on
ways to cost-effectively add specific functions or new elements.
" Identify your objectives for making changes to your booth, i.e.,
What are the benefits of the current design? What are the elements that
do not work well?
" Prioritize the elements that are missing and work to achieve the
most important. If it is brand awareness, placing the company name/logo
more strategically and in different/more visible materials may be an easy
and cost-effective change.
" If it is to be able to better demonstrate your products, you may
need to invest in counters and demo stations that will cost more but also
provide more storage space and opportunities for more graphics/messaging.
" If it is to elevate your image to a more professional look, perhaps
you change from multiple small graphic panels to one very large and bold
image that communicates more to attendees. In pop-up booths, paying to
create one or more larger scale images as your back wall, which can be
interchanged depending on the objectives of the show, is very cost-effective.
" If you want flexibility to change themes year to year, chose basic
colors for your booth structure or include fabric panels and use lighting
or new graphic panels/plasmas to change the colors and overall look from
show to show or year to year.
© 2003 Columbia Publishing
Fresh-cut
Citrus Product Line Opening New Windows of Opportunity
Fresh Cut
October 2003
By D. Brent Clement
Managing Editor
Presenting citrus products to consumers in a form that
is specially prepared and ready to serve may be the key to the future
of a whole new fresh-cut fruit category.
Michael N. Harrell of Florida Citrus Partners, Okeechobee, Fla., believes
that's the case. "The time is right," he says, "to aggressively
pursue developing this virtually untapped market."
"Typically, when you buy citrus products, they've always got a peel
on the bottom," he points out. "In a restaurant setting, you'll
either be served a whole orange, in which when you peel it, you get messy;
or you'll be given a slice as a garnish instead of something you really
want to eat. Serving a fresh-cut product, or 'sections,' as we call them,
is a refreshing alternative that takes away the mess and provides convenience."
As vice president of Florida Citrus Partners, Harrell is working closely
with the company's other director, Pam Davis, to develop what the two
feel could be an exciting future niche market for the citrus industry.
Local growers are firmly behind them, hoping to see additional options
to the juice and packing shed markets.
Florida Citrus Partners came into being in 1999 as a partnership venture
between Industries Training Corporation (ITC) of St. Petersburg, Fla.,
and DNE World Fruit Sales of nearby Ft. Pierce. DNE officials were looking
for ways to help local citrus growers add value to their products. They
spearheaded sales and marketing while ITC headed the facility operations.
Time Is Right
"I'm very optimistic about the future," Harrell says, pointing
out that after exploring several new and different markets he feels "the
time is right" for a variety of fresh-cut citrus products.
The Florida Citrus Partners product portfolio includes several citrus
juices - orange, grapefruit, tangerine, lemonade - as well as citrus (fresh-cut)
sections. Both sides account for approximately 50 percent of total business.
The company is also certified to produce organic juices and is exploring
to increase organics in every area of its business. The fresh-cut citrus
sections sold are primarily grapefruit or oranges, but there is growing
interest in fresh-cut mangoes, papayas and other exotic fruits. The citrus
section remains the most important in terms of volume of sales.
"We're now selling product into a variety of different markets,"
Harrell explains, including both foodservice and retail. Distributors
play a major role. Some product is sold to other fresh-cut fruit processors
who, in turn, use it as an ingredient. Other product goes into citrus
salads or becomes part of a mixed fruit package for the retail environment.
Florida Citrus Partners also markets its citrus sections and juice products
in various retail stores under the "Simply Elite" label. While
that is an important part of the business, management is more concerned
with boosting sales among private labelers, which accounts for approximately
80 percent of total sales.
Yield Loss Challenge
One of the challenges of marketing fresh-cut citrus products, according
to Harrell, is to minimize yield losses during processing. Yield losses
with cut fruit can run as high as 70 percent. Being located near various
citrus groves has been a big help. The company is able to avoid the downtime
and risk of product breakdown normally expected when bringing in product
from out of state.
"We started this business using infusion technology, peeling citrus
without a knife," the company vice president says. "Since then,
we've discovered that our customers want more of a cut look. Hence, we've
modified a few things and have come up with a simple, efficient method
of providing them with what they want and very quickly."
The cutting equipment was produced in-house, specifically for handling
citrus products, Harrell says.
The Packaging Challenge
A second challenge with handling citrus sections is selecting the right
kind of packaging, according to Harrell.
"We're using a wet solution in a variety of PET- and HDPE-type containers,"
he explains, "and we're experimenting with a couple of other types
of packaging more conducive to the retail market. Our product has a fresher
look than being in a jar or a bottle, therefore it provides us with a
distinct advantage."
Harrell estimates shelf-life for most of the company's fresh-cut citrus
products at 21 days, the preferred length of time. An additive--not a
preservative and unique to citrus--helps keep the fruit intact and provides
enhanced firmness. By adding a light additive, shelf life can be stretched
to 30 days. And for customers who demand even more shelf life, another
version can extend product life up to four months.
Located about 14 miles north of Okeechobee, Florida Citrus Partners owns
a large, modern plant containing 36,000 square feet that is USDA certified
and meets all HACCP requirements. Included are facilities for both juice
and fresh-cut citrus processing. On the extraction side, the juice moves
from the extractors to a juice pasteurizer. Steam tunnels on the front
end of the receiving line are used to help reduce the bacterial count.
Tight safety standards are enforced, and an in-house quality assurance
lab monitors everything. Cold storage space is provided both on and off
site, as both juice and fresh-cut citrus are produced year-round.
Florida Citrus Partners markets its products throughout the Northeast
and Midwest. However, several new markets, including a large grocery chain
in the West, also appear to be materializing. The establishment of brokers
throughout the country has spurned the interest in the Western market.
Inmate Training Program
One unique aspect of the Florida Citrus Partners operation is its utilization
of nearby prison inmates in its workforce. ITC, a management services
company, provides services for a diverse group of businesses and is involved
in everything from digital imaging, high speed data scanning to cold weather
clothing, remanufacturing automobile components and eye glasses. All utilize
prison inmates.
"We provide on-the-job training for these workers, and we have another
company that will actually hire them when they are released from prison,"
Harrell explains. "We place them in jobs with the goal being that
they do not return to prison."
The success rate has been phenomenal. If all of the companies involved
in the group of companies are included, approximately 5,000 inmates receive
on-the-job training each year. Thus far the recidivism rate is only 18
percent compared to 50+ percent for the general prison population. The
cost saving to society is enormous.
"The bottom line is people in prison are really on
welfare. You and I are paying for their stays," Harrell points out.
"With this company, they are providing on-the-job training. They
gain a work ethic and a sense of responsibility. Many have never worked
or have held only marginal jobs. Giving them a sense of responsibility
teaches them soft skills such as reporting on time and respecting authority.
These workers are paid an hourly wage, and part of that money goes to
offset the cost of their incarceration, including victims' restitution
which is administered by the state."
Food Safety/Quality Not an Issue
The quality and safety of inmate work has never really been an issue,
according to the Florida Citrus Partners vice president.
"These are highly motivated workers," Harrell
says. "They know that if they get out of line there are 1,700 other
people in the compound willing to take their place. Everything is voluntary;
no one is forced to work. Inmates fill out applications, interviews are
conducted and all workers are hired based on their qualifications."
The physical health of each worker is carefully screened.
"We are probably one of the few companies that can meet or exceed
all government safety standards because we only receive workers that are
medically cleared. We also have a full-time USDA inspector in our facility,
and all of our supervisors and management have background checks and submit
to drug screenings.
After serving their sentence, inmates employed by Florida
Citrus Partners are picked up by another one of the companies, Labor Line,
with a goal to help ex-offenders and underemployed people obtain a meaningful
job. Labor Line will provide the individual with temporary employment
if they cannot find them a permanent job. Special assistance is provided
to them for temporary housing, clothes and transportation to work.
The future looks bright for Florida Citrus Partners due to their distinctive
high quality and elite product offering, as well as their motivated workforce.
With a variety of fresh-cut citrus section and juice products, the company
hopes to be able to tap into an exciting new niche market.
© 2003 Columbia Publishing
Innovative
Product Is More Than About Sliced Apples
Fresh Cut
October 2003
With last year's sales for NatureSeal® in the United
States up substantially and literally going through the roof in Europe,
the management at Mantrose-Haeuser Co., Inc., Westport, Conn., couldn't
be more optimistic.
Used to extend the shelf-life of fresh-cut fruits and vegetables, NatureSeal
has literally revolutionized the apple industry, helping create a whole
new category of apple products. Forward thinking processors with support
from the Washington, New York and Michigan apple commissions and the Mantrose-Haeuser
team of technical advisors made it possible for the first sliced apple
products to roll off the production lines.
"In the past two years, we have seen sliced apple products make their
debut in school cafeterias, the Olympics in Salt Lake City and now finally
on fast food menus," says William Barrie, president of Mantrose-Haeuser.
"Consumers will soon purchase sliced apples by the bag just as they
do baby carrots and salad greens. Consumption will rise as sliced apples
become a staple item. This is only the beginning."
More than Just Apples
But NatureSeal is more than just about apples. The NatureSeal family of
products includes treatments for sliced pears, avocados, potatoes, carrots,
celery, bananas, peaches, plums, nectarines and grapes. Each treatment
is individually formulated.
NatureSeal has made it possible for the pear industry and others to experience
positive, new market growth, according to Barrie. With pears, for example,
NatureSeal's patented technology helps produce the "perfect"
slice.
In Europe, a very popular use for NatureSeal has been on a whole generation
of prepared carrot products--carrot sticks in crudite packs, carrot batons
and carrot "coins" in microwave packs and, of course, baby carrots
for snacking, Barrie says. NatureSeal is used on both baby carrots and
celery. The product prevents the drying out and subsequent whitening and
bending of carrot sticks as well as browning of the cut ends of celery
sticks. While these issues are common in the U.S. marketplace, European
consumers reject products that do not have the appearance of "just
cut" freshness; carrots showing any signs of blushing are shunned
by the UK shopper.
Europe has proven to be very cutting edge, adopting treatments for stone
fruit as well, Barrie points out. Leading U.K. retailers Marks and Spencer
now offer more fresh-cut than whole fruit. Currently, approximately 80
percent of fruit and vegetable sales are represented by either value-added
or fresh-cut produce.
"We've been working closely with our processors and supermarkets
there," Barrie says. "When they come up with a concept, we do
what we can to develop a treatment that will permit them to successfully
market the product. The European market is probably a bit more 'take away'
than here in the U.S."
Some European supermarkets are now experimenting with combinations such
as fresh-cut nectarines and yogurt or celery sticks with a particular
dip, he adds.
Avocado Market to Grow
In the U.S., the next fruit product expected to take off is pre-cut avocados,
Barrie believes. This includes halves, slices and chunks. Avocados are
one of the fastest growing fresh ingredients, with 46.3 percent of U.S.
households already purchasing them on a regular basis.
While NatureSeal was developed specifically for the Hass variety (which
accounts for 80 percent of U.S. avocado consumption), it also works on
all varieties, Barrie stresses. NatureSeal protects fresh-cut avocados
from color, flavor and texture changes for up to two weeks.
The availability of fresh-cut avocados is expected to boost both foodservice
and retail market sales.
Health Conscious Consumers Fuel the Demand for Healthy
Snacks
A major factor behind the growth in NatureSeal sales over the past few
years is changing consumer demand, according to Barrie. Today, the public
is more health conscious than in the past. Consumers are concerned about
obesity and are eating more fruits and vegetables. This is opening new
windows of opportunity for fresh-cut processors who also are able to promote
convenience and labor savings. Many use products such as NatureSeal to
ensure freshness while extending product shelf life.
NatureSeal is free of sulfites, allergens and Genetically Modified Organisms
(GMO), according to Barrie. This vitamin-mineral blend, approved by the
FDA, dissolves almost instantly in cold water and acts as a clear dip
for sliced apples as well as pears. A consumer retail pack will be available
nationwide later this year.
"What excites me is the fact that major fast food chains are now
offering fruits and vegetables as an alternative," Barrie says. "That
is opening a whole new category. Look at the salads that McDonald's is
offering, and now the company is looking at sliced apples."
Decade-Long Effort
The early research that led to the development of NatureSeal began with
the U.S. Department of Agriculture in the late 1980s, Barrie points out.
Researchers there were looking for a way to slice apples and keep them
for an extended period without altering their taste, appearance and texture.
They wanted the product to be identical to freshly cut. Strong support
was provided by several state apple commissions, all looking for new markets
for their growers.
Working in a partnership arrangement with Mantrose-Haeuser, the combined
research team eventually came up with a product in 1999. Later, that product
was trade named NatureSeal and sales began to take off.
While various markets have grown over the years, research teams at NatureSeal
and Nutri-Tech, Inc. continue to look for ways to boost apple consumption
in public schools.
Nutri-Tech, Inc. is a professional consultant group dedicated to providing
schools and the foodservice industry with comprehensive and innovative
training programs, as well as customized services.
While it has long been said that apples may keep the doctor
away, the challenge has been getting children to eat them, according to
Barrie. After polling school foodservice professionals across the country
this past June, research teams at NatureSeal and Nutri-Tech discovered
the following:
• Regardless of how often whole apples are offered on the school
lunch menu, students opt not to take an apple 75 percent of the time.
• Of the small percentage of students (25 percent) who do select
an apple, most eat less than half the apple (65 percent).
• The primary factor observed as the key interference with the consumption
of an apple was the difficulty of eating a whole apple, due to braces,
missing teeth, etc. (58.7 percent). Other factors included: (1) preference
to an alternative food choice offered that day (18.7 percent), and (2)
not enough time to consume (2 percent).
• The grade level that is noted for eating less of the whole apple
is elementary schoolchildren (75 percent).
• But perhaps the biggest finding from the Fresh Apple Survey also
suggests a solution to this dilemma.
When asked if they believed more students would select and eat a sliced
apple rather than a whole apple, 91 percent of foodservice directors said,
yes.
"These findings suggest a pattern across the country
with respect to apple consumption among school children," says researcher
Thelma Becker of Nutri-Tech. "Simply put, the majority of students
are not selecting whole apples for their lunches, and of the small percentage
who do, they are not eating enough of the apples to achieve the optimum
health benefit from them. But, if the apples were offered sliced, the
foodservice professionals were nearly unanimous in agreeing that students
would indeed eat them."
The results of the Fresh Apple Survey mirrors a 2000 study conducted by
the Washington Apple Commission in a school system in Sarasota, Fla. The
test was conducted with a Florida school district where cafeterias put
sliced apples, treated with NatureSeal anti-browning agent, on their a
la carte lunch lines instead of whole apples.
According to the Commission's Welcome Sauer, sliced apples were offered
in place of the apple basket in half of the schools surveyed -- one apple's
worth of sliced apples per plate. After tracking apples sales for a month,
they found schools that offered apple slices sold 80 percent more apples
than they had in the previous month of whole apple sales.
"Basically, the short way to say this is that apple
sales increased 80 percent when the schools offered sliced apples,"
Sauer said.
Proof Is in the Eating
To further test these observations, Barrie says Mantrose-Haeuser intends
to launch an in-depth study this fall to see if students will actually
select and consume more apples if they are offered sliced. Interested
school districts will receive a free, one-week sample of NatureSeal for
Apples to offer in their cafeterias in exchange for the school tracking
sliced apple selection and consumption during the test period. The research
team at NatureSeal and Nutri-Tech will track and monitor the study and
release the findings in late November.
"Our pledge to American children is to offer a solid solution to
the growing pediatric obesity epidemic in this country," Barrie says.
"If we can increase the number of children who both select apples
as a choice for lunchtime and a snack and actually eat more of them because
the apple is sliced, then we are making great strides in conquering the
obesity problem among children - and perhaps even adults as well."
Apples are considered one of the most nutritious and convenient fruits
on the market. According to the U.S. Apple Association, apples are an
excellent source of dietary fiber and are loaded with pectin, which aids
digestion and may help reduce the risks of cancer and heart disease. Apples
have also been found to have significant amounts of what research is now
uncovering to be a wide array of important phytonutrients. These have
extremely important health benefits against such diseases as cancer, stroke,
cholesterol and more.
Nutri-Tech partner Beverly Lowe, a registered dietitian, supports serving
apples in a form that encourages consumption. "School nutrition professionals
nationwide are in business to nourish student bodies not garbage cans,"
she says.
Looking for More Solutions
Meanwhile, NatureSeal researchers continue to work with various processors
to help them find solutions to their challenges, whether it be with fresh-cut
apples, carrots, potatoes or other fruits and vegetables.
"It is a common practice for our research and development teams to
be out in the plants helping our processors solve their problems. Our
mission here is to listen to what our customers would like to do and come
up with solutions for the barriers that may be in the way," Barrie
says.
© 2003 Columbia Publishing
Providing
Value-added Services for the Fresh-cut Industry and Others
Fresh Cut
October 2003
Is this produce the best quality available? Should I
buy now or wait until tomorrow? Am I paying too much? What will happen
in the market to affect my supply?
When Fresh Network was founded in 1986 in Salinas, Calif., Derek Derdivanis,
Bill Joest and Larry Gamble focused their attention on providing answers
to just such questions. They envisioned becoming more than "telephone
jockeys," as brokers are often referred to in the trade, those who
put together deals but offer little else. They hoped to see their fledgling
company become the most effective, full-service produce procurement organization
in the United States and do it by providing value-added services.
The American Dream
Today, 17 years later, Fresh Network represents the fulfillment of the
American dream. The multimillion dollar produce procurement and distribution
service is one of the largest procurers of bin lettuce in the U.S. The
company handles 14 bin items (from different cuts of lettuce to romaine,
broccoli, cabbage, carrots and celery), more than 35 foodservice packs
and 18 pre-cut items. In all, it handles 27 fruits, more than 50 vegetables
and 200-plus types of herbs.
While the company headquarters remains in Salinas, there are satellite
offices in both Yuma and Nogales, Ariz., and Fresno, CA.
Approximately 60 percent of Fresh Network's current customer base is foodservice,
but Fresh Network also is a key produce procurer for the fresh-cut fruit
and vegetable industry. The company is a charter member of the International
Fresh-cut Produce Association (IFPA), founded in 1987. In fact, Derek
won the name contest for the IFPA newsletter, "Fresh Cut."
A former lettuce shipper, wholesaler and distributor, Derdivanis quickly
recognized the IFPA's value as well as the direction in which the produce
industry was moving. Fresh-cut lettuce and other products were beginning
to appear in the marketplace. Bin lettuce sales were gaining momentum,
while carton lettuce was losing market share.
"We realized that regional processors need servicing," says
Al Gracio, Fresh Network bulk commodity manager. "At that time, most
people were treating bin lettuce like hardware. The thinking was that
all you had to do was order and every bin would be the same. Unfortunately,
that's not the case."
Visit Fresh Network's Salinas war room and you will find it a beehive
of activity, as its team of professionals actively monitors and purchases
over 100 commodities. Some compare the action to the New York Stock Exchange.
Staff members are busy recording price changes and other information on
a huge commodity board adorning an entire wall.
Multi-state Source Operations
Fresh Network has source operations in California, Arizona, Idaho, Washington,
Texas and Florida and consolidation dock in both Salinas and Yuma. The
company offers both convenient and cost-effective consolidation and drop
shipments.
Quality control is considered the cornerstone of Fresh Network's business,
according to Derdivanis. Seasonal inspectors are in the fields in Arizona,
California, Colorado, Idaho, and Washington, where most of the fruits
and vegetables sourced are purchased. They check produce quality, feed
in price information and help customers determine whether they are getting
quality buys.
Fresh Network offers its customers daily Early Bird Quotes, a weekly Network
News newsletter, a bio-monthly Lettuce Update U, an Onion Gram, The Spud
Cellar for those interested in potatoes, Vine of the Times, a daily Top
Ten Lettuce Report as well as commodity price tracking. Its Network News
contains information on upcoming market conditions, anticipated quality,
harvesting locations, new products, market specials and more. Daily quotes
and inspections, market tips and other produce information also are provided.
As part of its value-added services, bulk bin lettuce customers, for example,
received information on weights, quality defects and size range. Color
photos also show typical product availability and note any defects or
concerns.
"Our goal is to select the highest quality product available at the
most competitive price," Derdivanis stresses, adding that while price
is important, "it is the quality that you can purchase for the same
price that tells the real story."
Fresh Network purchases produce from 16 different bin shippers. Working
with a larger pool increases the likelihood of locating high quality produce
and reduces the chances of an interruption in product supply, the greatest
fear of any processing or foodservice organization.
Quality Control Inspection Team
Fresh Network also has in-house quality control inspectors in California
and Arizona, according to Derdivanis. These full-time inspectors monitor
product quality as it is harvested from the field and again as it is loaded
in the truck going to the customer. The Fresh Network team considers this
key to its ability to adhere to quality specifications set by processors,
foodservice organizations and national accounts.
"Our 'eyes and ears at the source' gives us the product and market
information necessary to consistently ensure that you will be buying the
best quality product available on the market at a competitive price,"
Derdivanis points out. "No other procurement organization dedicates
its own quality control inspectors to look at so many types of produce
items. Our inspectors are able to select harvested lots and monitor their
cooling and loading on the truck to insure our quality standards are met.
The selected lots are marked with Fresh Network stickers so you know that
the product we have selected, monitored and labeled is the product that
arrives to you on the truck. We are definitely an extension of our customers
into the fields."
Good information is key to the company's "competitive and superior
quality purchasing," Derdivanis adds.
Market Service Area
Today, Fresh Network procures as well as ships produce for customers throughout
the U.S. and Canada as well as the Pacific Rim. It also procures produce
for the U.S. Military, which has some of the strictest safety and quality
standards in place anywhere. Last year, several key Fresh Network personnel
were honored with plaques for outstanding service provided.
A relatively new addition to Fresh Network's value-added service package
is its Network Management systems. It provides pricing information, for
example, to restaurant customers like Applebee's and Denny's. Such customers
can view benchmark price forecasts for the week and stabilize their pricing
while maintaining their quality specs. So when product is received and
the bills come in, they can know whether they are being charged as agreed
upon.
"We gather input on average pricing from approximately 400 shippers
and freight companies to determine what the market should be," the
managing partner explains. "This adds up to millions of dollars in
savings for our end-user clients. We are looking at approximately one
percent savings on produce purchases, which when factoring in the volume,
adds up quickly."
© 2003 Columbia Publishing
>>
Return to top
Taking
the Mystery Out of Package Design
Fresh Cut
November 2003
You can sell your fresh-cut produce using hi-tech tools like phones, faxes
and e-mails. You can even visit buyers and speak to them personally. Once
your package is on the supermarket shelf, however, it has to communicate
on its own or consumers may not take it home, according to Loralee Lyman
of Flipside Design, Inc.
Lyman, who has been making fresh-cut produce and other products look good
for two decades, has created eye-catching designs for such prominent produce
companies as Earthbound Farm, Capurro Marketing, OBIM Fresh-Cut Fruit
Company, Pacific International Marketing, Pacific Pre-cut Produce, River
Ranch Fresh Foods and Taylor Farms. She has also created packaging for
other companies such as Aloha Ice Cream, Carmel Candy Company, Kellogg
Garden Products, Monterey Peninsula Winery and Pavona Wines.
She's more than just a designer of outspoken packaging. She has also developed
an entire product line from the ground up, designing and engineering jars
and measuring utensils, labels, efficient shipping cases and logistics,
point-of-purchase materials and retail displays for Tiger Tree Orchid
Food.
IFPA Guest Speaker
A guest speaker at the International Fresh-cut Produce Association's 16th
Annual Conference & Exhibition last spring in Tampa, Florida, the
award-winning product designer demystified the process of launching a
product and introducing it to the marketplace by walking her audience
through it step by step.
Using Skippy® Peanut Butter as an example, she started by discussing
what is or isn't in a name and the most effective way to put a moniker
on your product.
"Name generation and slogan development is important in the long
run," she reported, referring to a jar of Skippy. "What are
we more likely to remember today: 'Skippy' or 'freshly roasted, really,
really, really smashed peanuts'?"
Even without the catchy name, however, consumers would still know what's
inside the familiar wide-mouthed jar because the label design conveys
the image of "swirly, creamy stuff on a knife" with whole peanuts
pictured around the edge of the illustration.
"I think it visually conveys what's inside without the consumer even
actually knowing the name," she explained, cautioning processors
to avoid ambiguity in their packaging designs. "I don't think it's
always visually apparent what is inside the package with fresh-cut produce.
Even though they are only minimally processed, they are different from
their natural state and it's a lot to ask of a busy consumer to actually
recognize what product you have in the package."
Packaging must act as a "silent salesman" when fresh-cut products
are placed on supermarket shelves, Lyman reasoned. Without speaking verbally
to shoppers, the package must communicate not only what product is inside
but also what attributes it possesses to convince the ultimate customer-the
consumer-to buy it.
"Whether you're developing it or whether your customer requests it,
your product still needs to instantly communicate its qualities to both
the buyer and the consumer," she explained, emphasizing the importance
of effective visual communication. "You can generate a lot of enthusiasm
about your product ahead of time by talking it up, but who is going to
get that message across to the consumers? They weren't around when you
hyped your product to the buyer. How are they going to know if you don't
tell them? More importantly, how are they going to know if you don't show
them?"
The first step in good visual communications is to develop a distinctive
name consumers can begin to associate with the product. She again referred
to Skippy Peanut Butter as an excellent example of a name that can be
linked to the product. Since 1932, when Skippy was first used as a trademark,
the name has become synonymous with peanut butter.
Pick a Great Name
"Skippy is a great name," Lyman told the IFPA audience. "It's
arbitrary. It's unique. It's fanciful. It doesn't mean anything. It's
a perfect name for peanut butter. Through the passage of time, there comes
a consumer association with that name that begins to build the brand equity,
which is what you want to do in the long run."
Effective visual communication should include both verbal and graphic
information that clearly tells consumers what the product is, and states
the important attributes that will make consumers want to buy it, according
to Lyman.
While the product name can refer indirectly to the product or its attributes,
the best product monikers don't have any meaning, Lyman explained. They
take on meaning as consumers begin to associate them with the products
over time. Slogans and other descriptive phrases can be used to shed additional
light on the nature of the product or its unique qualities.
Creating an imaginary bag of sliced or diced onions for the sake of example,
Lyman dubbed it "Cry Babies," then illustrated the package with
a caricature of a crying onion, a knife and a cutting board to signify
that it is sliced and ready to use. She also discussed researching potential
names on the U.S. Patent and Trademark web site to avoid conflicts with
other products. She suggested putting a "TM" on the package
after filing an "intent-to-use" application to protect the new
name until a registered trademark can be obtained.
Target Your Audience
Slogans should target the primary buying audience. In the case of packaged
salads and fresh-cut fruits and vegetables, Loralee cited research data
and statistics that indicate the target audience for these products is
primarily women who still prepare most meals in the home. She added the
phrase "No more crying!" to the package to further communicate
that the product is convenient. Then she prominently displayed the word
"New" to give consumer additional information.
Because some products like diced onions tend to settle in the package,
she also included a header or "concealment panel" across the
top of the bag, leaving the product visible at the bottom, but covering
empty space at the top.
"We know our products are healthy and it's our job to tell consumers,
because we can't assume they all know," she reasoned. "For instance,
we know onions are high in vitamin C, but they might not. We should also
tell them these products are fat-free.
"Another research study I found revealed that cooking times and recipes
are very important to consumers, so I thought it would be good to tell
them how many cups of product are in this bag. I really want the consumer
to see this package, so I'm going to use a color or colors that best accentuate
the product inside. We should also provide a caution for the consumer
to keep the product refrigerated."
While her IFPA presentation did much to take the mystery out of product
design, Lyman is also helping to reduce prohibitive upfront costs-and
risks-involved in creating effective packaging that speaks out boldly
to consumers and builds brand equity.
To measure the effectiveness of a new package, she urges customers to
compare before and after sales. When she redesigned packaging for Pacific
Pre-Cut Produce Co., Inc. of Tracy, California, the results were impressive,
according to Steffanie Smith, president.
"The new packaging definitely enhanced sales," she asserted.
"It had a dramatic impact and exceeded our expectations."
As a Valentine's Day promotion, Lyman designed a strikingly colorful bag
for romaine hearts that played on the word "hearts," as well
as the theme of romance.
Deanne Cagnacci, director of marketing for Capurro Marketing, LLC, recalls
how dramatically the pink, red and violet package with a stylized heart-shaped
product window and pair of red lips caught the attention of consumers.
At a local grocery store, she set up some bags for a photo, but consumers
repeatedly walked past and put the bags in their carts, thwarting her
efforts to keep the display properly arranged long enough for her snapshot.
It took her more than an hour to get the picture.
"With the coloring, the bag just popped out," Cagnacci recalls.
"The graphics and everything just drew people to it. It was definitely
catching people's eyes."
Capurro ran an informal test with another local grocer, asking the owner
to buy equal amounts of both the new package and the old.
"The new package was definitely making a difference," she recalls.
"We had changed the logo at the same time and, at first, people thought
it might have been a different brand. But the brand didn't matter. It
was the idea of the package that grabbed their attention. Whether it had
been someone else's brand, they still would have grabbed it because it
was the look of the package. People were just pulling that bag."
In two decades of package and product design, Lyman has other stories
to tell, but the essence of her message at IFPA's conference is that when
coupled with sound marketing practices, improvements in packaging can
make a significant difference in sales of any product.
She currently offers a results-oriented package design program exclusively
for IFPA members, providing them with an affordable program for improving
the appeal of their products.
Editor's Note: Flipside Design, Inc. is headquartered
in Carmel, California and Loralee Lyman can be reached at (831) 625-1222
or by e-mail at loralee@productlaunchdesign.com. Skippy® is a registered
trademark of Unilever Bestfoods.
© 2003 Columbia Publishing
Major
Juice Processor Enters the Fresh, Sliced Apple Market
Fresh Cut
November 2003
Following up on what it perceives as a "huge potential market"
for fresh, sliced apples, Tree Top, a world leader in the apple juice
consumer market, has entered the marketplace with a new, smartly packaged
entry.
The Selah, Washington-based company is using its strong name recognition
in the marketplace, particularly in the western United States, to gain
market share. Tree Top has quietly been turning out a limited quantity
of "Tree Top Apple Slices," working its way through an expected
learning curve to meet the needs of what it perceives as a huge market,
hungry for new, healthy food alternatives.
Ned Rawn was hired May 1 as Tree Top's new business manager - fresh slice.
He comes to the cooperative from the Washington Apple Commission, where
he served approximately five years as a regional foodservice manager for
the western U.S.
"Basically, we spent this past summer planning and working out the
start-up problems associated with processing any new product," Rawn
says. "We've been following Tree Top's well-established formula for
launching new products: plan first and execute second. With the new crop
coming in, we are now ready to move ahead."
The processing facility for Tree Top's fresh, sliced apple program is
located at Milton-Freewater, Ore., just across the boarder from Walla
Walla, Wash. It is one of seven production facilities operated by the
1,750-member cooperative in the Pacific Northwest. There are five more
in the state of Washington and one in southern California.
While plans are expected to change as Tree Top's fresh, sliced apple program
swings into full gear, the coop is currently shipping raw fruit to Milton-Freewater
for processing. From there, the packaged product is transported back to
corporate headquarters in Selah, where it is shipped via refrigerated
trucks to various marketing destinations across the country.
Three Foodservice Packs
Tree Top is currently marketing three different foodservice packs - 2
ounce (either 140 per master case or 64 per master case), 12-12 ounce
and 4-3 pound pack. The 2-ounce servings are for use in airlines, schools
and other accounts requiring a single serving type product, Rawn explains.
The 12-ounce bag was highly successful in the company's initial test marketing,
so will remain as part of the product mix. The 3-pound bag is a good fit
for the institutional, bulk trade, where it can be used in a variety of
applications. Tree Top is exploring other bulk packages and configurations
as well.
The current promotional campaign is targeted specifically at the foodservice
trade, Rawn says, adding that if things come together as expected, the
next step will be expanding to retail.
"One of the fun projects throughout the summer this year was a test
run with apple slices for Alaska Airlines," Rawn says. "Passenger
response was unbelievable. It was a new venture for them, trying a product
with shelf life issues, but the bottom line is the product was a big hit
and the response from the airline itself was also very positive. If we
can make it work again, we'd like to do that."
Fans attending a Seattle Mariner's game and ordering garlic fries also
have been receiving servings of Tree Top's fresh, sliced apples. And now,
with a new marketing campaign under way, the public can expect to see
the crisp, natural and ready-to-serve apple slices showing up in additional
settings.
Tree Top currently markets both sweet and tart tasting apples. The sweet
is mostly red-skinned varieties - Galas, Jonagolds, Cameos and Pink Ladies;
the tart variety, Granny Smith.
A Healthy Future
With the growing public focus on health-related issues, Rawn sees an exceptionally
bright future ahead for fresh, sliced apples. Child obesity concerns are
driving the call for healthier snacks in school menus, for example. Fresh,
sliced apples represent a much needed addition.
While working for the Washington Apple Commission, Rawn says the commission
conducted a series of studies to determine whether school children would
eat sliced apples. And the answer, in every case, was "an equivocal,
yes!" he recalls. One example was the quadrupling of apple consumption
in one Sarasota, Florida school district, when fresh, sliced apples were
served. Prior to that, students - many with missing teeth or wearing braces
- seldom picked up an apple to eat. And for the few that did, the majority
would take a bite or two and throw the balance in the trash. Apples were
just too difficult to eat.
"There is a constant drum beat out there now for more fresh products
and consumers are gravitating in that direction," Rawn says. "Society
is beginning to realize that everything in moderation is okay, but they
have missed out on the fresh fruit component."
Rawn believes that if Tree Top can deliver quality, reliable product multiple
times per week to the marketplace on a consistent basis, there is "an
absolutely huge opportunity ahead."
"It is the way the apple and fruit industries are going," he
observed, predicting there will be more and more cut fruit sold in the
future. "We're already seeing that now."
Years of Slicing
An interesting note pointed out by Pat Moss, Tree Top's corporate communications
manager, is the company is not new to apple slicing. For years, it has
been slicing apples for the ingredient side of its business. Some are
frozen or flash frozen. Others are dried or processed in various ways
to meet specific customer requests. Tree Top may be the leading apple
slicer in the world, she says.
Hence, setting up a processing line to slice apples was not a trip into
the unknown for Tree Top plant managers, according to Moss. True, there
was a learning curve when it came to handling, packaging and marketing
fresh sliced apples, but the production team was very knowledgeable about
the equipment needed for processing.
Since its formation as a grower-owned cooperative in 1960, Tree Top's
sales have grown from $1.7 to nearly $300 million a year. Fresh, sliced
apples are the latest product launch, but pure apple juice and cider remain
the backbone of Tree Top's retail sales. The cooperative also markets
consumer packaged goods, such as blended fruit juices and apple sauce.
Tree Top also produces and sells in bulk an extensive array of dried,
frozen and concentrated juice fruit products as ingredients used in the
food industry.
Brand Identity Opening Doors
The present marketing plan is to piggyback, to some extent, on Tree Top's
existing business core which already has a strong customer base and brand
identity. The fact that the cooperative's new fresh, sliced apples carry
the Tree Top name already is opening many doors.
"My job is to provide those groups within the company doing the selling
with the tools and motivation to confidently talk to their customers about
our new fresh, sliced apple products," Rawn says. "Whether they
are out there talking about apple sauce or the different beverages we
sell, we want them to feel comfortable introducing these new products.
We'll be using our resources. We already have contacts within the distribution
side of the business, and they have contacts as well.
"We all need to remember that it is the end users who specify whether
they want Tree Top sliced apples, the schools, corporate dining programs,
airlines and others. They may already be using TreeTop products, but we
now have an opportunity to extend that brand awareness to their customers
and guests. We're providing something that is new and exciting, and they,
too, are looking for new opportunities. There isn't a company in the marketplace
that doesn't want its vendor partners to keep bringing new products to
the table.
"Its new products, such as fresh, sliced apples, that will help them
grow their business," he smiles, "and that's exciting."
© 2003 Columbia Publishing
Fresh-cut
Sales of Retail Produce Approaching $4 Billion a Year
Fresh Cut
November 2003
ALEXANDRIA, Va.—Retail fresh-cut produce annual dollar
sales are quickly approaching $4 billion, according to a report from the
International Fresh-cut Produce Association's (IFPA) 10th Annual Seminar,
held Sept. 29-30 in Alexandria, Va.
Speaking during the opening session, Craig Delaney, IFPA chairman, detailed
new statistical data from Information Resources, Inc., that show the fresh-cut
industry is very much alive and growing at a near double-digit percentage.
Delaney is also executive vice president and chief financial officer of
Ready Pac Produce, Inc., Irwindale, Calif.
Total fresh-cut retail sales for the 52-week period ending Aug. 31 totaled
$3.864 billion, Delaney said. That is up 8 percent from the previous 12-month
period. The major driver is fresh-cut salads, which continues to dominate
overall fresh-cut produce sales. At $2.394 billion, fresh-cut salad sales
were up 9 percent.
Retail sales of fresh-cut vegetables reached $1.227 billion, up 6 percent,
he added. And while still representing only a small portion of overall
sales, the fresh-cut fruit industry expanded at a 15 percent annual growth
rate. At $243 million during the same time frame, the retail fresh-cut
fruit industry is expected to witness major growth over the next few years
as processors gear up to meet the needs of on-the-go consumers aware of
the need to eat more healthy diets.
General Trends
With more Americans overweight or obese than in any other time in the
country's history, Delaney said specific campaigns, answering concerns
such as childhood obesity, are heightening consumer awareness of health
issues. He quoted a study showing 55 percent of consumers say they "care
more about personal health and wellness than they did a year ago."
A second study shows that 25 percent have increased their produce consumption
for diet or health reasons.
There is increasing demand for "healthier" foodservice options,
he added, noting that the promotion of specific health benefits of produce
"will drive increased consumption."
Citing figures from a USDA study, Delaney pointed out that in 1975, 75
percent of consumer food dollars were spent on food prepared at home.
By 1999, that had slipped to only 51 percent. One in every five meals
is now eaten in the car.
Quoting another study, the speaker pointed out that meal preparation time
continues to decrease. Today, half of all meals are prepared in 30 minutes
or less, and there are fewer dishes per meal. Nearly half of all main
meals are one-dish affairs.
Such trends present opportunities for fresh-cut produce processors, Delaney
said. Key will be showing shoppers how fresh-cut produce can help them
with fresh, quick meal preparation. There are opportunities for products
that can be purchased in-store for out-of-home/on-the-go consumption.
New trends already are beginning to show up in marketing studies, he said.
For example, recent research shows 90 percent of U.S. households purchased
some fresh-cut produce last year. Of that, the average purchase cycle
was 6 weeks. Less than 13 percent of the units were purchased by those
under 35.
What does that mean?
"There is little room to bring totally new users into the category.
They are already there," Delaney stressed. "However, there is
a huge growth opportunity to increase category purchase frequency, achieved
by getting more shoppers to buy more often. There also is an apparent
need to draw in younger consumers."
Fresh-cut Salad Opportunities
Fresh-cut salad sales in U.S. supermarkets continue to grow at a nearly
double digit pace, Delaney said, pointing to a growth chart put together
by Information Resources, Inc. It shows a steady increase in sales between
1993 and 2003. If the projection from September through December of 2003
proves valid, fresh-cut salad sales will have increased from $197 million
in 1993 to a projected $2.453 billion by the end of this year.
Salad blends are driving category growth, up 17 percent versus a year
earlier, the speaker said. Salad blends now account for nearly half of
all fresh-cut salad sales ($2.065 billion versus $2.394 billion, according
to one study). Garden salads, salad kits, organic salads, Romaine hearts
and coleslaw also are important contributors. The organic category was
up solid 20 percent.
The retail fresh-cut salad segment is maturing, but still has significant
room for growth, Delaney said. The industry needs to make fresh-cut salads
a regular weekly purchase and the opportunity to do so is there.
Fresh-cut vegetables now account for 31 percent of total prepackaged produce,
the speaker said, quoting an Information Resources, Inc. study. Carrots
lead the pack, with nearly half of the total. Other popular fresh-cut
vegetables include spinach, potatoes, celery and mixed vegetables.
The same study also shows that meal prep and side dishes are driving category
growth and now account for 37 percent of total fresh-cut vegetable sales,
the speaker said. If the fresh-cut vegetable category is to continue to
grow, varieties beyond carrots will be critical, Delaney said, adding,
however, that fresh-cut salad buyers are great sources for cross-segment
promotions.
Fresh-cut Fruit Opportunities
Turning his focus to fresh-cut fruit, Delaney cited research showing double
digit growth last year in fresh-cut fruit. An Information Resources, Inc.
study showed 2003 fresh-cut fruit sales at $243 million, up 15 percent
from the $211 million reported a year earlier.
Mixed fruit, with 31 percent of the pie, is the largest segment of total
dollar sales, he said. Other segments include pineapple, 16 percent; watermelon,
14 percent; melon mixes, 13 percent; fruit trays, 13 percent; cantaloupe,
7 percent; and others, 6 percent. Ninety-three percent of shoppers purchase
fresh fruit, according to one research source cited, even though U.S.
per capita consumption of fruit slipped 2 percent in 2000 to 120.7 pounds
per consumer. While the number of consumers purchasing fresh fruit is
extremely high, actual consumption is going down. However, marketers see
this as an opportunity to use fresh-cut to reverse this negative consumption
trend by adding convenience.
The fresh-cut fruit category is still very young, but many believe it
represents a huge growth opportunity, Delaney said.
Delaney was one of more than a dozen speakers participating in the seminar.
© 2003 Columbia Publishing
>>
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Fresh-cut
Fruit: The Next Growth Category
Fresh Cut
December 2003
The fresh-cut fruit category continues to explode with
growth, a trend discussed at PMA Fresh Summit 2003, held Oct. 17-21 at
the Orange County Convention Center in Orlando.
Dennis Gertmenian, chairman and CEO of Ready Pac Produce, Irwindale, Calif.,
said he has never seen a more exciting time in his 34 years of fresh-cut
experience.
Gertmenian was one of four participating on a panel, "Fresh-cut Fruit:
The Next Growth Category." The others were: Emanuel Lazopoulus, vice
president of Del Monte's North American Division of Produce, Coral Gables,
Fla.; Eric Schwartz, president of Dole Fresh Vegetables, Salinas, Calif.;
and Sam Petro, a partner in Country Fresh, Inc., Houston, Texas.
Ready Pac has eight operating facilities throughout the U.S. and Canada
and markets a comprehensive line of fresh-cut salads, fruit and vegetables.
With over a 30 percent market share, the company is No. 1 in fresh-cut
fruit nationwide, more than double the size of any other brand.
While Ready Pac today enjoys the dominant position in fresh-cut fruit,
"the category is just getting started, and it is anybody's game,"
Gertmenian acknowledged.
Retail and Foodservice Opportunities
There are huge opportunities for fresh-cut fruit processors in both retail
and foodservice, Gertmenian pointed out, touching briefly on the explosive
growth taking place over the past three years. Most has been on the retail
side, but foodservice sales also are beginning to ignite. The category
today is approaching $350 million and is forecast at $1 billion by 2008.
"(Fresh-cut fruit) is a (significant) opportunity for all of us in
this room as well as the produce industry as a whole, and I'm glad to
be part of it," Del Monte Fresh Produce's Lazopoulos commented during
the panel.
Lazopoulos predicted that within five or six years, the fresh-cut fruit
category will soar to the $2 billion range, a dramatic increase over current
production levels.
The Del Monte brand was established in 1892, and its fresh business, Del
Monte Fresh Produce, was separated out in 1989.
Del Monte Fresh Produce is profitable and growing, Lazopoulos said. The
company now farms in 15 countries, sells product in more than 50 countries
and employs more than 25,000 people.
Differences in the Numbers
Dole Fresh Vegetables' Eric Schwartz acknowledged that there are differences
in the industry and among the speakers on the level of fresh-cut fruit
sales but agreed with his peers that the future for the category is bright.
There is "huge potential," he declared. "More importantly,
the category could grow at a faster rate than packaged salads or other
cut vegetables because the infrastructure, already developed, is in place.
From logistics to food safety programs, everything is transferable, for
the most part, to the fresh-cut fruit category. All of this should accelerate
growth."
With fresh-cut vegetable category sales slowing down somewhat, Schwartz
said Dole is diverting more of its resources into developing the fresh-cut
fruit side of its business.
Dole Fresh Vegetables is the largest supplier of fresh vegetables in the
U.S. and has functional responsibility for packaged salad operations in
Scandinavia, Latin America and Asia.
The Sky Is the Limit
Country Fresh's Sam Petro believes the sky is the limit. He predicted
that within five years he and other processors will be marketing fresh-cut
fruit products that in the past were technologically impossible to produce.
The science is now here and more breakthroughs are expected in the years
ahead, he said.
Petro repeatedly emphasized the importance of quality, noting that disappointed
consumers do not come back.
"We've all got to realize that when the housewife (or whoever) is
doing the shopping, she is going to pass by this category (fresh-cut fruit)
in the produce department on her way to buy a head of lettuce, a bag of
salad or a grapefruit," he said. "She is going to pass cut fruit
a hundred times or more, and then, one day, something will trigger a sale.
It may be that her husband calls and is bringing somebody home. Whatever
the reason, she is going to buy product that day.
"When she does, we've got to understand she is a little bit (miffed),
because she doesn't like spending $4.99 or $5.99, or whatever the price,
especially when she turns around and sees whole cantaloupe for 99 cents.
She is not happy spending the extra money, so when she gets home, the
product damn well better be good. If it's not, you are not going to see
her again."
Fresh-cut fruit products, if they are going to be a hit with consumers,
have got to be good, Petro warned, noting the importance of using only
U.S. No. 1 grade. He emphasizes the need for freshness and is not an advocate
of the push to extend shelf life.
"We've found that if we can get (a consumer) to buy our fresh-cut
fruit product three times, we have a good chance of it becoming a shopping
list item-bread, milk and cut fruit," he said. "Pineapple is
driving the category. We all pretty well know that. There's not a housewife
or house husband that likes to fool around cutting pineapple or cantaloupe
at home. If they can get the product, if they can get the quality at the
price they want, and if it is easy to eat, they are going to pay that
little bit of extra money."
It is quality, not price, driving the fresh-cut fruit category, Petro
stressed.
With its headquarters in Houston, Texas, Country Fresh, Inc. has processing
facilities in six locations across the country and product in thousands
of retail stores.
Real Learning Curve
As with fresh-cut salads, handling fresh-cut fruit involves "quite
a learning curve," Gertmenian acknowledged. Finding the appropriate
seed varieties, sourcing quality, year-round raw product and picking fruit
with the right kind of taste and texture are all important, he said. Fresh
taste and texture are extremely important, because consumers want to "see"
the freshness.
Maintaining adequate food safety is one of the top challenges facing the
fresh-cut fruit category, the speaker said. There have been several widely
publicized incidents of food-borne illness traced to spoiled fruit. Adherence
to good manufacturing practices throughout the supply chain is critical,
as is adequate cold chain management. Proper merchandising is key.
Lazopoulos underscored the importance of supply consistency, stressing
that inputs "must be the best." Also important are stringent
quality and micro testing and investment in research and development,
including quality assurance and food safety programs, he said. Part of
that is benchmarking and auditing and programmed flow within a protected
cold chain.
"Stringent quality is extremely important," he cautioned. "We
test throughout, and we have great recall procedures in place in case
there is a problem. We need to prevent that problem from happening, thus
maintaining the cold chain is imperative."
Don't Forget Taste
On the taste side, Lazopoulos said Del Monte is particularly excited about
its new Gold Pineapple variety, a payoff from its research and development
program. The Del Monte Gold Pineapple variety has an extremely great taste
and is contributing to the company's fresh-cut fruit category as a whole.
The Del Monte go-to-market strategy is pretty simple, he explained. It
is get product into the plant and then to the market as quickly as possible.
In some cases, Del Monte delivers its fresh-cut fruit directly to the
market.
Dole Fresh Vegetable's Schwartz stressed the importance of food safety,
emphasizing that "It is more than a phrase; it is a cost of doing
business."
Fresh-cut programs help eliminate back room cross-contamination, which
can occur when an operator, for example, is cutting poultry with a knife
one minute and then crosses over to slice melons, he said. Today's fresh-cut
processing equipment also is designed with sanitation considered as important
as productivity. It is easier to clean.
Also contributing to fresh-cut fruit growth is the fact that shelf life
today is more predictable and longer, the speaker observed. Processing
also is more automated and equipment is less proprietary. Raw material
quality has become more quantitative versus subjective.
© 2003 Columbia Publishing
MAP
Application for Trimmed, Cored Iceberg Lettuce
Fresh Cut
December 2003
By Bill Bernard
After many years of involvement with the produce industry's
development of Modified Atmosphere Packaging (MAP), including bulk bin
applications, I will attest to and expand on some of the information presented
by Ralph Schneider in the June 2003 Fresh Cut article, "Why Clean
and Core Lettuce in the Field?" While Schneider's emphasis was on
the application for source processors, my interest and focus has been
on the successful transport of field-processed lettuce to regional processors.
My personal involvement is three-fold:
• MAP application
• MAP equipment for removing ambient air, gas back-flushing and hermetically
sealing bin liners
• Correct bin liner construction for the MAP application
As Schneider suggested, once you remove wrapper leaves and cores the yield
of head lettuce is approximately 65 percent, at best. Cull chute lettuce
waste that was once sold for a few dollars a ton for mixing with cattle
feed is now left in the fields for soil enrichment. Field harvesting will
result in some loose leaves in the bins, and when the product is delivered
onto conveyers for transport to the cutters, some of that product can
be salvaged.
Field Process Approach
The field processing approach was an extension of the six trimmed heads
of lettuce in a MAP package, four bags per carton. Later, the heads were
cored as well as trimmed and were in competition with the chopped and
shredded lettuce packaging format.
At the onset growers were attempting to "clean up the fields"
after harvesting the carton lettuce, but the quality and condition of
the remaining product did not meet the demands of the foodservice industry.
On the other side of the spectrum, some growers went to the extreme of
harvesting first cut lettuce a few days early to satisfy the demands of
some accounts, such as McDonald's.
Conveying the trimmed and cored heads into the bins has improved dramatically.
No longer are the heads of lettuce tossed into the bins like basketballs!
Lettuce heads are now gently conveyed into the bins, and the overall process
is less stressful on the product.
Field harvesting equipment and technique have also evolved over the past
few years. The early harvesting rigs traveled over several rows of lettuce,
and the trimmed and cored heads were placed on conveyors and carried to
the bins. Some of the newer rigs travel over nearly 30 rows of lettuce
in the fields, and the trimmed and cored heads are positioned for a core
cavity washing process as they are conveyed to the bins.
Specs More Complex
Specifications for the bin liners are now more complex. The liners are
now longer. This precludes them from slipping into the bin and not allowing
enough material for sealing purposes. Liners have increased in gauge for
added strength, and specific resins are used to address the oxygen transmission
rate (OTR) issues. With the volatile resin markets, knowledgeable film
operators have to address the most economical means of achieving the desired
'dart' and 'tear' values, as well as the OTR.
If a bin liner is damaged in the field process, the likelihood of core
cavity and overall product discoloration is more likely, which results
in re-work at the processing plant. In warmer weather, and where staging
loads in the field takes longer, some operators will use tinted bin liners
for the heat reflective value.
Once the lettuce is cooled, the MAP process is addressed. Operators essentially
remove the ambient air with a vacuum process, flushing the bin with an
inert gas such as nitrogen and sealing the bin liners. Two types of seals
are commonly used: heat seal and clip seal. For heat sealing, the high
energy impulse technology has been proven to be extremely reliable. (See
related article, December 2000 Fresh Cut - "New Sealer Helps Bin
Lettuce Shelf Life"). Some use hot bar heat seal technology, while
others use cable lock clips.
With the volume of product being processed by regional plants, many operators
have become more sophisticated in measuring the residual oxygen levels
at both shipping point and final destination. The proper MAP application
contributes to keeping the core cavities free of oxidation. As with all
produce applications, temperature management is the primary concern; no
rinse or MAP application will serve as a substitute for correct cold chain
procedures.
Editor's Note: Bill Bernard, headquartered in
the Phoenix, Ariz. Area, is the western U.S. representative for several
foodservice-related companies including M-TEK, Inc. and BJK Flexible Packaging.
He can be reached by calling (623) 594-7138 or E-mail: billbernard@cox.net.
© 2003 Columbia Publishing
Chiquita
Launches Fresh-cut Fruit Campaign
Fresh Cut
December 2003
ORLANDO, Fla.—Chiquita Brands International has hit
the market with a new fresh-cut fruit product aimed at solving the No.
1 challenge expressed by retail customers and consumers - combining great
taste with a fresher, longer-lasting product.
Making the announcement at the recent Produce Marketing Association's
Fresh Summit 2003 in Orlando, officials said they are combining Chiquita's
proprietary process, called Flavor Savor™, and packaging system to
market fresh-cut fruit products that provide great taste and have longer
shelf life.
Midwest Campaign Underway
The initial target market area is the Midwest, within a 500-mile radius
of Manteno, Ill., home of Chiquita's fresh-cut fruit facility. The market
introduction began in the fourth quarter of 2003, with the goal to have
significant distribution presence by mid-2004.
"Prior to the launch, we tested our products with focus groups in
four different cities around the country to get their reactions,"
explained Jill Albrinck, senior vice president of strategy and new business.
"We had an independent group do the study, and wherever we put these
products with other offerings - blind, they didn't know our products from
others - the intent to purchase was over 75 percent. The combination of
the Chiquita brand name and an innovative product is powerful."
Studies show that consumers have been more than willing to try fresh-cut
fruit products but that only 12 percent were purchasing them on a weekly
basis. "This tells us that consumers are highly interested in fresh-cut
fruit, but are dissatisfied with current products," Albrinck said.
"Chiquita hopes to change that by supplying the marketplace with
product that addresses the need for a fresher, longer-lasting product
in the varieties and sizes that meet their needs."
The fresh-cut fruit category is "ripe for growth" and "we
have the right product at the right time," Albrinck said. "Our
product is on trend. It's the sweet spot in meeting consumers' need for
healthier foods and snacks to meet their 'on-the-go' lifestyles."
Chiquita Brand Recognition a Plus
Chiquita plans to use its nationally known name recognition to attract
and win new customers.
"We are uniquely positioned to lead the category and drive velocity
and volume for retailers," Albrinck said. "First, we have a
breakthrough fresh-cut fruit product and, secondly, it will be marketed
under our well-known and trusted brand. It's a terrific fit for our capabilities
and a natural evolution for us."
Chiquita's current fresh-cut fruit product line includes pineapple, watermelon,
strawberries, honeydew, cantaloupe and grapes - 12 straights and 10 blends.
All packages are reusable and the line offers single, multi-serve and
party sizes (6-, 12-, 24-, 32-, 48- and 64-ounces). The products are all
natural. No sugar or preservatives are added.
"We've come out with an initial product line, but have every intention
of adding additional products under the fresh-cut fruit umbrella,"
Albrinck said. "We're excited about our products. The combination
of our technology, sourcing and marketing program amounts to a home run."
Chiquita's state-of-the-art Flavor Savor™ process cleans, cools and
cuts fruit in a unique way, she explained. It helps lock in fruit juices
and reduces the "weepage" that can compromise fruit quality
when it comes to taste and appearance |
