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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
>>
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'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 paren | 