Food Safetyin the Packing House

Chalmers R. Carr IIIRidge Spring, South Carolina

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Who we are….

• Founded in 1999, by first generation farmers

Chalmers & Lori Anne Carr.

• 1500 acres – peaches

• Today, we have diversified and grown our

farming operation to over 7,500 acres of

peaches & vegetables and we harvest crops

more than 40 weeks of the year.

• Completely vertically integrated organization.

Family Owned & Operated

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Product Brand Menu

PEACHES• Titan Brand• Carolina Beauty• Lori Anne Peach• Southern Charm

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Distribution across the United States

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Industry Leading Technology

••

• Industry leading consistent precise sizing Most gentle fruit handling system in the marketplace

Compac’s Spectrim technologyAccurately evaluates each piece of fruit based onsoftness, blemishes and other fruit characteristicsutilizing nine cameras per lane.Infrared technology LED lighting

2019 SQF Code 2000 Level 2 Certified

Driven By Technology – Quality First

Most technologically advanced packing equipment in the world! (2015/2016)

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Titan Farms – Video

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Why Food Safety?

No farmer can live with the fact that something they grow, pack or ship caused an illness or death to anyone.

Titan Farms is committed to producing and

supplying only safe high-quality fruits and

vegetables.

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Why is Food Safety Important?

• Ensures the food supply is safe by shifting the focus from responding to contamination to preventing it.

• Protect Consumers

• Protect Retailers / Wholesalers- Satisfies customer requirements

• Protect Growers & the Industry – Recall Prevention

• IT IS NOW THE LAW!!!

FACTS

•Food Borne diseases on average cause 48 million people (1 in 6 Americans) get sick, 128,000 are hospitalized, and 3,000 die each year from food borne diseases. - the Centers for Disease Control and Prevention.

• These outbreaks are not only blows to victims' health, but also the economy. In the United States, the economy lost about $7 billion every year due to these outbreaks. - Washington Times

CDC Issues Lettuce E. Coli Recall

Date: April 2018 to end of June 2018

Total Illnesses: 210

Hospitalizations: 97

Deaths: 5

Yuma, Arizona

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The lack of traceability after passing through several intermediary shippers hands complicated the trace back process and caused delays. CDC eventually steered people away from eating any romaine from the Yuma region because of a lack of timely traceability info.

Outbreaks drove romaine sales down by 71 million dollars in 2018.

Recalls affects everyone

Sometimes those who are not involved

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CDC later stated that “The investigation showed that

jalapeño peppers, serrano peppers and a water source on a farm in

Mexico were the source of containination.

Originally thought tomatoes were possibly a source, particularly early in the outbreak but samples of jalapeño and serrano peppers were collected on a

farm in Mexico were the main cause of the outbreak.

Date: May 2008

Total Illnesses: 1,442

Hospitalizations: 286

Deaths: 2

Still devastating for Tomato Growers” Tomatoes that were going for $18-19 per box before the FDA announcement. After announcement they were selling for just $4 afterwards. Some Florida growers reported selling boxes for fifty cents to $1.

Growers say they lost $100 to $125 million due to the

mislabeled recall

OR

Recall in Fresh Peaches – Summer 2014

• Export to Australia

•Product test positive for listeria•<10CFU

• United States has ZERO tolerance for listeria

•Grower issued voluntary recall

•No deaths or illnesses reported

•Pulled product from every retailer (D&D)

•Emotional & financial stress

California Peach Operation

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Food Safety Evolution

1994HACCP Alliance, SQF, and Primus GAP guidelines

Formed

1998BRC was Formed

2000GFSI

Formed

2002Bioterrorism

Act

2012 Safe Food for

Canadians Act

2011FDA FSMA

2019USDA

Harmonized GAP Plus + Standard

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GAP vs. GFSI

VS.

GFSI - much more robust- striving for continuous improvement. Allows growers to expand their markets and satisfy customer requirements

GAP - voluntary program, covers basic food safety requirements- more affordable options for growers

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Titan Farms Food Safety Program

• Deeply committed to the highest level of food safety

• Leader in the industry

• 2019 SQF Code 2000 Level 2 Certified• Score of 99% - Excellent

“We don’t just do food safety on the day of the audit, we live and breathe it.”- Chalmers Carr

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Huge Key to Success - Employee Training

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Educating everyone on food safety, food defense and security is the best way to protect the

public, employees, and their families. Properly trained employees can improve food safety and help reduce risks that may lead to

product contamination.

HACCP Hazzard Analysis Critical Control Points Points HACCP Steps: map the flow of product from the field through your facility.

Identifies areas where products may become contaminated (Critical Control Points, CCP’s) figure out how to best mitigate risks

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Risk Assessment

Matrix

Risk based method of identifying and

controlling food safety related critical control

points - CCPS

Packing House Analyzing the process flow

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Out to Consumer

Product In From Field

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Receive Peaches at Packhouse

(16)

Hydro Cooler (22)

Dumper (24)

Pre-leaf table (25)

Washer,Wax, Dry (26)

Sort Tables (28) #2 (34)Weighed and Packaged

Processing Bins(30)

Disposal (56)

PLU Labels (36)

Sort by Size (35)

Convey to box fillers (37) Hand Pack (42)

ReWork (45)

Processing Bin Storage (31)

Pallet Tags (46)

Shipping Cooler (50)

Transport (54)

Receiving of Packaging (19)

Packaging Storage (20)

Receive Returned

Products (55)

Palletizing (40)

Chlorine Dioxide Water (21)

#2 Grade Conveyed (29)

TransportMexico Product to Fumigation Chamber (51)

Fumigate (52)

Mexico Product to Shipping Cooler (53)

Receiving Cooler (23)

Pre-Graders (27)

Box fillers (38)

Box closers (39)

Case labels (44)

QC Box Weights (43)

Receiving of Chemicals (17)

Chemical Storage (18)

Presort Totes (47)

Tote Storage (48)

Tote commit to pack (49)

Downgrades Conveyed (29)

Ripes Selected and Packaged (33) QC – Size and

Quality (41)

Processing Bin Transport (32)

Soap (58)

Wax (59)

Water (57)

Dump Tote ()

Grade (61)

Bag/Tray (62))

PlU Label ()

Packhouse Process Flow

It is important to line out each step of the process in a visual manner, so that each step can be identified and analyzed for risk

Process Flow – Hydro Cooler

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Receive Peaches at Packhouse

(16)

Hydro Cooler (22)

Dumper (24)

Pre-leaf table (25)

Receiving of Packaging (19)

Packaging Storage (20)

Chlorine Dioxide Water (21)

Receiving Cooler (23)

Receiving of Chemicals (17)

Chemical Storage (18)

Soap (58)

Water (57)

Ingredient – Process Step

Potential hazard introduced, controlled or enhanced at this step

Is the hazard significant?

Justification for Decision Is this step a critical control point?22) Hydro

CoolerP: None

B: Pathogens

C: Chlorinated water solution

No

No

No

P: No hazard identified

B: Not reasonably likely to contaminate the product, due to Pack House prerequisite programs such as GMPs, SOPs, and training; effectiveness of these programs verified with monitoring.

C: Chlorinated system generates chlorinated water which is effective in reducing pathogens on product. Limits: ORP 700-900pH: 6.0-7.7. The Hydro Cooler is monitored by Pulse Instruments constantly and ORP will be monitored by a specially trained employee on a 60 minute basis.

No

No

No

Hydro Cooling – Cooling of Product – Pre-Packing

Has potential to spread contamination/cross contamination

Risk = recycled water

**HACCP Analysis- mitigate risk with water treatments, sanitation SOP’s and training

* Titan Farms utilizes Chlorine Dioxide Generation system for treatment and measures ORP for control and monitoring

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• Water Quality- annual testing- must be performed at an accredited lab

• Temperature- must be monitored to ensure water is at adequate temperature for commodity when used for coolingo thermometers should be used to gauge temperature

• ORP (Oxidation Reduction Potential)- used to measure the ability of the water to clean and sanitize surfaces that it toucheso 700-900 mV is the appropriate range to prevent

cross contamination. Should be monitored through dosing system and meter

Brush Bed Washer

Single Pass water: (Spray bars)

Risk = Brushes are hard to clean

** HACCP Analysis – Water treatment and proper sanitation to mitigate risk

• Water Quality- annual testing- must be performed at an accredited lab

• pH- can disrupt the efficiency of sanitizers. Monitor at consistent frequencyo can be monitored through test strips or pH meters

• ORP (Oxidation Reduction Potential)- used to monitor microbial levels in watero 700-900 is the appropriate range to prevent cross

contamination. Should be monitored through dosing system and meter

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Product Handling

**HACCP Analysis Potential risk for cross

contamination via produce handlers and

surface areas

Establish SOP’s and train workers on all

procedures

Good Manufacturing Practices: Hairnets,

Beard nets, Gloves, Aprons

No jewelry

No food or drink

Proper handwashing

Allergen Awareness

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Cold Storage

* HACCP Analysis – Potential pathogen growth in moist cool environment

• Inspect regularly to ensure areas are clean and cooler is functioning properly

• Regular cleaning schedule should be implemented for cooler and drains

• No condensation should be present

• Door should be sealed

• Cooler temperatures should be monitored and recorded to ensure temperature is at appropriate level for commodity

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Cleaning vs. Sanitation

CleaningUse of chemical and mechanical processes to remove soil from a surface

Sanitation/SanitizingThe application of a specific chemical (a sanitizer) or other treatment to a previously cleaned surface to kill bacteria and/or pathogens

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Goals of Cleaning & Sanitation

•Remove Soil –Soil is food for bacteria

•Kill any bacteria remaining on food processing surfaces

•Remove or prevent the formation of biofilms

•Provide a clean and sanitary environment for packing

•Maintain a clean and sanitary environment throughout the operation day

•Prevent migration of bacteria between zones

What is Biofilm? Biofilm is the buildup of bacteria that adheres to the surface

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Verification of cleaning

Visual Inspection Pre-Operational Swabs Provide feedback to

the sanitation team

Effective Cleaning is 99% of the sanitation job. The remaining 1% is the job of sanitizers

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A Successful Sanitation Program Requirements :• Commitment from Management

• Engagement of all departments –Sanitation, Maintenance, QA/QC, Ops

• Employee Training in Sanitation, Food and Personal Safety

• A Documented Cleaning and Sanitation Program

• Adequate Supply of Potable Water with Appropriate and Functioning Sanitation Equipment/Tools

• Effective Cleaning and Sanitation Products

• Good Sanitary DesignStainless Steel- Corrosion Resistant therefore it is holds up integrity to prevent harborage areas

• Adequate time to clean what need to be cleaned

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Environmental Monitoring

• Frequency- weekly, monthly • Timing- pre-operational, during operation• Locations- by Zones• Techniques- sponges, swabs

Focus on Zone 1• Goal is to find pathogen and eliminate before it becomes

problem

Product sampling?• If you’ve implemented a robust environmental monitoring

program, product testing is redundant- you’ve already verified your cleaning and sanitation program

High risk areas: brush, rollers, contact surfaces, coolers and drains

Adapt your program to your facility, equipment, and

products

Identify zones and areas of importance for swabbing- validates cleaning and sanitation program, identifies problem areas, ability to form trends of overall conditions, evaluates hygienic design of equipment

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Zones

Zone 3Below the production flow, still subject to environmental and sanitation concerns for an RTE (ready to eat) facility.

Zone 2 Non-Food Contact: table legs, floors, drains, aprons

Zone 1Product Contact Surfaces: belts, conveyors, cups

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Traceability Regulation Requirements

Procedures need to be in place to identify raw

materials and packaging from receipt through

process to finished product and distributions.

“one step forward, one step back”

Annual testing is required to test this process-

records must be maintained.

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From…..

- Field Block Farm

- Harvest Crew

- Raw Storage Location

- Packout Data

- Case Labeling

- Packed Inventory

- Shipping

- Retail Warehouse

To…..

Your Local Grocery Store

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Case/Pallet Labeling

Key for our ability to trace products from farm to retail location.

1) GTIN – Farm ID

2) Lot Codes

a) Pick Date

b) Variety

c) Field/Block

d) Storage/Location

e) Quality

3) Product Information

a) Size

b) Package

c) Variety

d) Pack Date

e) Quality 32

July 27

Final Keys to Success - Record Keeping

• Records are an important tool for analyzing and improving food safety.

• False records will not help improve the system or help you reach your goal of improved food safety!

• Records help provide proof that staff members complete necessary activities and that these activities are performed effectively.

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Documentation over kill!Say what you do and do what you say!

Cost of Food Safety program and investments made

Annual Costs of Titan’s Food Safety Program:

Category Total Supplies - PPE 15,000.00 Pathogen Swabs 4,400.00Water Samples 5,000.00 MRL Testing 14,200.00 3rd Party Audits 8,500.00 Auditing Fees 1,900.00 Professional Fees 1,600.00

Chemicals- Sanitation 25,000.00 Sanitation Utensils 5,000.00 QC Supplies 3,000.00Digital Food Safety Portal 10,00.00Service Contracts 5,500.00

$89,100.00

Investments:

• Time Can’t get there overnight

• Personnel

• Custom Traceability Software

• Enclosed facility

• Segregated room/packing area

• HVAC system

• Stainless Steel Machinery

• Poly Urethane coated flooring

• Web-based electronic monitoring

34$0.05 per Box

Do Food Safety Everyday!!

We don’t just do food safety on the day of the audit, we live and breathe it.”- Chalmers Carr

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Everyone Should Wear The Food Safety !!

Titan Farms5 R. W. DuBose Road

Ridge Spring. South Carolina 29129

THANK YOU!

Chalmers R. Carr III

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QUESTIONS??