Chilled (produce) Supply Chains. For HPA 13/11/06
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1 Chilled (produce) Supply Chains For HPA 13/11/06
2 Crop Groups for Prepared Salads Salads Repeat harvested crops Destructively harvested crops Cucumbers Leaf Peppers Tomatoes Drilled crops seed is sown into the soil Head crops seeds are raised in a plantraiser Spinach Endives Baby Leaf Commodities Herbs Specialities Brassicas
3 Structure of food distribution channels Own label Brands
4 Retail Produce Supply Chains Retail Market Major Multiple Independent Raw Material Source & Standards Whole: Direct purchase from specified suppliers/dedicated growers with full traceability, Assured Produce etc Prepared: Manufacturers supplied direct by specified suppliers/dedicated growers with full traceability, Assured Produce etc Whole: Wholesaled variable standards and traceability Whole: Small amount of direct purchase from growers variable standards Prepared: Some manufacturers supplying prepared produce/ products containing produce to major multiples have their own brands supplying independents, with the same standards as for major multiple supply Yellow highlight = CFA members
5 Wholesaled/Publicly Procured Produce Market Wholesaled Publicly Procured Markets, Cash and Carry Schools, Hospitals, Prisons etc [In general bought on price] Raw Material Source and Standards Various sources variable standards and traceability Whole & Prepared: Some manufacturers supplying major multiples have their own brands supplying wholesale, with the same standards as for major multiple supply See Wholesaled variable standards and traceability Small amount of direct purchase from growers variable standards Yellow highlight = CFA members
6 Foodservice Produce Supply Chains Market Raw Material Source and Standards Major chains Whole & Prepared: Specified suppliers with full traceability, Assured Produce etc Whole & Prepared: Some manufacturers supplying major multiples have their own brands supplying foodservice, with the same standards as for major multiple supply Entrepreneurs (e.g. non-chain take aways, cafes, restaurants, some franchises inc petrol & railway stations) Majority wholesaled/spot purchased variable standards and traceability Whole: Small amount of direct purchase from growers variable standards Whole & Prepared: Some purchased from major multiples Yellow highlight = CFA members
7 Salads Raw Material Supplier Approval Procedures into prepared for major UK retailers
8 Audit Documentation Supplier Code of Practice and Guideline Documents Available in English, Spanish, French, Italian Detailed Audit Documentation Same Technical Requirements for all suppliers - UK and Non UK
9 CFA Guidelines 4 th edition CFA Best Practice Guidelines for the Production of Chilled Food (2006) Microbiological Guidance for Growers English language version (2002) supported by major UK multiples Spanish version (2004) Finnish version (EVI) (2005) Pesticides Due Diligence (2002) 2 nd edition Water Quality Management Guidance (2005) Guidance on the use & interpretation of micro testing (2005) CFA/BRC Guidance on the Practical Implementation of the EU Micro Criteria Regulations (2005) More than 30,000 copies distributed to date
10 Supplier Monitoring Specified suppliers All suppliers are monitored by sites against a range of commercial and technical criteria Field practices Irrigation water control Microbial loading (E. coli) Pesticide residue analysis Contaminant levels Quality criteria etc
11 Leaf Production Cultivation Harvesting Leaf chilling Processing Despatch Distribution Shelf life
12 Cultivation Seed selection and screening Harrowing Bed forming Drilling seeds into the seed bed Irrigation Source and quality Method of application Type and end use of crop
13 Harvesting Hygiene People Medical screening Hygiene training Equipment Cutting whole head Cutting or scything baby leaf Weather conditions Minimise impact
14 Chill Controls Remove field heat to minimise micro and biochemical activity E.g. chilling to 3ºC in under 60 minutes We adopt a keep it cold move it fast philosophy E.g. measure degree hours from harvest to customer
15 Processing Sorting Remove damaged produce Remove extraneous matter Trimming Removed damaged tissue Manual inspection Mixing leaves Washing Bagging
16 Post-Process Chain Despatch and distribution to retail <5ºC Retail storage <8ºC legally Consumer storage Shelf life (bagged salads) UK: 4-7 days USA: days
17 CFA Produce WG Growing controls Industry guidance CFA Micro Guidance for Growers Assured Produce ADAS Safe Sludge Matrix (still awaiting UK law) Retailers protocols 1999 ECFF VTEC WG Report presented to EC SCF EC SCF produce risk assessment Input into FSA guidance Sprouted seeds production control measures Farmyard manure guidance for growers Research proactive and reactive
18 CFA-funded Research CFA/DEFRA/IFR pathogen attachment research Commercial driver = safety (expanding markets) Industry commitment Potential exploitation Business benefits Chlorine usage reduction & environmental benefits & potential perceived consumer benefits Reducing costly waste Sound scientific approach Timetable
19 Our Positive Impact Volumes of bagged leafy salads (1990+) UK: 2.6 x10 9 packs Worldwide: 1.8x10 10 packs + other presentations of prepared produce Potentially prep leaf-related VTEC incidents USA 26 outbreaks (>900 cases) (lettuce + spinach) since 1993 Europe 2 outbreaks (>200 cases) (wholehead, Sweden) UK 0 outbreaks
20 Leaf Sales Summer 2006 From RETAIL sales 28/5-4/8/06 (8 wks) Bagged leaf 60M packs = 180M servings Wholehead 55M units = 265M servings 3 week period (average) Bagged: 24M bags, 70M servings Wholehead: 20M units = 100M servings TOTAL RETAILED: 48M units = 170M servings FOODSERVICE: est 1/3 of retail vol: 35M servings GRAND TOTAL ave 3 wk: 205M servings ~50:50 Retail:Wholesale (servings)
21 Conclusions Over a decade of CFA proactive work Field controls established = critical to assuring safety Best practice guidance in place Attachment research underway Incident alerts and resolution Network of expertise internationally CFA s strong industry ties - authoritative Government linkage - accessible FSA DEFRA HPA PSD
22 The centre of excellence for the chilled food industry
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