Nearly three quarters of these recalls corresponded

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1 Meat & Poultry, Ready Meals Industrial Weighing & Product Inspection 20 News Prevent Recalls A Safety Plan in Four Steps The average cost of a recall is at least $10 million and it directly affects your reputation with consumers. A preventive control plan using hygienically designed equipment and label control helps to prevent recalls. Recalls in the meat industry are expensive and damaging to your brand. Common reasons that a food producer has to recall one of his products are: Contamination by microbes, such as salmonella or listeria Presence of foreign objects, such as metal fragments or bones Allergen ingredients and food colorings not declared on the label; and Mislabeling From 1994 to 2013, the Food Safety and Inspection Service (FSIS) reported nearly 1,300 meat and poultry recalls for the USA, representing 638 million pounds (289 million kilograms) of product. Nearly three quarters of these recalls corresponded to the most severe class of recalls, in which the violating product could cause serious health consequences. Whilst the number of recalls differs from country to country, microbial contamination is a universal driver of food recalls. As a preventive measure, food firms invest substantial resources to reduce the probability of food safety hazards. Weighing and inspection devices are an important part of a quality assurance process. Consider the following four steps in your safety plan for optimized equipment selection.

2 2. Allergen cross-contamination FSIS has recognized a notable increase in number of recalls because of undeclared allergens and ingredients of public health concern in food products. Comparable to BRC s allergen management recommendations, at the end of 2015, FSIS issued a new compliance guideline for allergens ( This guideline provides best-practice recommendations, including the use of equipment that is specifically constructed for its intended purpose and ensures cleanliness in production. 3. Label control Missing or wrong label information is a common cause of recalls. Proper labeling, including nutrition labeling or labeling for the major food allergens, is required for most prepared foods, according to FDA standards and EU regulations. Vision inspection systems are designed to inspect product labels for any type of packed goods. They check that trays or meat packages are properly labeled and that the expiration date is clearly printed. They offer the option to automatically re- Spend Less Time Cleaning and More Time Producing Learn the seven points to consider when cleaning scales to speed up the process while maintaining effectiveness. White Paper Prevent Recalls 1. Hygienic design Because bacteria and allergens are one of the primary causes of contamination in the meat and poultry industry, a sanitation plan with detailed cleaning instructions is important. An effective and efficient sanitation process begins with high-quality and easy-to-clean equipment. Available on the market are scales with certificates from leading sanitation and hygienic design organizations that declare that scales, such as the ICS689 bench scale, are designed for easy and efficient cleaning. 7 Considerations for Cleaning Production Equipment in Hygienically Sensitive Environments Scales, used in hygienically sensitive industries, such as the meat industry, are often in direct contact with the product. They are consequently a potential contamination risk. Independently, if they are used in a basic weighing application in the goods entrance or as a checkweighing solution in the packaging area, they are located in hygienically sensitive areas that follow strict sanitation procedures. Such an equipment sanitation procedure has to ensure adequate cleaning of product-contact and product noncontact surfaces. A common sanitization standard for contamination reduction of food-contact surfaces is generally accepted as % achieved in 30 seconds. The sanitization standard for non-food contact surfaces is accepted as a reduction of 99.9%[1]. Disinfection, in contrast, must destroy or irreversibly inactivate all specified organisms within a certain time, usually 10 minutes[2]. To achieve those requirements, the equipment has to be hygienically designed and efficiently treated during the sanitation program. This white paper provides guidance on where to focus when cleaning equipment, such as scales and checkweighers, and provides a typical example of a sanitation plan. Contents 1 Choose a hygienically designed scale 2 Prepare a surface for sanitizing 3 Cleaning with detergents 4 Visual control 5 Disinfection 6 Final rinsing 7 Verification of procedure 8 Summary move incorrectly labeled products from production lines. 4. Foreign-body control Product-inspection systems form an integral part of any food safety plan. Reducing foreign bodies in the beginning stages of the supply chain by inspecting all raw materials as they come into the factory helps to reduce foreign-body risk as early as possible. Checking for foreign bodies again at the end of a production line protects against production contamination and further increases product safety. There are many options for making beef, pork or poultry food production safer. Modern equipment helps you stay ahead in food safety. Automated Label Inspection Improving Quality, Increasing Production Efficiency The demands of new food-safety legislation coupled with increased competitiveness in the meat and poultry industry are driving manufacturers to review inspection processes and improve product labeling. The use of vision-inspection technology supports both of those challenges. Created to protect consumers, industry regulations such as EU 1169/2011 (also known as the Food Information Law) and the U.S. Food Safety Modernization Act (FSMA) continue to evolve, making greater demands on meat product processors. Product recalls due to non-compliance can be very costly for manufacturers. Data from the U.S. Food and Drug Administration (FDA) suggests that up to 40 percent of recalls can be attributed to product labeling. The use of automated quality checks for product labels can reliably ensure regulatory requirements are met and avoid product recalls. Download our White Paper: No More Manual Inspection In the past, production speeds were slow enough for human visual inspection to take place. Some manufacturers have traditionally used unreliable random sampling to identify product labeling errors, but this is a high-risk strategy. This approach also fails to meet the latest requirements of food safety standards. and achieve high-speed inspection to give them an edge in competitive markets. Advantages include better accuracy, a reduced need for inspection staff and the assurance that every product on the line is inspected. label presence and label contents (including allergen declarations) as well as barcodes, lot numbers and use-before dates at high line speeds. Publisher / Production Mettler-Toledo GmbH Industrial Division Heuwinkelstrasse CH-8606 Nänikon Switzerland Vision Moves Forward With the advent of faster line speeds, manufacturers are now turning to vision inspection technology to improve labeling quality Various solutions Vision systems perform label inspection on flat, oriented packs or round, unoriented products, checking for Subject to technical changes 09/2016 Mettler-Toledo GmbH 2 3

3 Case Study / Statistical Quality Control Ending Overfilling Using Precise Process Technology A leading producer of delicatessen products is harmonizing its fill-quantity monitoring systems at all of its sites, reducing overfilling costs and simplifying reporting. Overfilling by a gram or two may not seem like much, but when producing thousands of products a day, it all adds up. HOMANN Feinkost GmbH produces delicatessen salads, fish products and dressings. Since it was founded 125 years ago, the company has grown steadily, joining the Theo Müller Group and becoming one of the leading suppliers of delicatessen items in Europe. The company ships thousands of tubs and bottles every day, filled with all kinds of delicatessen products. Homann supplies its products to various discount supermarkets and the food-service industry. Efficient fill-quantity monitoring Producing and packaging products in large quantities requires precise process technology and comprehensive statistical quality control. Homann is careful to ensure that all products are packaged within the legally stipulated quantity tolerances and that the fill quantity remains constant within the bounds of process-related fluctuations. Underfilling is illegal, while overfilling pushes up production costs. SAP connectivity is a must Previously, statistical quality control was carried out on a site-specific basis. Although all six production sites were mapped in SAP, each had its own monitoring system. Homann approached with a request for a standardized fill quantity monitoring system at all of its sites. The company wanted to harmonize its existing solutions to enable standardized reporting FreeWeigh.Net, a PC-based, networked statistical quality control software and the use of an interface with SAP while still ensuring that the systems were specific to the respective sites. Statistical quality control The system rollout is making great progress, with the statistical fill quantity monitoring system FreeWeigh.Net already introduced at several production sites. Thanks to the system s modular design, it can be adapted to the key requirements for each individual site. FreeWeigh.Net makes it easy to connect multiple dynamic and static scales, such as automatic or static manual checkweighers. FreeWeigh.Net is also capable of delivering reliable data and analyses whether it is handling straightforward manual sampling checking or 100 percent quality control for each tub. As FreeWeigh.Net stores the process parameters for every product, deviations from the tolerance range can be identified quickly. The operator is informed immediately and can readjust the fill quantity in order to reduce further losses. Thanks to FreeWeigh.Net, Homann now has a fill-quantity monitoring system that is connected to SAP via the DATA IO module and produces relevant statistics for each site. This not only ensures compliance with the minimum quantity monitoring requirements, but also optimizes the fill quantity processes at all sites. Savings achieved will allow future investments in other areas. FreeWeigh.Net provides: Significant reduction of product overfill costs Compliance with legal fill requirements Standardized and simplified processes Online monitoring and alarms Short intervention time in production Automated reporting ERP integration 4 5

4 X-ray Inspection Detecting Smaller Contaminants X-Ray System Handles Challenging Applications The challenges of inspecting slurries, pastes and liquids in pipelines will be familiar for processed meat and seafood processors. New, advanced x-ray technology can provide increased contaminant detection sensitivity and contribute to improved process efficiency. Handling and inspecting some product types such as ground meats, pates or raw chicken cuts have always posed a challenge for manufacturers due to their composition and tendency to flow like a viscose liquid. The ability to pump these products through process pipelines makes inspection using x-ray technology a viable and realistic possibility. A new inspection solution X38 Series pipeline x-ray inspection systems from represent a major step forward in the inspection of meat and poultry products in pipeline scenarios. These systems provide high levels of contaminant detection sensitivity with enhanced production efficiency. 6 Production flexibility To suit a variety of applications, meat and poultry processors can choose from an extensive range of systems configured to suit their specific applications and requirements. System calibration and set-up can typically be as short as 20 seconds, increasing equipment availability and potential production capacity. Enhanced safety and quality X38 systems have a small footprint and can easily be integrated into existing production lines. Manufacturers can achieve throughput levels of up to 14 tons per hour when inspecting slurries. More challenging pumped products such as raw chicken portions can be inspected at rates up to 9 tons per hour. Hygienic design The X38 Series incorporates hygienic design in all models with a standard rating of IP69. This ensures systems are suitable for use in harsh wash-down environments such as meat processing plants. The hygienic design is further enhanced by sloping surfaces that allow water to easily run off after wash-down and a modular pipeline manifold that is fully removable for cleaning. Ergonomics have also been considered, making the system easy to use. All operations are controlled through an easyto-operate screen interface. Supporting compliance Inspection process data from X38 pipeline systems can be readily collected via external USB, Ethernet connectivity or Ethernet IP in order to document inspection processes and support compliance with food safety standards. These systems can also be linked to s ProdX product inspection software for even greater production and quality function support. Improving the Safety of Pumped Meat Products White Paper Increasingly, food safety standards are placing more emphasis on the responsibility of manufacturers to ensure products are of sufficient quality and fit for human or animal consumption. Contamination risks inherent in manufacturing processes mean that meat and poultry processors must satisfy their duty of care and prove they have exercised due diligence in their production procedures. Metal Detection & X-ray Inspection Improving Food Safet y Inspection of Pumped Products Contents 1. Why Submit Pumped Foods to Product Inspection 2. Introduction to Metal Detection and X-ray Inspection 3. Factors Affecting the Sensitivity of Product Inspection Equipment on Pumped Food Lines 4. Which Technology - Metal Detection, X-ray Inspection or Both? 5. Establishing Critical Control Points for a Product Inspection System on a Pumped Food Line 6. Typical Applications of Pumped Product Inspection 7. Factors to Consider when Installing Product Inspection Equipment on a Pumped Food Line 8. Conclusion X38 Series is designed with hygienic principles in mind to perform in the most challenging working environments. Why should you inspect? Which technology should you use? What factors should you consider in pipeline inspection? Find out more. Download our free white paper 7

5 Statistical Quality Control Statistical Quality Control With the Touch of a Button Net content control impacts a company s profitability by reducing product giveaway through overfills. A new net-content control terminal makes data collection fast and easy for every operator, and provides reports for real-time process intervention at the touch of a button right at the production line. Ensure compliance with country-specific net-content legislation Equipment resists harsh and wet industrial environments Save costs by reducing overfilling Video The IND890SQC terminal is a stand-alone compact solution that has been developed for quality and process control with manual random sampling. It helps to ensure production of high-quality products in line with international and national net-content legislation, as well as global guidelines, such as IFS or BRC standards. Compliance and control Compliance is an important consideration in filling operations, in which underfilling is illegal and overfilling is wasteful and expensive. With the IND890SQC, operators can define a large number of products and choose an applicable tolerance system, which supports customers in complying with net-content legislation and global guidelines. Built tough and easy to use The IND890SQC weighing terminal is rated IP69K for rugged industrial environments allowing it to be used right at the production line. Its touchscreen makes operation simple, while USB flash drive connectivity allows easy data transfer. Statistical reports that can be run for each product on the line arm quality managers to make informed decisions about their production process that impact both quality and productivity. Easy operation IND890SQC is designed to make net content control as easy as possible for operators. Routine sampling can be performed by following on-screen instructions all at the touch of a button to help keep processes running smoothly. See how a food manufacturer reduced their overfilling costs with IND890SQC. Watch Video here:

6 Checkweighing Hygienic Equipment Design Risking Cross-Contamination? Not with Hygienically Designed Equipment Product recalls due to microbiological and cross-contamination issues continue to be a challenge for meat and poultry processors. Ensuring weighing, processing and inspection equipment is designed with hygienic principles in mind can help reduce the risk of issues that may result in recalls. Recent studies by the U.S. Food and Drug Administration (FDA) indicate that nearly half of recent recalls were attributed to bacterial contamination (mainly salmonella, listeria and E.coli). In addition, a further 38% of recalls are due to undeclared allergens being included in the product. It is clear that hygiene standards in food processing and packing areas can play a major part in this. Well designed and implemented hygiene and washdown routines will inevitably reduce the risks of bio-contamination. Thorough cleaning between production batches can also avoid any risk of cross-contamination, particularly where potential allergens may be present. ufacturing Practice (GMP) and hygienic equipment design. Applications and environments Responsible manufacturers must give consideration to the process application and the working environment when designing equipment for use in food processing areas. Sanitary design and features to make cleaning regimens easier and foolproof are paramount. Preventing the ingress of water used during washdown is also important. In dry, benign areas equipment may be specified with an IP65 rating. This means it can be washed down with water at low pressure. An IP66 rating may be applicable if higher pressure water is to be used and an IP69K rating may be defined for very harsh environments where water at very high pressure is used on a regular basis. Sanitary design criteria An Equipment Design Task Force created by the AMI defines 10 principles of equipment design which provide a good frame- work for considering the hygienic credentials of weighing and inspection equipment. Making sure equipment is fit for purpose provides equipment for use in food processing, weighing and inspection areas which is hygienically 10 principles for hygenic equipment design Setting the standards There is no single body responsible for hygienic equipment design in the food industry. However, the European Hygienic Engineering & Design Group (EHEDG), the US FDA, 3-A Standards Inc., the American Meat Institute (AMI) and the National Sanitation Foundation International (NSF) are all seen as leading organizations and experts in this field promoting Good Mandesigned and fit-for purpose. Systems of this type will help to avoid the risks associated with bacterial and cross contamination. 1 Cleanability Design to ensure effective and efficient cleaning. 2 Construction Materials Utilize suitable materials compatible with the working environment. 3 Accessibility Make all areas of the equipment readily accessible. 4 No Liquid Collection Ensure liquids run off the machine rather than pooling. 5 Hermetic Sealing Open hollow areas (e.g. in frames) should be closed. 6 No Niches Niches, cracks and dirt traps should be avoided. 7 Operational Performance Ensure sanitary conditions are maintained during operation. 8 Maintenance Enclosures Enclosure should be sealed but still allow for easy access. 9 Hygienic Compatibility Make sure the design is compatible with the wash-down routine. 10 Cleaning Validation Document sanitation and cleaning protocols. Guide for Sanitary Construction- Sanitary Design Guide For Sanitary Construction For Total Brand Protection Safe, sanitary design can help avoid product recalls and support compliance with food safety standards. For more in-depth information, visit: SAFELINE HI-SPEED CI-VISION Metal Detection & X-ray Inspection List courtesy of the American Meat Institute (AMI). Metal detectors designed to operate in high-pressure wash-down conditions 10 11

7 Are You Testing Enough? Or Too Much? ISO9001 requires that weighing equipment must be calibrated and verified at defined intervals. But how those tests should be done or how often is not specified. Our GWP Verification service provides testing recommendations based on your process requirements. Minimize risks and reduce costs Optimize your routine testing to ensure consistent weighing results. Save costs by eliminating unnecessary tests. Assure traceable documentation including testing procedures and frequencies. Improve Your Scale Testing For more information Mettler-Toledo GmbH Industrial Division CH-8606 Nänikon, Switzerland Local contact: MTSI