Let s Build a Hygienic Cold Chain in Fresh Fruit and Vegetables Business

Transcription

1 Let s Build a Hygienic Cold Chain in Fresh Fruit and Vegetables Business Prof. Dr. Y. Onur Devres (onur@devres.net) Devres Technology and Consulting Ltd., Istanbul, Turkey Industry-End Users: Future Vision in Cold Chain Panel Strengthening HVAC&R: Building the Future Together

2 2 Devres Technology and Consulting Ltd. Prof. Dr. Devres (ME, : The Scientific and Technical Research Council of Turkey (TUBITAK), MRC, Food and Refrigeration Department; : Istanbul Technical University, Food Engineering Department; : Head of the Department; since : Devres Technology and Consulting Ltd.). Devres Technology and Consulting Ltd. is specialized in engineering operations in food industry: Cold and Frozen Storage, Fruit and Vegetables Processing Lines: Fresh, Freezing, Canning, Drying etc. Packaging, Hygienic Design in Food Processing Plants, Training (EHEDG and custom made).

3 3 Devres Technology and Consulting Ltd. Prof. Dr. Devres: A book on Drying published by Istanbul Chamber of Industry. Editor and author of a book namely Food Safety and Cold Chain published by Turkish Food Safety Association and Air Conditioning Refrigeration Producers Association. In editorial board of a book Industrial Kitchens published by Boyut Publishing. Published many scientific papers ( A patent on a cooking device namely Device for cooking by means of electrical resistance.

4 4 Devres Technology and Consulting Ltd. Prof. Dr. Devres serves both in Turkey and also in surrounding countries as an engineer, consultant and business developer; introduces new techniques, technologies and products to companies on food processing.

5 5 What are the Food Loss and Waste? Food losses refer to the decrease in edible food mass throughout the part of the supply chain that specifically leads to edible food for human consumption. Food losses take place at production, postharvest and processing stages in the food supply chain. Food losses occurring at the end of the food chain (retail and final consumption) are rather called food waste, which relates to retailers and consumers behavior.

6 6 What are the quantities? Roughly one-third of the edible parts of food produced for human consumption, gets lost or wasted globally, which is about 1.3 billion ton per year. In medium- and high-income countries food is to a great extent wasted, meaning that it is thrown away even if it is still suitable for human consumption. In low-income countries food is mainly lost during the early and middle stages of the food supply chain; much less food is wasted at the consumer level.

7 7 What are the quantities? Roughly one-third of the edible parts of food produced for human consumption, gets lost or wasted globally, which is about 1.3 billion ton per year. In medium- and high-income countries food is to a great extent wasted, meaning that it is thrown away even if it is still suitable for human consumption. In low-income countries food is mainly lost during the early and middle stages of the food supply chain; much less food is wasted at the consumer level.

8 8 What are the quantities? The per capita food loss in Europe and North- America is kg/year. In subsaharan Africa and South/Southeast Asia it is kg/year. The total per capita production of edible parts of food for human consumption is, in Europe and North-America, about 900 kg/year and, in subsaharan Africa and South/Southeast Asia, 460 kg/year. Food waste at consumer level in industrialized countries (222 million ton) is almost as high as the total net food production in subsaharan Africa (230 million ton).

9 9 What is Value Chain? Value: the amount of money that something is worth. It is set in the mind of the person who hold the money. But a chain is something that can be broken, and breaking the value chain is to lose all the value of the product.

10 10 What is Cold Chain? Cold chain: The supply and distribution of commodities that must be kept within a defined temperature range throughout the cycle between production and consumption.

11 11 What is Cold Chain? The aim of the cold chain is to sustain the value of the product from harvesting to consumption. The cultivation techniques affect the quality of the product in its shelf life. Therefore it should be taken into consideration primarily.

12 12 Shelf Life A bomb on the shelf Product Step 1 Ingredients Composition History/Data Step 2 ph Water activity Preservative content/ Preservation technique Step 3 Storage trials Product testing Sensory trial Shelf Life Orchard sanitation Precooling Drenching Primary Product (F&V) Cultivation (fertilizers, chemicals, irrigation etc.) Harvesting Food Safety Issues Maximum Residue Levels (MRLs) Minimum Hygiene Requirements Traceability

13 13 Shelf Life Shelf life is extremely dependent on storage conditions.

14 14 Traceability

15 15 Traceability: RFID

16 16 Traceability Go to Hygienic Design

17 17 Production GLOBALG.A.P. Certification covers: Food safety and traceability, Environment (including biodiversity), Workers health, safety and welfare, Animal welfare. Includes: Integrated Crop Management (ICM), Integrated Pest Control (IPC), Quality Management System (QMS) and Hazard Analysis and Critical Control Points (HACCP).

18 18 Production The GLOBALG.A.P. standard is primarily designed to reassure consumers about how food is produced on the farm by minimizing detrimental environmental impacts of farming operations, reducing the use of chemical inputs and ensuring a responsible approach to worker health and safety as well as animal welfare.

19 19 Product Supply: Contract Farming Objective of Contract Farming To achieve consistent quality, To achieve regular supply, To improve quality of produce, To stabilize the agro-raw produce, To stabilize the price to each part as it is not affected by market prices.

20 20 Product Supply: Harvesting

21 21 Product Supply: Harvesting

22 22 Distribution Farmer Farmer Farmer Farmer Agents/ Broker Agents/ Broker Agents/ Broker Agents/ Broker Manufacturer Manufacturer Manufacturer Manufacturer Wholesalers Wholesalers Wholesalers Wholesalers Retailers Retailers Retailers Retailers Consumer Consumer Consumer Consumer

23 23 Product Receiving Specifications should be defined and checked precisely at the beginning of processing (If they are not already fulfilled in the orchard/field carefully): Postharvest disease (especially mold etc.) Size Color Ripeness Dirt Under- or oversized Injured Squashed Burst Puffy Postharvest diseases should not be entered to processing plant: Microbial resistance against common fungicides.

24 24 Processing

25 25 Water Treatment: Drinking Quality 3-4 more times of processed fruit and vegetables capacity. Raw water tank (at least 5-6 hours of usage) Processed water tank (at least 5-6 hours of usage) Drinking water quality tank (stainless steel)

26 26 Packaging Modified Atmosphere Packaging (MAP) Types of Packaging Vacuum Packaging Shrink Wrap Packaging

27 27 Packaging: MAP

28 28 Packaging

29 29 Storage Cold store types Precooling: 0ºC/+8ºC Cool storage: +8ºC/+14ºC Cold storage: -1ºC/8ºC Frozen storage: -18ºC/-24ºC Deep freezing: -35ºC/-45ºC Controlled Atmosphere Storage Products

30 30 Storage Product storage temperature and relative humidity, Product entrance temperature, The amount of daily product entrance, Storage capacity, Dimensions of cold store, Number of rooms and corridors,

31 31 Storage Location, Construction type, Insulation thicknesses, Storage room door type and dimensions, Height from the ground, Storage room floor type, Packaging sizes.

32 32 Boxes

33 33 Pallets Model EUR, EUR 1, ISO1 EUR 2, EUR 3, ISO2 EUR 6 USA USA Size 1200 mm x 800 mm 1200 mm x 1000 mm 800 mm x 600 mm Customized size 1100 mm x 1100 mm 1100 mm x 1200 mm Customized size

34 34 Pallets

35 35 Cold Store Racking System

36 36 Processing Plant HYGIENIC DESIGN Zoning Avoid horizontal surfaces Drainability Pipe connection features Easy cleanability is a must Framework features Open cabling Welding, Joints, Seals

37 37 General Recommendations Drainability Avoid sharp edges and corners (r > 3 mm) Cabinets slope away from product No overlap joints or press-fit Joints continuously welded or sealed Avoid soil or microbial accumulation Make it close if possible Keep it covered

38 38 Drainability The exterior and interior of all equipment and pipework must be Self-draining or drainable, Easily cleanable. Horizontal surfaces(upwards or downward facing) must be avoided. Surfaces should always slope away from product. In case of external surfaces: slope away from the main product area. Drainage of condensates should be considered when appropriate.

39 39 Top Rims!!! (a) (a) (a) (a) (a) (a) (a) product area, (b) residues of soil and product, (c) continuously welded rim

40 40 Transportation Forklifts Trucks: Refrigerated Loading: Dock levelers and lifts Hydraulic Mechanical Dock seals

41 41 4. MAFEX Maghreb Food Exhibition, Casablanca Morocco, December 9-11, 2015

42 42 Transportation Temperature Temperature data loggers/recorders Spy Wireless RFID (Radio Frequency IDentification)

43 43 Points of Sales

44 44 Calibration International Bureau of Weights and Measures (BIPM, Paris) National Metrology Laboratory (The National Direction of Metrology, Morocco) Accredited Laboratories User Testing/Calibration Laboratory

45 45 Technology Distribution chain should be well tracked by means of information technology. Global Trade and Identification Number (GTIN) Barcodes ecom Global Data Synchronization Network

46 46 Training Workers are staying at the heart of the all cold chain operations. A person in harvesting A person in packaging Forklift operator They shall be trained continuously on fundamental knowledge; also informed and aware on how he/she is important individually.

47 47 Results Food Safety Expectations in Cold Chain Operations Cleanable (also drainable) Reachable to clean and to service Traceable (on temperature and time basis) Low T (Temperature difference between evaporator and room temperatures) Low energy

48 48 Results The success of a cold chain is hidden in the value chain: If you can find a buyer that pays a good price to your product: it means that your cold chain activities are perfectly accomplished. If someone pays a better price to your competitor: it is time to check your cold chain operations before go to bankruptcy. So the result is simple: Quality at the end earns its value.

49 Do you have any questions? Prof. Dr. Y. Onur Devres Devres Technology and Consulting Ltd., Istanbul, Turkey