Supermarket Perimeter - January 2019 - 66

FOOD SAFETY

1. Zones of control:
If a facility is going to house both raw and ready-to-eat
(RTE) product, the building must be designed to completely separate these products to avoid cross-contamination. The design should also incorporate segregated
welfare areas for employees who handle raw products
from those who handle RTE products, including separate locker rooms, cafeterias and support areas.
2. Temperature and moisture control:
There must be a clear understanding of each room's
function to ensure sufficient room temperatures based
on the intended use of the spaces. Installing reliable
mechanical systems to control humidity within the plant
is critical to eliminating potential bacteria harborage.
3. Food safe materials:
Materials inside the plant should be selected for both
durability and cleanability, including the ability to resist
harsh cleaning chemicals and temperature variations.
The two ideal surfaces for food safety are stainless steel
and solid aluminum, because they are easy to clean and
sanitize. The design should also include ample space
above, around and under physical constraints, such as
process equipment, with separate levels established for
proper cleaning and maintenance of the building and
the process equipment.
4. Air pressure and flow:
Appropriate air balance can reduce the risk of unwanted
moisture and condensation that can foster bacterial
growth. Consider the direction and frequency of airflow
as well. For example, the air from areas where raw
poultry are handled must never flow to areas such as
packaging, where airborne bacteria could infect the final
product. Air must always flow from clean to dirty, not
dirty to clean. The same goes for traffic flow: Designers
must consider the flow of workers, waste materials and
product through the plant to minimize cross-contamination of these sensitive products.

for Jacksonville, Florida-based
design-build firm Stellar.
Needs of processors can
vary widely depending on what
fresh-perimeter product is being
produced in the facility, Allsup
says. Take fresh produce. As soon
66 - JANUARY 2019

as it's harvested, it becomes a
dying product. It's a race against
the clock to get that product to
the consumer and maximize its
shelf life.
"There is increased pressure on processors to get fresh

Packaging flexibility
Another trend becoming more
prominent in new food production facilities is packaging flexibility, Allsup says.

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"There needs to be a focus
on designing flexibility into a
facility so producers can easily
accommodate ever-changing
consumer demand," Allsup says.
"In today's marketplace of niche
segments and specialty products,
it's no longer just about producing a particular SKU as quickly as
possible. Manufacturers are also
prioritizing fast changeovers and
nimble processing."
As a result, today's facilities
must be designed with enough
space to adapt to growth and
produce new SKUs quickly as
market changes dictate. Clients
tell Stellar that they want packaging flexibility to meet the needs of
a variety of clients.
"They need to be able to
package their products for individual retail, bulk wholesale clubs
and foodservice clients," Allsup
says. "If you have greater packaging options, you have a wider
spectrum of potential clients
who have different packaging
size needs."
A new packaging segment
is also emerging with the growth
of online delivery and curbside
pick-up for groceries. Packaging
for these products is often a lot
simpler (and cheaper) since manufacturers don't have to attract
the eye of a shopper perusing
in-store shelves, Allsup says.

Food safety
To ensure the highest food safety
standards are met, Austin has
food scientists on staff - one of
only a few companies to do so,
Wright says. "The Austin Co. has
been a leader in food-safe design
for many years," he says. "We
have been designing facilities
that meet the new FSMA requirements for years."
Food safety drives everything. For instance, Austin
facilities implement automation
where possible - but only, Wright

AUSTIN, STELLAR

STELLAR'S DESIGN BASICS

produce through the plant as
quickly as possible," Allsup says.
"Newcomers to this space - and
existing companies looking
to build new plants - need to
consider the entire supply chain
and how they want to lay out
their facilities to increase speed
to market and compete in the
marketplace."
Companies that shortchange
this factor in their facility design
will pay for it in lower profits,
Allsup says. The longer the shelf
life, the less spoilage and the
more profit.
Poultry and seafood
processing facilities, on the
other hand, have a different set
of needs, Allsup says. Poultry
facilities use a lot of water for
washdown, so it's important
to design systems correctly to
manage the flow of washdown
and clean-up. "Downtime spent
on cleaning is time not spent
producing revenue, so it's
important to plan these cycles
effi ciently," he says.
There is currently an increased focus on automation in
the poultry and seafood segments, Allsup says. Historically,
these products have been
manually intensive, requiring
substantial personnel on the
plant floor to facilitate processing.
But given the current economy
and unemployment rate, there's
a noticeable labor shortage, particularly when it comes to finding
employees to work in these
harsh, refrigerated environments.
"This trend, coupled with
the decreasing cost of automation and robotics, is driving
investment in these technologies
where it makes sense," he says.


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Supermarket Perimeter - January 2019

Table of Contents for the Digital Edition of Supermarket Perimeter - January 2019

Supermarket Perimeter - January 2019
Editor's Note - More of a good thing
Contents
The wire
Ready to run
YOUTH MOVEMENT
From passion to profits
Bakery - Natural ingredients
Pastries
Deli - Seasonal merchandising
Snacking cheeses
Meat & Poultry: Dietary callouts
Flavor enhancers
Produce: Brand power
Leafy greens
Seafood: Sustainable gains
Food safety - Equipment innovations
Commissary Insider
FOOD SAFETY - FACILITY DESIGN
PRODUCT CATEGORY SPOTLIGHT - SANDWICHES
PACKAGING - SINGLE-SERVE PACKAGING
R&D - CLEANING AND SANITIZING
Product Showcase
Advertisers
Fresh takes
Supermarket Perimeter - January 2019 - Supermarket Perimeter - January 2019
Supermarket Perimeter - January 2019 - Supermarket Perimeter - January 2019
Supermarket Perimeter - January 2019 - 2
Supermarket Perimeter - January 2019 - Editor's Note - More of a good thing
Supermarket Perimeter - January 2019 - Contents
Supermarket Perimeter - January 2019 - 5
Supermarket Perimeter - January 2019 - The wire
Supermarket Perimeter - January 2019 - 7
Supermarket Perimeter - January 2019 - 8
Supermarket Perimeter - January 2019 - 9
Supermarket Perimeter - January 2019 - 10
Supermarket Perimeter - January 2019 - Ready to run
Supermarket Perimeter - January 2019 - 12
Supermarket Perimeter - January 2019 - 13
Supermarket Perimeter - January 2019 - YOUTH MOVEMENT
Supermarket Perimeter - January 2019 - 15
Supermarket Perimeter - January 2019 - 16
Supermarket Perimeter - January 2019 - 17
Supermarket Perimeter - January 2019 - 18
Supermarket Perimeter - January 2019 - 19
Supermarket Perimeter - January 2019 - From passion to profits
Supermarket Perimeter - January 2019 - 21
Supermarket Perimeter - January 2019 - 22
Supermarket Perimeter - January 2019 - 23
Supermarket Perimeter - January 2019 - Bakery - Natural ingredients
Supermarket Perimeter - January 2019 - 25
Supermarket Perimeter - January 2019 - 26
Supermarket Perimeter - January 2019 - 27
Supermarket Perimeter - January 2019 - Pastries
Supermarket Perimeter - January 2019 - 29
Supermarket Perimeter - January 2019 - 30
Supermarket Perimeter - January 2019 - 31
Supermarket Perimeter - January 2019 - Deli - Seasonal merchandising
Supermarket Perimeter - January 2019 - 33
Supermarket Perimeter - January 2019 - 34
Supermarket Perimeter - January 2019 - 35
Supermarket Perimeter - January 2019 - Snacking cheeses
Supermarket Perimeter - January 2019 - 37
Supermarket Perimeter - January 2019 - 38
Supermarket Perimeter - January 2019 - 39
Supermarket Perimeter - January 2019 - Meat & Poultry: Dietary callouts
Supermarket Perimeter - January 2019 - 41
Supermarket Perimeter - January 2019 - 42
Supermarket Perimeter - January 2019 - 43
Supermarket Perimeter - January 2019 - Flavor enhancers
Supermarket Perimeter - January 2019 - 45
Supermarket Perimeter - January 2019 - 46
Supermarket Perimeter - January 2019 - 47
Supermarket Perimeter - January 2019 - Produce: Brand power
Supermarket Perimeter - January 2019 - 49
Supermarket Perimeter - January 2019 - 50
Supermarket Perimeter - January 2019 - 51
Supermarket Perimeter - January 2019 - Leafy greens
Supermarket Perimeter - January 2019 - 53
Supermarket Perimeter - January 2019 - 54
Supermarket Perimeter - January 2019 - 55
Supermarket Perimeter - January 2019 - Seafood: Sustainable gains
Supermarket Perimeter - January 2019 - 57
Supermarket Perimeter - January 2019 - 58
Supermarket Perimeter - January 2019 - 59
Supermarket Perimeter - January 2019 - Food safety - Equipment innovations
Supermarket Perimeter - January 2019 - 61
Supermarket Perimeter - January 2019 - 62
Supermarket Perimeter - January 2019 - 63
Supermarket Perimeter - January 2019 - 64
Supermarket Perimeter - January 2019 - FOOD SAFETY - FACILITY DESIGN
Supermarket Perimeter - January 2019 - 66
Supermarket Perimeter - January 2019 - 67
Supermarket Perimeter - January 2019 - PRODUCT CATEGORY SPOTLIGHT - SANDWICHES
Supermarket Perimeter - January 2019 - 69
Supermarket Perimeter - January 2019 - 70
Supermarket Perimeter - January 2019 - 71
Supermarket Perimeter - January 2019 - PACKAGING - SINGLE-SERVE PACKAGING
Supermarket Perimeter - January 2019 - 73
Supermarket Perimeter - January 2019 - 74
Supermarket Perimeter - January 2019 - 75
Supermarket Perimeter - January 2019 - R&D - CLEANING AND SANITIZING
Supermarket Perimeter - January 2019 - 77
Supermarket Perimeter - January 2019 - 78
Supermarket Perimeter - January 2019 - 79
Supermarket Perimeter - January 2019 - Product Showcase
Supermarket Perimeter - January 2019 - Advertisers
Supermarket Perimeter - January 2019 - Fresh takes
Supermarket Perimeter - January 2019 - 83
Supermarket Perimeter - January 2019 - 84
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