Supermarket Perimeter - August 2019 - 66

FOOD SAFETY

Choose a level
Determining which level of isolation will work best for a bakery
requires a consideration of several variables including the facility's
limitations, customer requirements, current allergen matrix
and future production needs.
To choose the appropriate
level of isolation, bakers must
first identify what the risks for
cross-contamination are and
where opportunities for contamination exist in the process.
"We begin with a review of
products and any allergens that
are part of the recipes," Carr
says. "Next is predicting future
products and allergens that may
be used. With this information,
Austin incorporates into the
design what isolation is required
and how it is to be achieved."
Considering what allergens
and level of business a bakery
might want to attract in the
future can guide bakers to what
level of segregation they'd like
to make room for in the event of
future expansions.
If a company isn't building
a new facility, it's important
to evaluate the existing facility for changes to prevent any
cross-contamination opportunities. For example, air locks
are necessary to keep allergens
from traveling across segregated
production lines within a plant.
However, existing mechanical
systems must provide extra air
to pressurize these locks. Bakers
should also consider their budget
66 - AUGUST 2019

and how much they are willing
to spend.
"The most effective form of
isolation is to create physical
separation by assigning rooms
to different allergens," says Pablo
Coronel, director of food processing and food safety at CRB, an
engineering firm based in Kansas
City, Missouri. "However, this may
be costly and requires planning
long in advance."
When working with an existing
facility, the building itself may
have limitations, specifically on
space, that dictate how much
isolation a bakery can achieve.
Segregated warehouses, air locks,
dedicated productions lines and
their support systems all need
space that some bakers just
might not have without building
a new facility.
Changeovers can signal to a
baker when it's time to make the
leap from segregated lines to a
dedicated allergen-free facility.
When changeovers become
cost-prohibitive, it's time to make
the change.
"Of course, that tipping point
looks different for every company
depending on its particular process and demands," says Kevin
Wilson, senior process engineer
for Stellar, Jacksonville, Florida.
"If you're experiencing a greater
demand for your allergen-free
products, it may be worth shifting
those SKUs to a dedicated plant
to increase throughput and
minimize downtime."
Customers, whether they are
end consumers or a brand, also
have a big say in whether a bakery
decides to use a dedicated facility
or simply segregate the lines.
"A dedicated facility becomes
necessary when products containing allergens are made at the
same time as products that do
not contain allergens, and the client wishes to avoid label disclosures such as 'made in a facility

Heightened concern around allergens has companies that deal with
many allergens looking to segregate production to prevent crosscontamination.

which also processes tree nuts'
or when production is aimed at
an allergy-sensitive population,"
Coronel says.

Isolated organization
In a facility dedicated to being
peanut-free, gluten-free, tree-nut
free or dairy-free, preventing
cross-contamination is pretty
straightforward. Nothing containing the offending allergen is allowed inside the facility, whether
that's ingredient deliveries, employee lunches or vending machine contents. This high level of
security combined with stringent
sanitation programs minimizes
the risk of an allergen sneaking
onto the production floor.
A bakery with shared production lines, no matter how
segregated, requires specific
design strategies and operational
practices to ensure no cross-contamination occurs.
"If isolation is to be achieved
in a single building, several issues
need to be addressed, including cross-contamination at the
receiving docks or silos, separate and isolated storage areas,

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misuse of tools and equipment,
air movement and employee
movement," Carr says. "It's always
easier and less costly to include
isolation systems when the plant
is first constructed. The cost and
disruption to make modifications
later can be mitigated if those
future changes are planned in the
initial design."
Ingredient segregation is a critical first step in keeping allergens
away from other production
areas. Ingredient receiving is a
soft spot where allergens can
come into contact with ingredients for non-allergen product.
It's important that these are
received on separate docks and
then stored away from the others.
Warehouses can be segregated
by racks. Dr. Coronel suggested
that half-used containers be
secured with double closures to
prevent powders and particulates
from accidentally mixing with
other products.
"Shipping and receiving should
be aware of allergens, and extra
care must be taken to prevent
damage to allergen bags and
cross-contamination," he says.

CRAIG VANDER LENDE

allergen-free production. While
dedicated plants may be closest
to a sure-thing in preventing
cross-contamination, it's
not always feasible for every
company.
"As a co-manufacturer that
manages all types of allergens,
building dedicated plants is not
practical," Child says.


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Supermarket Perimeter - August 2019

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

Supermarket Perimeter - August 2019
Editor’s note - A good suggestion
Contents
The Wire - Impossible Burger coming to retail
New Price Rite stores highlight perimeter
Online shoppers still mostly shopping instore
Younger shoppers demand transparency
ADDING VALUE
SUGGESTIVE SELLING MEETS AI
Packaging innovations
Keeping food crisp with packaging technology
Innovations at IBIE
Bakery - A to Z: Equipping the Bakery
Cookies
Deli - Dinner demand
THE DELI AS A SHORTCUT TO HOME PREP
HELPING SHOPPERS
Fried chicken
KEEPING FRIED FOOD FRESH DURING DELIVERY
Meat & Poultry - Merchandising TRENDS
Bacon
THE TURKEY ALTERNATIVE
Produce - Back to SCHOOL
SINGLE-SERVE, EASY-TO-EAT
Fresh-cut
FRESH-CUT PACKAGING
Seafood - Tuna & swordfish
NOAA makes progress on restoring tuna, swordfish populations
Food safety - BEST PRODUCE PRACTICES
Keeping an eye on supply
Commissary Insider - August 2019
CONTROLLING ALLERGENS
SPOTLIGHT - CAKE PRODUCTION
TECHNOLOGY - PRODUCTION MANAGEMENT
OPERATIONS - OUTSOURCING SANITIZATION
Product Showcase
Advertisers
Supermarket Perimeter - August 2019 - Supermarket Perimeter - August 2019
Supermarket Perimeter - August 2019 - Supermarket Perimeter - August 2019
Supermarket Perimeter - August 2019 - 2
Supermarket Perimeter - August 2019 - Editor’s note - A good suggestion
Supermarket Perimeter - August 2019 - Contents
Supermarket Perimeter - August 2019 - 5
Supermarket Perimeter - August 2019 - Younger shoppers demand transparency
Supermarket Perimeter - August 2019 - 7
Supermarket Perimeter - August 2019 - ADDING VALUE
Supermarket Perimeter - August 2019 - 9
Supermarket Perimeter - August 2019 - 10
Supermarket Perimeter - August 2019 - 11
Supermarket Perimeter - August 2019 - SUGGESTIVE SELLING MEETS AI
Supermarket Perimeter - August 2019 - 13
Supermarket Perimeter - August 2019 - Packaging innovations
Supermarket Perimeter - August 2019 - 15
Supermarket Perimeter - August 2019 - Keeping food crisp with packaging technology
Supermarket Perimeter - August 2019 - 17
Supermarket Perimeter - August 2019 - Innovations at IBIE
Supermarket Perimeter - August 2019 - 19
Supermarket Perimeter - August 2019 - Bakery - A to Z: Equipping the Bakery
Supermarket Perimeter - August 2019 - 21
Supermarket Perimeter - August 2019 - 22
Supermarket Perimeter - August 2019 - 23
Supermarket Perimeter - August 2019 - Cookies
Supermarket Perimeter - August 2019 - 25
Supermarket Perimeter - August 2019 - 26
Supermarket Perimeter - August 2019 - 27
Supermarket Perimeter - August 2019 - 28
Supermarket Perimeter - August 2019 - 29
Supermarket Perimeter - August 2019 - Deli - Dinner demand
Supermarket Perimeter - August 2019 - THE DELI AS A SHORTCUT TO HOME PREP
Supermarket Perimeter - August 2019 - HELPING SHOPPERS
Supermarket Perimeter - August 2019 - 33
Supermarket Perimeter - August 2019 - Fried chicken
Supermarket Perimeter - August 2019 - 35
Supermarket Perimeter - August 2019 - KEEPING FRIED FOOD FRESH DURING DELIVERY
Supermarket Perimeter - August 2019 - 37
Supermarket Perimeter - August 2019 - Meat & Poultry - Merchandising TRENDS
Supermarket Perimeter - August 2019 - 39
Supermarket Perimeter - August 2019 - 40
Supermarket Perimeter - August 2019 - 41
Supermarket Perimeter - August 2019 - Bacon
Supermarket Perimeter - August 2019 - THE TURKEY ALTERNATIVE
Supermarket Perimeter - August 2019 - 44
Supermarket Perimeter - August 2019 - 45
Supermarket Perimeter - August 2019 - 46
Supermarket Perimeter - August 2019 - 47
Supermarket Perimeter - August 2019 - Produce - Back to SCHOOL
Supermarket Perimeter - August 2019 - 49
Supermarket Perimeter - August 2019 - SINGLE-SERVE, EASY-TO-EAT
Supermarket Perimeter - August 2019 - 51
Supermarket Perimeter - August 2019 - Fresh-cut
Supermarket Perimeter - August 2019 - FRESH-CUT PACKAGING
Supermarket Perimeter - August 2019 - 54
Supermarket Perimeter - August 2019 - 55
Supermarket Perimeter - August 2019 - Seafood - Tuna & swordfish
Supermarket Perimeter - August 2019 - 57
Supermarket Perimeter - August 2019 - NOAA makes progress on restoring tuna, swordfish populations
Supermarket Perimeter - August 2019 - 59
Supermarket Perimeter - August 2019 - Food safety - BEST PRODUCE PRACTICES
Supermarket Perimeter - August 2019 - Keeping an eye on supply
Supermarket Perimeter - August 2019 - 62
Supermarket Perimeter - August 2019 - 63
Supermarket Perimeter - August 2019 - 64
Supermarket Perimeter - August 2019 - CONTROLLING ALLERGENS
Supermarket Perimeter - August 2019 - 66
Supermarket Perimeter - August 2019 - 67
Supermarket Perimeter - August 2019 - SPOTLIGHT - CAKE PRODUCTION
Supermarket Perimeter - August 2019 - 69
Supermarket Perimeter - August 2019 - 70
Supermarket Perimeter - August 2019 - 71
Supermarket Perimeter - August 2019 - TECHNOLOGY - PRODUCTION MANAGEMENT
Supermarket Perimeter - August 2019 - 73
Supermarket Perimeter - August 2019 - 74
Supermarket Perimeter - August 2019 - 75
Supermarket Perimeter - August 2019 - OPERATIONS - OUTSOURCING SANITIZATION
Supermarket Perimeter - August 2019 - 77
Supermarket Perimeter - August 2019 - 78
Supermarket Perimeter - August 2019 - 79
Supermarket Perimeter - August 2019 - Product Showcase
Supermarket Perimeter - August 2019 - Advertisers
Supermarket Perimeter - August 2019 - 82
Supermarket Perimeter - August 2019 - 83
Supermarket Perimeter - August 2019 - 84
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