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Optimizing Cold Storage: How Warehouses are preparing for the Food Safety Modernization Act Update

The U.S Food and Drug Department (FDA) estimates that nearly 1 in 6 Americans suffer from a foodborne illness per year, resulting in about 128,000 hospitalizations and 3,000 deaths. Needless to say, there is no place for compromise within food safety parameters. Studies show that a mere 20% of consumers completely trust manufacturers to ensure proper safety measurements, and 60% avoid businesses responsible for even one illness incident. To combat illnesses and restore buyer confidence, the FDA has now shifted its focus to proactively preventing illnesses from festering within the manufacturing and distribution process as opposed to simply targeting system breakdowns. Per the updated Food Safety Modernization Act, supply chains will be expected to enhance track-and-trace systems to record and store data for up to 2 years by November of 2022. Data should be retrievable within 24 hours to enable quick farm-to-table traceability. To achieve this, businesses are encouraged to strengthen the following pillars of dependable traceability:

  1. Monitor growing/manufacturing process to ensure only verified ingredients are used.

The FDA’s Food Traceability List allows manufacturers to prioritize real-time visibility for at-risk foods within the very first steps of production. Freezer-ready technologies like the MC9300 can help streamline inventory control by combining data capture and processing onto one digital platform. Rugged labels should also be employed to preserve barcode readability, so ingredients can be verified during production.

 

        2. Optimize communication at the receiving dock, so products are not idly waiting in dangerous temperatures.

Just-in-time replenishment has become evermore commonplace in most distribution centers, which means teams must be able to effectively communicate when items arrive to prevent spoilage or inventory loss. Whether it be through automatic alerts via handhelds or group calls through a push-to-talk system, team communication at the loading dock ensures food safety measures are carried out the moment products arrive.

 

        3. Track handling process for at-risk foods such as shellfish, fruit, leafy greens, eggs, cheese, and ready-to-eat salads.

For real-time inventory management, RFID and locationing systems prove to be indispensable. Because RFID tags can hold as many as 40 different codes per tag, RFID systems empower teams to track multiple status points for each product at once to see if they were handled properly.  Automated data recording further simplifies future auditing since data can be retrieved automatically with less risks for error.

 

        4. Notify delivery teams and other members in the supply chain of shipping timeframes and inventory status.

These FDA changes have placed greater responsibility on the entire supply chain, which means proper tracking must extend beyond the four walls. This is where Bluetooth-powered technologies like Zebra’s Electric Temperature Monitoring Sensors prove highly beneficial as businesses can track transportation temperatures in real-time to prevent spoilage.

 

Regardless of how you choose to approach food safety, one thing is certain: Visibility is key.  Whether it be through enhanced group communication or real-time inventory tracking, businesses must quickly adopt to establish proper food safety standards. For more information on how you can optimize your workflows to comply with the Food Safety Modernization Act, contact our automation specialists here.

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How will you avoid the next recall?

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In a span of a decade, the Food and Drug Administration (FDA) along with the Food Safety and Inspection Service (FSIS) have reported a 125% increase in food recalls. In 2020, the FSIS recorded a total of 1,394,585 pounds of recalled products, pulled from markets due to pathogens, allergens, presence of extraneous materials, and import violations. Studies show that grievous tracking and traceability gaps have been responsible for:

  • 47% of recalls stemming from microbiological contamination
  • $3.7 billion spent in medical treatments for salmonella 
  • Nearly 8.5 million food units recalled yearly by the FDA
  • 601,969 pounds of recalled chicken in 2020 alone

While these numbers are ominous, one of the primary reasons behind the increase in recalls are traceability technology and new safety regulations. Real-time tracking and labeling systems now provide easier verification of compliance codes in food safety. That means manufacturers can target and catch more mistakes than before with the help of new intelligent tools and better safety parameters set by the FDA, FSIS, and CDC. However, while timely recalls can prevent pathogen outbreaks, they quickly erode consumer trust. An estimated 80% of consumers do not completely trust brands to ensure safety, and over a third report avoiding businesses associated with food-borne illnesses for many months. Therefore, visibility systems must prioritize early detection to keep compromised products from leaving facilities in the first place. 

The key to establish real-time alerts based on actionable data

Less communication gaps empowers teams with a clear overview of how products are handled, packaged, stored, and moved. Labeling systems paired with handheld scanners and mobile computers can help eliminate gaps by transcribing data from each step into a centralized shareable database. On the other hand, new rugged tablets like Zebra’s ET80/85 2-in-1 tablets emphasize the power of agile adaptability in securing food safety by:

  • Providing a lightweight consolidated computer and scanner – Despite having an integrated scanner and higher durability standards, the ET80/85 is 20% lighter and 35% thinner for easy portability. Its larger screen size permits workers to monitor products at-a-glance when operating forklifts or other heavy machinery.
  • Facilitating data entry with a detachable keyboard – Keep workflows standardized with a device that adapts to preferred data entry mechanisms for administrators and production teams alike. Detachable keyboards and universal mounting options allow the ET80/85 to fit into different work environments, simplifying training and accelerating deployment. 
  • Reducing connection drops through flexible connectivity options – Leveraging several connectivity options such as WiFi 6E, 4G/5G, and Bluetooth, the ET80/85 prevents downtime and breakdowns from signal drops within the four walls, keeping your vital data constantly available to your workforce. This also means workers can update WIPs, notifications, and compliance codes in real-time for entire teams to track. 
  • Deploying seamless push-to-talk and secured texting – Lastly, Zebra’s Workforce Connect empowers manufacturers with real-time communication between individual workers and entire groups, all streamlined through one platform. Moreover, connectivity can extend beyond the four walls, allowing transportation teams and retailers to verify shipments are ready for sale. 

To efficiently start securing real-time workflow visibility, begin with a comprehensive operational assessment to target recurring points of communication breakdowns. Contact Avalon to start your assessment today and learn more about the next generation of technologies devoted to dependable food safety.

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You are What You Eat…And That’s Why You Need Compliance Labels

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Labels matter. Such a small statement is constantly put to the test in supermarkets across the nation since labels serve as the deciding factor in allowing foods to fall into customers’ hands. Equipped with an extensive list of requirements and regulations, government organizations such as the Food and Drug Administration (FDA) studies product labels to make sure foods contain what labels say. As a result, inaccurate labels can cost more than ink and time.

The 2012-2018 litigation between POM Wonderful and Coca-Cola serves as a prime example of the damage a little label can cause. Minute Maid’s 99% apple-based Pomegranate Blueberry Juice could have cost over $10 billion in settlements for POM’s lost profits. Furthermore, inaccurate packaging can also impact storage and transportation, leading to spoiled goods and lost inventory, which can also result in recalls and illnesses. To avoid the pitfalls of navigating through compliance labeling, Avalon Integration helps minimize labeling costs and errors with versatile Zebra Certified Consumables, designed to expand asset visibility while meeting application requirements.

Protect Assets with Compliance Labels

Protect Assets with QLN420 Compliance Labels

Protect Assets with QLN420 Compliance Labels

Food processing labels have been subject to scrutiny for decades. As new trends emerge, warehouses and distribution centers must keep up with new compliance practices while updating labels to reflect changes. Adaptable and durable, Zebra Certified Consumables help secure proper handling with three top benefits:

  • Expanded label longevity: Tested for both high humidity and extreme cold storage Zebra labels retain legibility in harsh environments without smudges, allowing your workforce to better handle and store your inventory.  
  • Label customization:  Using over 300 pretested materials, Zebra labels can be designed to fit your application requirements. Change color, shape, text, and graphics to design custom labels that best represent your inventory and safety codes. 
  • Faster replenishment – Sourced from four labeling converter facilities, Zebra labels can be shipped quickly to any location within continental North America, so if a reprint is needed, new labels are readily available. 

Identification labels will only become more predominant with the appearance of new foods and best-practice policies. Implement efficiency and adaptability into your workflow when you start your labeling solution with Avalon Integration and maximize visibility and customer trust with a labeling system that values your customers as much as you do. 

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