< PreviousCONTAINERS AND PALLETS 30 Food & Drink International www.fdiforum.net © Shutterstock /Fahroni Progress for 30-33.qxp_Layout 1 03/02/2021 13:22 Page 1Food & Drink International 31 CONTAINERS AND PALLETS From Brexit to sustainability strategies, a number of factors are influencing pallet use and choice, stimulating innovation from pallet producers or a simple material switch from food firms. Hygiene Hygienic pallets are vital when dealing with the sensitive goods involved in the food and drink industry, becoming even more so as food safety concerns grow in the minds of both consumers and regulators. Generally, smooth surfaces are a priority, i.e. pallets with no nooks where dirt and liquids can accumulate and compromise the safety of products on the pallet. The desire for such pallets has created much debate on what the best material for pallets used in our industry is, primarily surrounding the age-old fight between wood and plastic. A key argument for using plastic pallets is that, by the very nature of being plastic, they can be designed to meet stringent requirements through the use of virgin or food grade recycled plastic, and that as they are impermeable to liquids, dirt, et al., there is reduced risk for cross contamination. Plastic pallets, being non-porous, are also praised for being easier to wash down and disinfect for repeated use. It has also been put forward that the coarse surface of a wood pallet is more susceptible to microbial contamination. The arguments for the hygiene benefits of wood pallets meanwhile propose that clean, dry wood is not a breeding ground for bacteria, and is unlikely to harbour pathogens, and pinpoint wood’s natural antimicrobial properties. Furthermore, research indicates wood surfaces are able to absorb contaminants, making the surface clean. Thus if a wood pallet comes into contact with a contaminant, pathogens and liquids would be absorbed into wood fibres, away from the pallet surface, while with materials like plastic, contaminants remain on the surface. However, it is noted that wet wooden pallets, having reached the fibre saturation point, will not hold the same absorbing qualities and be vulnerable to mould. Wood is also highlighted as being easy to sterilise economically through heat treatment. Moreover, evidence has been put forward to illustrate that though new plastic is less likely to trap bacteria, wear on plastic pallets when reused is ideal for bacterial growth. As the war over safety continues to rage from both sides, influencing food and drink companies’ decisions, plastic and wood pallet producers point to studies and scandals showing advantages and potential hazards of each material. A scandal a few years ago for pallets came when deaths and illnesses related to Blue Bell Creameries products were found to have been caused by inadequate cleaning and handling with the use of dirty wood pallets, allowing Listeria to pass on to products. Ultimately, in choosing either material pallet it comes down to responsible production, use, control, and cleaning. Cost and strength Cost and strength are other core factors affecting pallet choice. Wooden pallets had an interesting 2020. Amidst Often overlooked, yet key for keeping the food industry and its products moving, pallets and containers are vital as platforms for transport, storage, and delivery. www.fdiforum.net 32 Á 30-33.qxp_Layout 1 03/02/2021 13:22 Page 232 Food & Drink International www.fdiforum.net CONTAINERS AND PALLETS the pandemic, the prices of wood rose to the highest level in two years as mills closed, and high demand for lumber saw a reduction in availability, impacting pallet cost. Though wooden pallets would usually be economical and easy to produce, many are considering a switch to plastic to embrace benefits like improved durability, where wood pallets are prone to chipping and splintering, and with the associated debris - from nails to wood fragments - comes damage to product packaging. Debris can even get carried into processing areas by workers. With no splinters, nails, sharp edges or chipping, plastic pallets also come with a lower risk of injury. When it comes to cost, plastic pallets are from the outset pricier, but in assessing this next to its wood rival, one should take into account the costs of heat treatment and certification for export. The ongoing costs of pallets more widely is shining a light on the question of whether to rent or buy. With rental there are no major upfront costs and rental charges can be set against tax liabilities. It is usually best suited to companies sending pallets to a plethora of locations through a 3PL. Buying however becomes the better option if you have no requirement for additional services that come in hand with renting, such as when pallets are being used internally. The environment & sustainability Food manufacturers, following societal trends, no longer want single use containers and pallets, impacting purchasing decisions. Durable, reusable, and recyclable plastic containers, for instance, transporting fresh produce are being used to minimise need for extra waste packaging, like shrink wrap and bags, as they can be washed repeatedly to be contaminant free. Eco-friendliness and evolving sustainability plans are also affecting pallet choice, use, and stimulating innovation. New pallets are being developed from more sustainable material options - banana fibre, corn stover (the remaining plant debris left after corn is picked), and coconut waste for example. Returning to a classic, the environmentally friendly nature of wooden pallets is being thoroughly © Shutterstock /Pictures_n_Photos 30-33.qxp_Layout 1 03/02/2021 13:23 Page 3Food & Drink International 33 www.fdiforum.net CONTAINERS AND PALLETS assessed as wood pallet manufacturers work to become greener. This can be seen in the expansion of pallet recycling programmes and refurbishment programmes so that, instead of throwing out pallets, slightly damaged pallets can be repaired quickly. Pallets can then be returned to owners or sold as recycled pallets, whereas those beyond repair are being turned into mulch and other products or burned for fuel. Wood pallet makers are also ensuring to source new lumber from forests certified by the Forest Stewardship Council (FSC) or Sustainable Forest Initiative (SFI), which indicate that trees are harvested at a lesser rate than new trees being produced - they come from sustainable and responsibly managed forests. When it comes to plastic pallets, producers are increasing sustainability by incorporating more recycled content, and food and drink firms are making use of their own scrap to make pallets. Simultaneously, the longevity of plastic pallets, and thus the less frequent need to replace them, is becoming a major plus for sustainability-conscious companies, alongside their light weight, which can boost fuel economy during transport. Plastic pallets can also of course be recycled, turned into a new pallet or product, with HDPE plastic one of the most easily recyclable plastic polymers and HDPE pallets being almost indefinitely recyclable. If thrown out however, HDPE plastic takes around a century to degrade. In addition, as plastic pallets typically come from petroleum or natural gas products, their carbon footprint is increased. Adding more fuel to the wood-plastic war, in 2020, researchers from Penn State found shipping pallets made of wood to be slightly more environmentally friendly and sustainable than those made of plastic, after conducting detailed comparisons of long-term performance of treated wooden and plastic pallets through a cradle to grave life cycle assessment, and with consideration of treatments needed to kill pests and the impact of resources consumed and emissions released in their life cycles. The peer- reviewed study also found a significant difference in how wood pallets are treated with those that are heat treated to kill pests having a carbon footprint up to 30% lower than those treated with methyl bromide fumigation, which involves a gas blamed for depleting the ozone layer. Pallet pooling and recovery is also growing as a method of bolstering eco-friendly pallet programmes. Brexit Another factor affecting food and drink firms’ pallet choices is Brexit. Reducing confidence in wooden pallets, at the end of 2020, there was a clear struggle in the UK to heat treat and mark enough pallets in time for the end of the transition period, when all wooden pallets travelling between the EU and UK had to become ISPM15- compliant - a rule intended to prevent contamination and the spreading of pests, but that comes with additional cost burdens. Pallets made from plastic and other material, however, are exempt from this, making businesses more likely to consider a switch. Connected pallets Furthermore, the integration of tech into pallets and containers is stimulating change. More companies are equipping pallets with sensors, allowing for better visibility of pallets, and the eradication of pallet loss. One could determine the exact location of a pallet, as well as weight and temperature of pallets, alongside other parameters. As the idea of connected pallets grows, smarter inventory management and more accurate tracking and tracing of goods can be achieved. PALLET TO PALLET TRANSFER SOLUTIONS With 5000 machines supplied to 65 countries across the world, Premier can call on over 41 years’ manufacturing experience of Pallet Inverter manufacturing.. Gressenhall | Dereham | Norfolk | NR20 4DT | +44 (0)1362 861066 | www.premierpalletinverter.co.uk 30-33.qxp_Layout 1 03/02/2021 13:23 Page 434 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING Microbiological testing is booming as companies look to address rising food safety awareness amongst consumers, comply with regulations, keep consumers safe, avoid expensive recalls, maintain brand reputation, and place more focus on environmental monitoring on top of raw material or end-product testing. The continuous stream of high-profile foodborne illness outbreaks is seeing further demand for microbiological testing of food products and facilities. Salmonella outbreaks, for example, hit headlines numerous times in 2020. One incident saw Thomson International, at the beginning of August, recall red, yellow, and white onions that had been shipped all over the US and Canada since May after salmonella cases were reported across forty-three states and in Canada. Though initially only red onions were of concern, these onions were all packed and processed with the same equipment. In October, the CDC announced that the outbreak appeared to be over, and the US Food and Drug Administration (FDA) noted it had concluded its traceback investigation, showing the onions came from Thomson International Inc. in California. In total 1,642 people were confirmed to be infected and at least 167 people required hospitalisation in the US. With the potential for such outbreaks, food firms are looking to identify and restrict harmful microorganisms to prevent foodborne diseases and spoilage and protect operations with testing, while also using microbiological tests for purposes like shelf-life studies and to home in on hygiene. Food processors are now making changes to sampling and testing plans, investing more into microbiological and pathogen control, collecting more samples, as they look to find and eliminate pathogens in production plants, acting in a more preventative, proactive manner. Routine sampling, pathogen environmental monitoring, and seek and destroy programmes to assess any missed areas and indicate hazards, are growing, enabling plants to be better cleaned, sanitation methods to be verified, and facilitating elimination of environmental pathogen sources to reduce contamination, recalls, and foodborne illness. This is creating more effective testing plans, with companies not simply focusing on testing finished products, meaning a more complete picture of a processing plant and its risks can be gained. Furthermore, in testing, outsourcing is growing to remove chance of pathogen contamination from a plant laboratory and to reduce costs. While for large companies an onsite lab may be favourable economically, for SMBs the expense of a lab for a small number of samples is often not justifiable. However larger processors are also more frequently turning to outsourcing, taking into account additional factors past a lab’s daily operation costs, such as training, hiring, certifications, and a widespread desire for independent, third-party lab data. New methods There are a variety of test methods used to identify and verify microorganisms including culture media and immunoassay, but there remains a need for improved testing and monitoring in the food chain, and better detection methods that offer rapid, easy to use, and cost-effective solutions. Polymerase chain reaction (PCR) and other genome sequencing techniques are increasing in use due to their fast, sensitive, and reliable pathogen detection, as well as ability to identify pathogens in low concentrations. Advances in microbiological testing are seeing the development of quicker detection methods that can keep up with the fast pace of food manufacturing - where rapid identification and response to contamination is vital - and allow for less product testing As food safety awareness rises, manufacturers are expanding testing plans. Investing in 36 Á 34-37.qxp_Layout 1 03/02/2021 13:28 Page 1Food & Drink International 35 www.fdiforum.net MICROBIOLOGY AND TESTING © Shutterstock /A.Mphotos 34-37.qxp_Layout 1 03/02/2021 13:29 Page 236 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING storing time. An international team of scientists have developed a new method that accelerates the identification process of salmonella, offering a more efficient method for food producers. Serotyping has been the conventional process for identifying the presence of Enterobacteriaceae family bacterial. For salmonella, it used to take three days and, in some instances, over twelve days to assign a final classification for complex servovars. Conventional serotyping has also been associated with high costs and complex sample preparation. Now, researchers from Cornell University, the University of Georgia, and the Mars Global Food safety Centre in Beijing have developed a method for whole- genome sequencing (WGS) to determine salmonella serotypes in two hours and the whole identification process within eight hours. In an associated study all thirty-eight salmonella strains – representing thirty- four serotypes – assessed were accurately predicted to the serotype level using WGS. This solution comes as food safety regulators, authorities and public health agencies embrace WGS methods for pathogen subtyping and reliable detection, as a technique that can analyse a wider swath of the genome and with which particular strains can be more precisely identified and the origin and path of a disease’s outbreak determined. The FDA for example collects swab samples during inspections and submits them for WGS analysis. Another recent development came at the end of 2020, when Molendotech Ltd was awarded £250,000 by Innovate UK for a project with the University of Southampton titled ‘Development of rapid testing technology to increase food security’. While currently fresh produce has to be stored while samples are sent to laboratories for microbiology culture (typically two to five days), resulting in a bottleneck that creates additional cost, additional energy use, delays in the supply chain and a reduction in shelf life, Molendotech has developed an assay that could evaluate pathogens in produce the same day and could be performed on site by non- specialist staff. Molendotech says its novel method to select and quantify specific bacteria in four to six hours will allow identification of pathogens in a time scale that will remove the need for extended storage of produce prior to release to supermarkets. The project is a collaboration with the National Biofilm Innovation Centre at the University of Southampton, which has been exploring the effect of bacteria within biofilms and viable but non-culturable bacteria (VBNC). Currently the only way of detecting the VBNC is by feeding these bacteria to worms to assess the impact on their lifetime. Molendotech technology, to be tested in this project, will enable a faster and more precise way of detecting VBNC and identify the strain of pathogenic bacteria. Moreover researchers at Purdue University have developed a bioluminescence-based assay, paired with a portable device that works with smartphones and laptops, for onsite testing for harmful E. coli in food samples. The silicon photomultiplier (SiPM) device uses low light from the bioluminescent assay to detect the presence of bacteria that cause foodborne illness in food samples. The Purdue team also created an electrical circuit with an amplifier, comparator and micro controller to send the data to laptops and smartphones via Bluetooth © Shutterstock /Festa 34-37.qxp_Layout 1 03/02/2021 13:29 Page 3Food & Drink International 37 www.fdiforum.net MICROBIOLOGY AND TESTING technology. Euiwon Bae, a senior research scientist of mechanical engineering in Purdue’s College of Engineering, said: “Our goal is to create technology and a process that allows for the cost-effective detection of the causes of foodborne illness using an easy, expedient and efficient process.” To show the proof of concept, the Purdue team tested the device with artificially contaminated samples of ground beef, injecting E. coli into the beef samples and using their device to analyse the sample within 10 hours of inoculation. The beef is rinsed and incubated with an enrichment liquid containing a modified phage, a virus for bacteria. The phage then infects harmful foodborne bacteria so that when a substrate is added, the bacteria emit light, which is detected by the SiPM. The device is able to count light pulses or photons. Artificial Intelligence (AI) and machine learning, meanwhile, are being utilised in testing to enhance culturing. Combining cell-marking and optical technologies AI and machine learning are facilitating the identification of targeted microorganisms at their initial stage of growth (the micro colony stage). Of course microbiological testing is only one aspect of food safety systems and thus cannot ensure product safety, however it is integral for gaining information on manufacturing processes, processing environment, and specific batches. To achieve optimum results, food processors should further build programmes such as Hazard Analysis Critical Control Point (HACCP), Good Manufacturing Practices (GMP), Recall Management, Traceability, and Sanitation Practices. © Shutterstock /Pixel-Shot BOTTTLED & BBAGGGED MMEDIIA Manufacturer of prepared culture media and associated products for microbiology. Find out more at www.sglab.com BESSPOKKE MEEDIA MANNUFAACTUURE PLAATE MMEDIAA CONVENIENCE YOU CAN TRUST. 34-37.qxp_Layout 1 03/02/2021 13:29 Page 438 Food & Drink International www.fdiforum.net CLEAN AIR SOLUTIONS © Shutterstock /Parilov 38-41.qxp_Layout 1 03/02/2021 13:31 Page 1Food & Drink International 39 www.fdiforum.net CLEAN AIR SOLUTIONS It’s almost inconceivable that a food manufacturer would shun or shirk a thorough washdown routine across their production line. Although much attention is rightly applied to contact surfaces and processing equipment, one of the most pervasive hygiene threats in the supply chain can’t be dealt with in the same way. That’s down to the fact that air is used in a variety of ways during production and processing. As well as helping to power certain pieces of equipment, it is also used to texturize some products, is frequently used in meat packing and in the production of plastic bottles. During these stages, contaminates can enter airflow and adversely affect a product or batch prompting a product recall further down the line. Even if no consumers are sickened, the reputational damage – not the mention the cost of a recall itself – can leave a company dealing with a costly fallout. According to the Food Marketing Institute and the Grocery Manufacturers An invisible issue During the COVID-19 pandemic, it’s even more critical for businesses across the food and drink supply chain to be cognisant of clean air solutions. 40 Á 38-41.qxp_Layout 1 03/02/2021 13:31 Page 2Next >