To ensure safety in the food chain, food processors are adding state of the art equipment.

As a part of the food chain, two food processors provide insight. Like their restaurant and other foodservice counterparts, food processors are taking serious measures to make sure strict food safety processes and procedures are in place. Many processors are building new plants, renovating existing plants and adding state of the art equipment to ensure that the food they supply to their customers-including restaurants and other foodservice operations- is safe.

Two such food processors, Suzanna's Kitchen, Inc., Duluth, Ga., and Hoekstra's Meat Co., Kalamazoo, Mich., share some of the steps they are taking to ensure food safety. These companies have taken a fresh look at their facilities and procedures to ensure the food they supply is as safe as possible.

Suzanna's Kitchen has served the food industry for about 40 years in the production of fully-cooked, frozen heat-and-serve beef, pork, veal, chicken, and turkey products. The company currently has two plants employing 175 people and spanning over 120,000 square feet.

"Microbiological issues have risen to the forefront," says Judy Adams operations manager for Suzanna's Kitchen. "Because we prepare fully cooked products, we segregate employees in the raw and cooked sides of the plant to prevent cross-contamination," she says. "We maintain two entirely separate facilities that include break rooms, bathrooms and locker rooms."

Ensuring food safety also includes streamlining operations by improving procedures and discarding others. "We no longer prepare par-cooked or browned products because the risks of working with these products is too great. Now we are strictly a fully-cooked plant," adds Adams.

Plant/Equipment Redesign
Building quality and safety into the finished product means getting things right from the beginning-starting with proper plant design. Sanitation is a primary consideration in the design of a processing plant. However, many processors who do not have the luxury of building new facilities are renovating their older plants to make them easier to clean and maintain. Smaller or older plants may have many small rooms without sufficient airflow that encourage the growth of certain microorganisms. Workers may inadvertently aid in cross-contamination as they go from room to room.

In both renovation and new construction, there are numerous considerations that can improve safety and quality including sealing the concrete to prevent molding, adding proper lighting to ensure dirt detection, using nonporous material for the walls, and avoiding materials that can rust.

"We have completely renovated our older buildings to comply with our current strict sanitation codes," says Colin Knight, plant manager for Hoekstra's Meat Co. "The older buildings were more difficult to clean. The updated facilities include boot baths, break rooms, and proper changing facilities."

Hoekstra's three Kalamazoo-based plants provide case-ready grinds; cuts of poultry, beef, pork, and lamb; cooked meats such as corned beef and prime rib; and portion-controlled steaks to foodservice and retail sectors. It has has over 100 employees, in addition to temporary staff.

Choosing proper equipment is another key factor in maintaining cleanliness. The criteria that food processors use as a guide to purchasing new equipment have changed dramatically over the years. "Today, as our number one priority, we look for equipment that is easy to clean-nonporous stainless steel equipment is the ideal," says Adams. "We are phasing out older equipment made out of aluminum or galvanized iron, which can harbor certain bacteria."

While new equipment is costly, Adams says the food safety factor more than makes up for the price. "It's imperative to go the extra steps to ensure food safety across the board," she states.

Training Workers is Key
Plant sanitation has become a top priority with food processors. As in the foodservice industry, training in food microbiology and sanitation are imperative for plant workers to understand and maintain cleanliness in all phases of operation. Processors generally send their employees to various sanitation workshops held at universities or companies who specialize in sanitation education.

This was not always the case, however. In the past, many sanitation departments lacked an adequate budget, and the department was omitted from much of the planning process. Companies are finally realizing that well-trained, knowledgeable individuals are one of their most valuable assets. "In the past, the sanitation crew was the forgotten third shift," says Adams. "Now they are one of the most important crews we have. Our sanitation crew is part of our quality team-they share responsibility with the quality assurance department."

Training at Suzanna's Kitchen involves a bilingual (English/Spanish) program. "We teach proper Good Manufacturing Practices (GMPs), including how to cough and sneeze safely, change gloves, and properly wash hands," says Adams. "HACCP (Hazard Analysis

Critical Control Point) and quality come first with each and every employee. All of our staff members have the authority to shut the line down, question QA, and recheck any questionable products," says Adams. "The old system of inspecting quality on the way out doesn't work-the employees have to make the products with quality and food safety already in them. Quality and food safety are not things you can ensure afterwards."