FOOD & BEVERAGE
PRIORITISING SAFETY AMID PROTEIN BOOM
Whenever there is a change in a process or packaging, risk professionals should revisit inspection protocols and hypothetical contamination scenarios to look at potential holes in the value chain
more of this product into their stock, the potential risk of physical contaminants during the cutting, trimming and deboning stage of production increases. Metal is the most likely contaminant to be introduced during this stage. Also, when equipment and surfaces deteriorate over time, they can present a possible contamination risk.
Phil Brown, Sales Director at Fortress Technology Europe, explores the ongoing protein boom and shows how companies can ensure consumer health and hygiene is prioritised
ver the last decade, two opposing diet trends have risen in popularity: poultry meat and plant-based meat alternatives. For food manufacturers, increasing and expanding production to adapt to these consumer demands creates new, diverse, inspection challenges. In an effort to combat diet-based health risks, many consumers are switching out overly-processed foods for high-protein, low- fat, nutrient-rich products. In an online survey, around half of consumers said ‘healthy eating’ is a personal priority and they are eager to reduce consumption of processed foods, sugar, fat, salt and, for some, red meat. In the UK, health, reducing consumption of artificial ingredients and sustainability featured highly on the list of changes to eating habits, in a McKinsey Insights report on conscious eating. Leaner meat, especially chicken, has gained popularity in the last decade. Simultaneously, the meat-alternatives market continues to steadily grow, with many big meat conglomerates now investing in plant-based protein lines. It is therefore important for manufacturers to review their current CCPs and safety controls as their facilities expand and production lines diversify.
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According to the British Poultry Council, the average person in the UK consumes more than 35kg of chicken meat annually, which is approximately 50% of UK meat consumption. Another food trend is protein-fortified foods. Supermarket shelves are now stacked with products containing added protein, from yoghurts and shakes to cereals and bagels. Alongside this trend, currently 79 million people globally identify as vegans, and many
seek meat and dairy substitutes with higher protein content. A growing consideration of the impact meat production has on the planet also means consumers are switching to plant- based meat alternatives. In 2022, the European retail market for plant based foods surged to €5.8 billion, up by €1 billion in two years. Measuring USD 10.37 billion in 2022, by 2032 the global protein market it is expected to reach around 23.34 billion USD.
This rapid expansion in the meat and meat- alternative market has naturally increased the amount of product passing through a single facility. When new equipment, processes and production lines are introduced, recalls and food safety threats multiply, prompting the need for additional control measures.
Regular food safety audits are integral to any management system. Poor record- keeping and non-compliance with established food safety plans are some of the top reasons food manufacturers fail audits. These issues can be prevented by being strategic when selecting high-contaminant- risk checkpoints and inspection equipment on protein processing lines.
“Once a food facility has developed and implemented its HACCP food safety plan, it must be periodically evaluated in order to ensure compliance with standards and regulations. The plan must be analysed again if there are any changes within the facility that might increase or introduce a food safety hazard,” highlighted Phil Brown.
In the UK, skinless breast remains the most popular chicken cut. As poultry processors add
28 DECEMBER 2024/JANUARY 2025 | PROCESS & CONTROL
With higher volumes of product passing through a metal detector or X-ray system, there may also be more opportunities for food safety hazards to be mismanaged. To overcome this issue, when a facility introduces additional inspection equipment, existing and new operating staff should be properly educated, trained and assessed on the standard equipment testing procedures. It is common for processors with fast- growing operations to target food safety hazards with multiple CCPs. One Fortress customer and protein processor reports that by including both upstream and end-of-line metal detection, they reduced good product waste costs, time and labour by 50 percent. Where there might appear to be a need for multiple machines to manage increased upstream output, Fortress recommends closely examining available options and speaking with the inspection system provider about the best system for the application. Providers offer guidance on maximising system benefits, such as saving factory floor space and cutting operational costs. Predicting the future popularity of current ‘consumer-favourite’ food products is always challenging. Given these rapid shifts, it is important for processors to remain diligent when identifying hazards and CCPs. Brown says that cutting corners on food safety is when non-compliance and brand- damaging contamination recalls are most likely to occur. “An annual HACCP assessment... will help to ensure that all essential inspection points are effectively managed and, most importantly, that they are retail and food- service compliant.”
Fortress Technology
fortresstechnology.co.uk
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