FAPC Magazine Fall/Winter 2014

The official magazine of the Robert M. Kerr Food & Agricultural Products Center, Oklahoma State University

fapc.biz

Fall/Winter 2014

Creating Leaders in Global

FOOD SAFETY

fapc.biz

contents

Fall/Winter 2014 Volume 9 | Issue 2

Managing Editor/Designer Mandy Gross | mandy.gross@okstate.edu Editor Laci Jones | laci.s.jones@ostatemail.okstate.edu Robert M. Kerr Food & Agricultural Products Center | Oklahoma State University 148 FAPC, Stillwater, OK 74078-6055 405-744-6071 | 405-744-6313 FAX www.fapc.biz | fapc@okstate.edu

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12 foundation focus

Creating Leaders in Global

FOOD SAFETY

The U.S. has the world’s safest food supply. Oklahoma’s food and agricultural leaders are keeping food safety a priority in food-processing facilities and supporting the education to prepare students to work in food safety and the food-processing industry.

3 director’s comments Meeting consumer demands 4 client success Sweet success 6 industry perspective I believe in rural Oklahoma 8 business & marketing Changing shopping habits challenge supermarkets The importance of training Food buiness records: What information is needed?

11 meat processing Donating meat to charities

14 oilseed processing Fats and oils: Are they good for your health?

16 food safety National Food Safety Education Month celebrates 20-year milestone 18 product development Brewing up the future 20 food processing Where’s the food?

22 quality management Unannounced Audits Are you ready?

Oklahoma State University, in compliance with Title VI and VII of the Civil Rights Act of 1964, Executive Order 11246 as amended, Title IX of the Education Amendments of 1972, Americans with Disabilities Act of 1990, and other federal laws and regulations, does not discriminate on the basis of race, color, national origin, sex, age, religion, disability, or status as a veteran in any of its policies, practices or procedures. This includes but is not limited to admissions, employment, financial aid and educational services. This publication is printed and issued by Oklahoma State University as authorized by the vice president, dean and director of the Division of Agricultural Sciences and Natural Resources and has been prepared and distributed at a cost of $2,200 for 700 copies. 1114 MG.

Meeting

director’s comments

CONSUMER DEMANDS

Earlier this year, findings of a Harris online poll of 2,200 adults were published showing consumer ranking of various product, food label and nutrition panel attributes they considered as important.

In this polling, cost of product was the most important item associated with a decision to purchase, nine times out of 10.

Nutrition label components of fat content, sugar content, total calories and sodium content ranked next in descending order of importance, affecting a decision to buy. Much lower on the importance scale was an organic claim or a nutrition label statement about allergen content.

If you stay current with consumer demands, it is likely these findings are not surprising. They continue to show the average consumer is very attentive to grocery product prices and are reasonably attentive to nutritional composition. Consumers are particularly attentive to the items they believe are most affecting their health.

If you would like to develop a plan for retail product comparisons or consumer buying preferences, contact FAPC.

It seems consumers, on average, appear to be opportunistic about organic products. There is some allegiance to organic products, and these products will be purchased when possible.

However, when the price point between organic and non-organic is too great, the decision by the average buyer for the typical family will be to purchase non-organically grown products.

Finally, the decision to buy grocery food items by most consumers is minimally affected by allergen claims on the label. It is understood that the allergen statements on the label are useful to the average consumer, but this poll demonstrates allergen statements do not account strongly for purchasing decisions.

As food processors in Oklahoma, you may have particular questions about what consumers want as they make their purchasing decisions. Possibly you may be considering a comparison of your products with your competitor’s products relative to consumer preferences. If you would like to develop a plan for retail product comparisons or consumer buying preferences, contact the Robert M. Kerr Food & Agricultural Products Center.

Scientists and technologists can assist you in developing and accomplishing a plan. If you have not completed a retail buying preference analysis of your products for some time, perhaps it is time to do so.

You might find that your products deliver unique and undiscovered characteristics or attributes that would bring added value to you.

By Roy Escoubas, director roy.escoubas@okstate.edu

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client success

Sweet

Success

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Photo/Todd Johnson

Many churches operate day care centers, preschools or even private schools as part of their outreach ministry and supplemental revenue stream to congregational giving. However, Christian Life Missionary Baptist Church in Oklahoma City took a unique approach by establishing Sweet Spirit Foods in July 2002.

This unique entrepreneurial enterprise was launched under the vision and leadership of Pastor Jayel Jacobs Jr. and the late Joyce Jacobs with one Snowie building, a mobile building with a self-contained water system, sinks, hand washing, hot water heater and other requirements of the Department of Health. The building is named for the company that designed it for serving shaved ice products.

Later, Sweet Spirit Foods would operate two mobile food trucks, four Snowie buildings, a convenience store and a car wash serving Oklahoma City, and a restaurant serving Langston, Okla., all run by church member volunteers.

The church soon focused on marketing Sweet Spirit’s barbecue sauces. Janee (Gipson) Jacobs, who married Pastor Jacobs following the passing of his first wife, began to drive that part of its mission.

The project of having Sweet Spirit barbecue sauce professionally bottled came about during the same time Janee Jacobs was diagnosed with breast cancer.

“God knew exactly what I needed,” she says. “I was going to radiation treatments every day, and I would come home and sit in front of the window with the church’s laptop. I didn’t know where to begin, but I knew the Internet would at least get me started.”

One of the first websites that Jacobs pulled up was step-by-step instruction on how to bottle barbecue sauce for sale to the public. The article discussed a low-cost way of having the sauce tested that suggested taking it to a local university.

In June 2003, Jacobs contacted Chuck Willoughby, FAPC business and marketing relations manager, to help identify a copacker and obtain nutrition facts information.

“Being an Oklahoma State University graduate, I was drawn to the campus I called home,” Jacobs says. “It was there

Photo/Mandy Gross

client success

that God connected us to Chuck Willoughby. From day one, he has been a great adviser. When we don’t know what to do or how to do it, but we want to do it right, we involve Chuck.”

Willoughby has been working with Sweet Spirit Foods for the past 11 years.

“I remember when Janee first called and noted that their sauce was really popular in their restaurant and how they wanted to sell it as a fundraiser in front of stores and even door to door,” Willoughby says. “I thought that was a very creative approach to entering the market, given the numerous brands of barbecue sauce already available in the retail market.”

FAPC has continued to work with Sweet Spirit Foods over the years, providing trade show opportunities and label review for Food and Drug Administration compliance, brainstorming marketing ideas, offering feedback for its revised website and taking new product photos.

Recently, Sweet Spirit Foods received its collegiate license granting the business the right to market OSU barbecue sauce.

“Being able to sell collegiate branded sauce will provide Sweet Spirit with additional opportunities for increased sales and market presence,” Willoughby says.

“Not only can they market OSU branded barbecue sauce to the over 60 grocery and specialty stores they currently serve, but

they will have the opportunity to market their sauces through other venues like sporting goods stores and event sales.”

Jacobs said now that they have a collegiate license and an OSU barbecue sauce, Sweet Spirit Foods is one of the Made in Oklahoma vendors selling the sauce outside of Boone Pickens Stadium before, during and after each home game.

“The Sweet Spirit family grows each game day with wonderful people from right here in Oklahoma and other states as well,” she says. “We are also grateful for the opportunity given to us by Bank SNB using Sweet Spirit as one of their promotional giveaways for their Spirit Day this past October and consider it a tremendous blessing.”

Sweet Spirit Foods has experienced many successes over the years.

“Janee’s entrepreneurial drive and the support exhibited by the church volunteers has given Sweet Spirit a great foundation in the food industry,” he says. “OSU’s brand strength will provide them even greater opportunities for growth in a competitive market.”

By Chuck Willoughby, business and marketing relations manager chuck.willoughby@okstate.edu

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industry perspective

I believe in ...

Rural Oklahoma

As I sit on the back porch of our farmhouse, I watch and welcome a late afternoon rain. The cattle are grazing the pasture with their calves, and the Canada geese just landed on the pond.

A proud feeling of my rural Oklahoma roots and my small town agricultural background warms over me.

The Oklahoma farmers and ranchers are admirable, hardworking people who have watched the afternoon showers break more than one drought. However, these down-to-earth Oklahomans recently have been faced with additional challenges.

They must master cutting-edge technology in a tough economic business climate. They must survive on razor-thin margins to improve their agricultural operations and profitability.

In spite of these challenges, Oklahoma farmers and ranchers build lasting relationships with family, communities and local businesses. They treat their land as a long-term investment and are concerned about future Oklahomans.

Agriculturists have been raised to support rural community growth and to help one another on a day-to-day basis.

As a person who has been associated with Oklahoma agriculture from a livestock production and food-processing background, I realize the need for agriculture after looking at data from the United States Department of Agriculture.

About 30 percent of Oklahomans live in rural communities, and 38 percent of the jobs in Oklahoma are located in rural areas.

From a business perspective, Oklahoma ranks fourth in the United States for the number of farms with nearly 86,000. From a crop production standpoint, Oklahoma ranks first in rye grain production, second in canola grain production, fourth in wheat and pecan production, and sixth in hay and sorghum grain production.

Furthermore, Oklahoma ranks fourth in total number of beef cows, sixth in calf-crop production, eighth in swine production, 11th in broiler production and 14th in red-meat processing production.

Oklahoma’s agricultural prosperity can be attributed to several factors, including relationships among rural towns, community lifestyles and individuals with strong family values.

Oklahoma’s prosperity can be measured by the success of rural small town America by workforce creation and personal per capita income.

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The rural Oklahoma personal per capita income during the last 10 years continues to increase at about $1,000 per year. From the standpoint of worker efficiency, rural Oklahomans are producing at an all-time high. The family farms and ranches are the most efficient unit in rural Oklahoma today.

In visiting with Lynn Gray, Oklahoma chief economist for economic research with the Oklahoma Employment Securities Commission, he says Oklahoma employment from 2000 to 2010 grew 3 percent.

Oklahoma’s three large metropolitan areas had no employment growth. The 18-micropolitan communities grew 11 percent, and other rural areas grew 6 percent in employment. Because of exports from rural communities, Oklahoma is a major player in the economy of crops and live animal production.

We must stay focused on the big picture of rural Oklahoma: agriculture, workforce development and our contribution to a global food economy.

blessings of life rural Oklahoma. I believe in the r I am mindful of the

lifestyle more than ever. We are wov

culture we can p from generation to generation. which provides a

By Tommy Kramer, Durant Industrial Authority tkramer@durant.org

industry perspective

Agriculturists have been raised

to

support rural community

growth and to help one another on a

day-to-day basis.

e we enjoy in

rural Oklahoma

ven from a fabric,

proudly pass on

Photos/Todd Johnson

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business & marketing

Grocery shoppers have changed and continue to evolve when making a trip to their local supermarket. Five or six years ago, the local grocery store was a “onestop shop.” Now, there are so many more choices. The retail industry has seen more growth and expansion in competition from places like Target, CVS, Walgreens, Dollar General and Family Dollar that have expanded their food category and selection for their shoppers.

Traditional grocery stores nationwide have lost up to 15 percent of their market share in the past 10 years, said Phil Lempert, a food industry consultant

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at Supermarket Guru. The list of options continue to increase for shoppers, who have no problem visiting multiple stores to stretch their budget dollar. This list of options may influence where they shop for particular items on their list.

Consumers are constantly comparing prices and selection from retailers. If a store stops being competitive, offering selection or consistent quality, shoppers will quickly move on to a competitor’s store. Although shoppers’ habits have been shifting for a decade, the recent recession has accelerated the change and attitude of consumers. Consumers are value-

conscious shoppers now, and traditional grocery stores are finding it difficult to be competitive on price alone.

Another factor affecting the traditional grocery store is the growth and competition from stores like Whole Foods, Sprouts Farmers Markets, Natural Grocers, Trader Joe’s, and other gourmet and specialty stores.

These stores offer a variety of products that are natural, organic, gluten free, sugar free and attract shoppers who specifically shop at these stores for the unique selection. A growing number of shoppers are considering the benefits of eating healthier foods and have made changes in the variety of foods they purchase. Price is not the main consideration in these decisions.

Many consumers visit their local Farmers Market each week to purchase in-season fruits and vegetables. These are contributing factors that affect sales in local supermarkets. Retailers have started to provide natural and organic products in their produce sections, but the “homegrown” and local connections still take sales from the local grocery stores.

Another consideration is the increase of Millennials, individuals born in the early 1980s to early 2000s. Also known as Generation Y and ranging from ages 18-34, this group is known to look for a more modern experience when shopping for their food purchases. They are tech savvy and use social media and apps for almost everything from restaurants to doctors.

They shop at a larger variety of stores for their purchases.

According to the U.S. Census Bureau, Millennials account for 25 percent of the current population, 80 million consumers and represent more than $200 billion in spending. The Millennials are the current and future customers, and local grocery stores are now providing products that will draw this group to their stores.

The local supermarkets have more competition than ever before and must stay relevant and innovative to retain their market share.

By Jim Brooks, business and marketing services manager jim.brooks@okstate.edu

“

business & marketing

“

of

The

IMPORTANCE TRAINING

What’s worse than training your workers and losing them?

Not training them and keeping them.” —

Zig Ziglar

Ongoing training and education is a necessary ingredient for successful companies to stay current. Companies are typically shown to have a more flexible, creative, adaptable and durable environment in terms of growth and survival when they encourage ongoing training for employees.

Training courses are not only for new employees but also for every employee to stay current in their education. Employees often are busy with day-to-day tasks and forget they must constantly look for self-improvement to be more competitive.

At the 2014 Safe Quality Foods International Conference in October, Holly Mockus, product manager at Alchemy Systems, emphasized the importance of training and how it goes hand-inhand with accountability and success of food-processing companies in today’s world.

Employees who participate in educational trainings are shown to become more effective in the workplace. Trainings help bridge the gap between what the employee knows and what the job demands. Employees also have increased job satisfaction and morale and become more innovative and motivated in their job.

According to “Learning to Succeed in Business with Information Technology” by Tim Lane, Motorola calculated that every dollar spent on training yields an approximate 30 percent gain in productivity within a three-year period. Motorola also used training to reduce costs by more than $3 billion and increase profits by 47 percent.

Training courses keep employees interested in their employer and increase their job skills and knowledge base. When an employee believes the company considers their personal growth important, the employee tends to stay longer. A higher retention rate ultimately reflects and impacts the overall company brand and reputation.

Companies that fail to train their employees are more than three times likely to lose them, according to a study by Louis Harris & Associates for Interim Services Inc. FAPC offers a variety of workshops to help food businesses with further training throughout the year. The award-winning Basic Training for Entrepreneurs is held multiple times during the year. Basic Training is geared towards anyone who wants to start a food business from the ground up and helps build a solid foundation.

Other trainings at FAPC cover more specific topics including food safety and quality, food allergens, food labeling (also available online), food defense, acidified and low-acidified canned food processing, cereal science, marketing and social media. Class participants can also learn about judging barbecue meats, pork and beef production, or come to the annual research symposium.

FAPC also provides training opportunities to food-processing companies interested in the Global Food Safety Initiative and the schemes that fall under GFSI. These include Basic Hazard Analysis Critical Control Points, Internal Auditing, Safe Quality Foods and Quality Management Roundtable.

Ongoing education or brand building never ends. The investment made in training employees and the benefits training brings far outweighs the cost and is imperative to be profitable in today’s environment.

For a complete list of trainings and dates for 2015, visit www. fapc.biz.

By Andrea Graves, business planning and marketing specialist andrea.graves@okstate.edu

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business & marketing

s d r o c e R s s e Food Busin

? d e d e e N Is n io t What Informa Food type? ?

Specific variety Lot number?

Date received?

Packaging?

Quantity?

Transporter?

Other?

In many ways, a food business is similar to any other business in keeping good records. A food business owner must maintain certain critical records that must be available for review and evaluation by Food and Drug Administration investigators.

These records include the immediate previous source of ingredients received.

Each one of these must include contact information, specifically the name of the company, telephone number, fax number and email address. Ingredient information, such as the type of food, brand name and specific variety, also must be included.

The documentation must list the ingredient by type. For example, listing “peppers” would be insufficient. It needs to be listed as “Billy Joes’ Jalapeno Peppers.” In addition, a manufacturer must include the date item is received, quantity and type of

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packaging, and who delivered the product and their contact information.

The business also must maintain records identifying the immediate recipients of all foods released. The information must include the name of the firm, address, telephone and fax numbers, and email address. The type of food, such as brand name and specific variety, date released, quantity and type of packaging need to be

included, as well as the identity of the immediate transporter to the recipients, name of the firm, address, telephone and fax numbers, and email address if available.

FDA states that persons who manufacture, process or pack food must include a lot or code number or other identifier if the information exits. The records also must include information that identifies the specific source of each ingredient that was used in the production of the finished product. This means each final product must be able to be traced back to each ingredient and its source.

Although FDA specifies the information that must be maintained, the way in which the information is kept is not. Therefore, the information can be kept in either electronic or paper form, as long as all the information is included.

Food manufactures may be thinking, “We have these records, but how long do we need to keep them?” FDA specifies records must be retained for a time period that depends on the perishability of the food.

The ingredient, ingredient source, final product destination, transporter and retention of records are just a portion of the important documents that must be maintained by a food manufacture. These help insure the traceability of the products from the farm to the consumer.

Source: Fact Sheet on Establishment and Maintenance of Records under the Bioterrorism Preparedness and Response Act of 2002.

Revised November 2005. www.fda.gov

By Erin Johnson, business and marketing client coordinator erin.joy.early@okstate.edu

Significant risk of spoilage, loss of value, or loss of palatability

Record Retention

Within 60 days

6 months

Occurring no sooner than 6 months

2 years

Minimum of 60 days but within 6 months

Animal Food (Pet food)

1 year

1 year

meat processing

Donating MEAT to CHARITIES According to the Oklahoma Regional Food Bank in Oklahoma City, about 17 percent of Oklahomans have serious thoughts each day about where their next meal will come from or how they will obtain it.

Oklahoma ranks among the top five states in the nation in the number of people who are hungry.

The Community Food Bank of Eastern Oklahoma, located in Tulsa, Okla., affirms these statistics. These two organizations, alongside churches, clubs and other similar organizations devote serious efforts to feeding folks who are in need of food.

Extending help to those in need is always defendable, but often the urge to help is quickly squelched when it becomes too much work.

It would be a safe guess that non-perishable items are the central food category of all direct food donations. However, if someone were to survey food bank and food-pantry personnel, they would quickly

learn that animal protein products are not at the top of their inventory volume.

The economic value of meat products, the inherent perishability and the general regulatory landscape of meat processing all contribute to reduced inventories within food-bank distribution channels.

The nutritional value of meat products are widely demonstrated in a broad range of literature, and it is easy to understand why food bank operators and recipients both express concern about the lack of fresh meat items.

Meat and poultry products that are safe, wholesome and capable of use as human food may be donated to non-profit organizations under appropriate circumstances. Certain misbranded product may be donated to non-profit organizations.

Examples of wholesome, misbranded products that may be donated include those labeled with the incorrect net weight or that do not meet purchase specifications.

Lack of fresh meat items are a concern for food banks.

Food companies can donate meat products that are safe and wholesome under appropriate circumstances.

Photo/Mandy Gross

Adulterated product may not be donated to non-profit organizations except when the product is economically adulterated. An establishment or firm cannot dispose of products adulterated for reasons other than economic adulteration by donating it to non-profit organizations.

The United States Department of Agriculture-Food Safety Inspection Service allows in-commerce firms to donate product that is misbranded or economically adulterated without temporary label approval from the labeling and program delivery staff. However, USDA-FSIS will not allow misbranded product that contains unlabeled ingredients of public health concern to be donated without temporary label approval. Unlabeled ingredients are required to be on the ingredients statement because these unlabeled ingredients are associated with adverse reactions such as food allergies and intolerance.

For products from official establishments to be eligible to be donated, the bill of lading needs to include the quantity of the donated product, a description of the donated product, the reason the product is diverted for donation and a statement that the product is “Not for Sale.� If the bill of lading does not contain all of this information, the product is not eligible to move in commerce and is not eligible to be donated.

Charitable organizations are always willing to receive wholesome, nutritious meat products. Meat-processing companies or establishments, which are in a position to contribute to these efforts, can help make the process easier and smoother, by understanding the regulatory obligations for product donations.

By Jake Nelson, meat processing specialist/facilities manager jacob.nelson@okstate.edu

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foundation focus

Creating Leaders in Global

FOOD SAFETY The U.S. has the world’s safest food supply. Oklahoma’s food and agricultural leaders are keeping food safety a priority in food-processing facilities and supporting the education to prepare students to work in food safety and the food-processing industry.

FAPC’s advisory board recognized the need to educate students in food safety and provided more than $1 million as a lead gift toward a fundraising goal of $3.4 million to create a faculty position focused on food safety at OSU. “We are so grateful that FAPC’s Industry Advisory Committee is embracing this opportunity to lead this fundraising effort,” says Chuck Willoughby, FAPC manager of business and marketing relations. “One hundred percent of the

advisory board has committed to support this financial campaign.”

The Plan

As a result of the gift, a curriculum proposal for the food-safety option is in the approval process and the College of Agricultural Sciences and Natural Resources is adding a food-safety faculty position in the Department of Animal Science.

“The potential for this academic program is exciting,” says Thomas G. Coon, vice president, dean and director for OSU’s Division of Agricultural Sciences and Natural Resources. “There has been very good leadership from the academic department in responding to this opportunity.”

John Griffin, president and CEO of Griffin Foods in Muskogee, Okla., and

spokesman for FAPC’s advisory board, says the committee has been discussing the need for a food-safety program for the past four years.

“It’s great to see the work of the advisory board on developing a food-safety program at OSU come to fruition,” Griffin says. “Once the food-safety option is approved and implemented, OSU will be among the first to offer an undergraduate food-safety option.”

The goal of the proposed academic program is to prepare students for foodsafety jobs for which they will be well trained to work in the food-manufacturing industry after graduation.

“Food manufacturers can invest their money to hire a qualified food-safety specialist from OSU instead of investing their

The Leadership: FAPC INDUSTRY ADVISORY COMMITTEE The Oklahoma Legislature established the Industry Advisory Committee to serve as an advisory board for FAPC. Members of the committee are Oklahoma food industry leaders, appointed by the highest positions of the Oklahoma state government and the vice president and dean of OSU’s Division of Agricultural Sciences and Natural Resources.

“The Industry Advisory Committee offers counsel, makes recommendations and takes leadership action to ensure FAPC makes sound short- and long-term plans to accomplish its mission and objectives,” says Roy Escoubas, FAPC director. “I am extremely appreciative of the advisory board’s dedication and commitment to the food-safety campaign.”

Members of the advisory board who are leading the foodsafety campaign effort are:

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Nancy Addington, Associated Wholesale Grocers, Oklahoma City Luis Bogran, Curwood, a Bemis Co., Pauls Valley, Okla.

Ed Clements, Clements Food Co., Oklahoma City Gary Crane, Ralph’s Packing Co., Perkins, Okla.

Scott Dvorak, Dvorak Farms, Perry, Okla.

John Griffin, Griffin Foods, Muskogee, Okla.

David Howard, Unitherm Food Systems, Bristow, Okla.

Virgil Jurgensmeyer, J-M Farms, Miami, Okla.

Rodger Kerr, Southwest Technology Center, Altus, Okla.

Tommy Kramer, Durant Industrial Authority, Durant, Okla.

John Patrick Lopez, Lopez Foods, Oklahoma City David McLaughlin, AdvancePierre Foods, Enid, Okla.

Allen Mills, Reasors Inc., Tahlequah, Okla.

Paul Schatte, Head Country Food Inc., Ponca City, Okla.

John Williams, Chef’s Requested Foods, Oklahoma City

Photo/Mandy Gross

Loretta Lawson, quality control technician for Griffin Foods, checks the seals on mustard bottles directly off the production line in Muskogee, Okla.

time and money to train someone in food safety,” Griffin says.

There is a huge demand for individuals who are specialized in food safety.

“The proposed new food-safety option will allow students to get the education they need to qualify for food-safety positions that food manufacturers desperately need,” Griffin says. “Like the movie ‘Field of Dreams,’ when we build it, the students will come, not just in Oklahoma, but nationally and internationally.”

The Impact

Food safety is not just the responsibility of the processor.

“It starts with the farmer through to the manufacturer, then to the distributor who delivers the product to the stores,” Griffin says. “All aspects of the supply chain are monitored and inspected for the safety of the consumer.”

With a growing demand for safe quality food products, the need for food industry companies to engage in food-safety programs is more important than ever.

With the support of the advisory board, FAPC implemented a Global Food Safety Initiative program to strive for continuous improvement of food-safety management systems that ensure safe food and consumer confidence.

The FAPC-GFSI program focuses on food-industry assistance in the areas of training, auditing, pre-third-party audit preparations, education, and in-plant tech-

nical assistance for food safety and quality programs.

The center’s quality management specialist, Jason Young, has filled the GFSI specialist role. One of the major ways Young assists food companies is by conducting internal audits.

“Globalization of the food industry has significantly affected almost every Oklahoma food processor directly and indirectly with mandated food-safety and security regulations and policies that cut across all food-processing sectors,” Willoughby says. “The FAPC-GFSI program provides services to meet the food-safety and security needs of Oklahoma’s food industry.”

Once a faculty member is hired, that person is expected to be instrumental in global food safety.

The Future

“This is a win-win,” Willoughby says.

“Graduating students with food-safety credentials not only provides industry with a prepared workforce, but it also provides opportunities for the graduates.”

Customer requirements and the new Food Safety Modernization Act are driving the need for improved, tighter food-safety systems. The demand for qualified individuals is great and will continue to grow.

“Oklahoma State University will set the standard that many universities will realize the need to follow,” Griffin says. “We truly appreciate President Burns Hargis

and the Division of Agricultural Sciences and Natural Resources for supporting the vision for this new food-safety program and option.”

The immediate focus is establishing the food-safety option under the current food-science degree and hiring the right faculty member to manage and grow the program.

It is expected that the future program will grow to provide scholarships, internships, undergraduate research opportunities, career development and a full complement of activities to enhance each student’s learning experience.

The program will serve beyond food manufacturing and will include all sectors of the food industry from production agriculture to wholesale and retail distribution channels. Ingredient, packaging and equipment suppliers also are affected by food-safety issues, as are regulatory entities.

This program will encompass all foodsafety needs, domestically and globally, once fully implemented.

“What is the future; what is our vision?” Griffin asks. “It’s constantly evolving as OSU’s commitment moves forward in opportunities to be world-renowned in food safety.”

By Mandy Gross, communications services manager mandy.gross@okstate.edu

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oilseed processing

FATS OILS Are they good for your health? and

If you are confused about the effect of diets, particularly dietary fats and oils, on your health because of many popular media articles, you are not alone. The scientific literature allows for a better understanding of these topics.

The relationship between fat and oil consumption and health is evaluated based on the research findings and the fundamental scientific knowledge generated over the years through the epidemiological, animal and human clinical studies.

This is not to say the science has simple and straightforward answers to the questions in the field today.

as frying. The melting point of the oil is also increased making the hydrogenated oils suitable for baking, confectionary and other food uses.

Since 2006, the U.S. Food and Drug Administration labeling rule requires that nutrition fact panels show trans fat content of the foods. In 2013, the Food and Drug Administration issued a preliminary determination that partially hydrogenated oils are not generally recognized as safe for use in foods. This ruling effectively means that partially hydrogenated oils have to be approved as a food additive before they can be used in foods. The approval of partially

Choosing the right type of oil or fat is the key to the nutritional value, texture, flavor and palatability of food products.

Fats and oils are composed of a very complex mixture of saturated and unsaturated fatty acids and other minor components. Double bonds or unsaturation on the fatty acids can exist in two forms: cis or trans.

Vegetable oils naturally contain unsaturated fatty acids in the cis form. Trans fats are generated during the industrial hydrogenation process that has been used since the 1950s to make margarines and shortenings. Hydrogenation reduces the number of double bonds on fatty acids increasing oil oxidative stability needed for high temperature applications such

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hydrogenated oils is a very lengthy and expensive process.

The U.S. commodity vegetable oils are low in saturated fats and high in healthy polyunsaturated and monounsaturated fatty acids. However, the fatty acids that make oils healthy also limit their use in many food applications. Food processors have replaced some of the partially hydrogenated oils in products with saturated fats such as fully hydrogenated oils, animal fats, palm or palm kernel oil fractions, and coconut oil. Since these oils are not produced in the country, palm oil imports have grown 670 percent, since 2002.

Obesity, heart disease and diabetes are the most prevalent health problems facing the nation. The cause of these health issues is still controversial. Fats of all kinds and saturated fats were identified as etiological agents in chronic disease. Consequently, butterfat and fat from animal tissues have been replaced with vegetable oil-derived margarines since the 1950s. During the period when the animal fat usage decreased, cardiovascular disease and obesity rates increased. Some scientists claim the link between consumption of saturated fat and serum cholesterol level in the blood is very weak. Other factors such as physical activity and body weight override the adverse relationship.

There is a renewed interest in low carbohydrate-high fat-moderate protein diets today. With the relatively new claims of the adverse effects of trans fats, saturated fats, including animal fats, have made resurgence in the popular media, on the Internet and in low-carbohydrate diet books.

In 2011, Norway ran out of butter just before Christmas due to a high fat, low-carbohydrate diet craze. There are also reports that Christmas puddings and chicken liver pate made with animal fats and edible animal tallow are appearing on Australian supermarket shelves since 2012.

In the U.S., coconut oil is being promoted as “healthy� on the Internet and popular media although most of the claims have not been scientifically substantiated. Coconut

oilseed processing

oil is highly saturated, containing more than 85 percent saturated fatty acids.

Not all saturated fats are metabolized the same way, though. For example, medium-chain fatty acids containing six to 12 carbon atoms are quickly burned for energy and not deposited in the adipose tissue. Medium-chain fatty acids are not abundant in foods, but they are found in butterfat and coconut oil. About 60 percent of the fatty acids in coconut oil have 12 carbons or shorter. Corn, soybeans and canola have almost no medium-chain fatty acids but contain long-chain fatty acids containing 16 or higher carbons.

Several studies indicate that mediumchain fatty acids may boost metabolism and satiety when they replace long-chain fatty acids in the diet. Coconut oil is rich in lauric acid, containing 12 carbon atoms, which is also present in breast milk. Infants convert lauric acid to monolaurin, which protects them from infections. However, if coconut oil is substituted for soy, corn or canola oil, both low-density lipoprotein, a bad cholesterol, and high-density lipoprotein, a good cholesterol, levels may rise.

The same result is observed when vegetable oils are substituted with most of the saturated fats. Some researchers argue that lauric acid does not increase bad cholesterol, but other saturated fats present in coconut oil, myristic acid and palmitic acids, may

raise LDL. A similar argument could be made for butterfat, which contains about 60 percent saturated fat. About one-third are short- or medium-chain fatty acids.

Several studies have shown that stearic acid, a saturated fat containing 18 carbon atoms, neither raises nor lowers total and LDL-cholesterol. Palmitic and mysristic acids raise LDL-cholesterol and blood triacylglycerides levels. Oilseed breeders have been developing high-stearic acid-producing oilseeds, which can be used in margarine or shortening formulations without hydrogenation. High-stearic acid sunflower oil developed in Argentina is already commercially available on a limited basis. It is expected that high-stearic acid soybean oil varieties will be commercially available by 2015.

Unfortunately, there are no easy general rules of thumb to explain the effect of diet on health. The confusing part when changing a diet is what to substitute and what to substitute with. Whether a specific type of oil or fat is “good” or “bad” for you depends on your genetics, current diet, health, food and energy intake and your lifestyle. The “good” and the “bad” diet contro-

versy is not going to be resolved anytime soon. For now, maintaining an appropriate body weight and staying on a balanced diet and regular physical activity regime are the best options for maintaining good health and preventing diseases.

By Nurhan Dunford, oil/oilseed specialist nurhan.dunford@okstate.edu

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food safety

oo d F l a n o i t Na

Safety Education Month

y e 0 a r 2 m s i e l t estone a r b e l ec This year marks the 20-year anniversary of National Food Safety Education Month, which is celebrated in September. Created in 1994, National Food Safety Education Month heightens the awareness about the importance of food safety education.

FAPC would like to take this opportunity to remind you of the various sources for food-safety information.

1.

FoodSafety.gov www.foodsafety.gov

This website is a generic food-safety portal from the U.S. government. One of the benefits of the website is the U.S. food recalls are listed chronologically, and it is irrespective of any particular regulatory agency. Viewers do not have to visit the United States Department of Agriculture-Food Safety Inspection Service site for meat and poultry recalls and then the Food and Drug Administration website for non-meat recalls. Aside from food recalls, other interesting sections are food poisoning and news and features for educators.

2.

Food & Drug Administration www.fda.gov/Food/default.htm

The FDA website contains a variety of information, including food safety. FDA is the presiding regulatory agent over the safety of all things consumed or applied topically. In 2011, FDA announced a proposed Food Safety Modernization Act that includes seven proposed rules: 1) Standards for the Growing, Harvesting, Packing and Holding of Produce for Human Consumption 2) Preventive Controls for Human Food 3) Foreign Supplier Verification Programs for Importers of Food for Humans and Animals

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4) Establish Current Good Manufacturing Practice and Hazard Analysis and Risk-Based Preventive Controls for Food for Animals 5) Designation of High Risk Foods 6) Focused Mitigation Strategies to Protect Food Against Intentional Adulteration 7) Sanitary Transportation of Human and Animal Food The final versions of these FSMA rules will be launched in 2015 at the earliest.

In addition, FDA recently announced the 2014 FDA Food Safety Challenge. This was born out of the 2010 America COMPETES Reauthorization Act. Grant agencies can establish prize competitions to spur innovation to solve tough problems. The current competition established by FDA is a Salmonella-detection competition to address the detection of Salmonella in minimally processed produce and is open to academics, innovators, entrepreneurs, scientists and others. Up to five finalists will receive $20,000 each for furthering their proposals to be presented in person with a final pool of $500,000 in prize money.

3.

U.S. Department of Agriculture www.usda.gov/wps/portal/usda/ usdahome?navid=food-safety Food Safety Inspection Service www.fsis.usda.gov/wps/portal/fsis/home

The USDA website has a generic food-safety emphasis covering various food-safety portals and general news items about food safety. The FSIS website covers food safety specific to its regulatory oversight including meat and poultry products. Current main news item of interest is Modernization of Poultry Slaughter Inspection. It also lists recalls specific to meat and poultry products. The science and data section has details in methodology of testing, including FSIS’s Microbiology Laboratory Guidebook for testing meat and poultry products.

food safety

4.

Centers for Disease Control and Prevention www.cdc.gov/

The Centers for Disease Control and Prevention is concerned with all things that are nationally and internationally harmful to humans. Currently, it is occupied with issues related to Ebola Epidemic 2014 and with various flu vaccinations to prepare for flu season. The CDC website also has a food-safety section, where it covers articles such as tips for safe grilling and detailed studies of foodborne outbreaks across the country. This includes highlights and trends in food safety for 2013, as compiled by data acquired through the national FoodNet program.

Muriana’s Comments

Although the U.S. has the “safest food in the world,� not all foods that consumers bring home are sterile and safe.

Consumers must recognize, appreciate and respond appropriately to sufficient home food-safety awareness. It is well known the self-inflicted food-safety illnesses are under-reported because they are few in number, often undetected and not understood. Individuals do not seek medical attention and therefore are oblivious to what may have caused their illness in comparison to large outbreaks that draw attention and get investigated.

Although food processors are continuously under pressure to provide safe foods, it must be recognized that all foods are not sterile and that mishandling them at home can often promote foodborne illness. Food-safety education is an important part of the process of reducing foodborne illness wherever and whenever foods are consumed.

By Peter Muriana, food microbiologist peter.muriana@okstate.edu

17

product development

g n i e h t w up re

B

r u t u F

The popularity of beer Beer is the most popular alcoholic beverage in the world.

To many beer aficionados, this fact may seem like saying fire is hot or water is wet. In other words, it is like the law of gravity, a fundamental force of the universe that pulls everything towards it. However, there are historical factors that helped make beer as popular as it is.

Beer was relatively easy and affordable to manufacture, with starting materials being readily accessible. Beer was also safe, compared to the untreated water that was available for drinking.

However, beer consumption in the United States may have taken a hit recently. During the first half of 2014, consumers in the United States seemed to have lost their thirst for beer.

According to the research firm Mintel, 22 percent of Americans reported they drank wine rather than domestic beer. An

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additional 18 percent of Americans reported they drank liquor rather than domestic beer.

The Technomic research firm also reported a per capita decline in beer consumption. In addition to competition from wine and liquor, consumers also reported they were drinking less domestic beer because they thought it had too many calories and was unhealthy.

However, according to a Gallup poll conducted in July 2014, beer had risen to the top with 41 percent of respondents expressing a preference for beer, 31 percent for wine and 23 percent for liquor. Imported and craft beer, along with flavored malt beverages and cider, appear to have played a large role in the resurgence.

Mintel predicted craft beer, regionally made in smaller batches with distinct flavor, would reach $20 billion in sales in

product development

2014. Perceptions of increased quality, along with more varieties and seasonal offerings, seem to have given craft suds the advantage over their bigger domestic beer brethren, particularly among younger consumers. Small brewers, by their very nature, are capable of quickly manufacturing limited runs of product that has unusual or unique flavors. These flavors may or may not appeal to everyone.

An example of the unique style of craft brewers is Stone Brewing Company, located in Escondido, Calif. The company produces Stone Saison, ale infused with herbs including lavender and lemon thyme, along with lemon zest. The ale is only available during the spring and summer months.

However, larger brewers are producing their own premium products to compete with their smaller rivals. The large brewers have started offering some of their more creative flavors to their U.S. consumers that were once only available overseas.

Heineken has started offering Desperados, a tequila-flavored beer, in Georgia and Florida. Heineken is expected to distribute the beer nationally in 2015.

The draft beer surge has even crossed over into the candy arena with the Jelly Belly Candy Co. producing a “Draft Beer Jelly Belly� jellybean. Even though the company says the candy has crisp flavor that packs a punch, the gold-colored jellybean is alcohol-free.

During the big game or barbecue, beer connoisseurs will rest assured knowing their thirst will not go unabated. Brewers, large and small, will continue to provide the classic suds from the past they know and love, while offering new, innovative and unique products that challenge their taste buds and notions of what beer is supposed to be.

re

By Darren Scott, sensory specialist darren.scott@okstate.edu

19

food processing

Where’s the food?

O

ne thing I remember from 1984 is the Wendy’s “Where’s the beef?” TV commercials. They were humorous ads starring Clara Peller. She was a little old lady, who referred to competitor’s hamburgers by posing the question, “Where’s the beef?” I can envision her today in various scenarios asking, “Where’s the food?”

The recent commercial with a different little old lady saying, “That does not look like a Buick” could be compared to the 1984 commercials. If the clock was turned back to 1984 and the cars removed, the statement could be, “That does not look like food.” The where and what of food continues to be questioned.

All of us have visited a grocery store in search of food. What we find is aisles of edibles and drinkables including snacks, cookies, candy, condiments and drinks of every type imaginable, as well as non-food items. Most of the products listed meet the definition for food in some way, especially during tailgate season.

Dictionary.com defines food as “any nourishing substance that is eaten, drunk, or otherwise taken into the body to sustain

20

life, provide energy, promote growth, etc.” Choosing what food to purchase also involves mental stimulus, when considering the many choices available. Finding specific foods can still be a hunting and gathering experience but is more likely based on marketing and convenience.

When entrepreneurs visit FAPC and attend its Basic Training Workshop, it is because they want to learn what is required to process or sell a specific food product they have interest or expertise in. Many entrepreneurs do not realize a product is only one piece of the puzzle.

There are sales niches that go beyond traditional food retail and Internet outlets where their product can be sold.

The short answer to “Where’s the food?” is that food appears to be every-

food processing

where in some shape or form and everyone wants to sell it.

Food sold in drug and similar stores date back to when food was consumed on site at the soda or lunch counter. Packaged foods are now part of the business model for most drug stores and general merchandise stores. Fresh and prepared foods are now featured at some locations.

The Walgreens Food Oasis Program is an example of an objective to expand availability of healthier foods in food desert locations. C-stores sell all foods noted above, ranging from doughnut holes to sushi. Farmers markets bring together fresh and local.

Packaged food is now a common sight in stores selling office supplies, farm

and home supplies, building materials, clothing as well as other retailers. It started with candy, gum, drinks and snacks by the checkout and has evolved into a food aisle or section at many locations. Food is found “outside the box” and within the “big box” stores.

Some “don’t pay department store price” stores have food sections featuring specialty foods. Their buyers appear to search out and stock unique food products seldom found in other stores. Small and regional companies make many of their products.

While traveling in South Dakota several weeks ago, I noted a newspaper insert from a local building and home supply store. On the front page was a “special buy” for bratwurst alongside gas grills.

The bratwurst was a well-known brand in the area, but no limit was specified for grills. This was great marketing to draw customers close to where outdoor cooking equipment is displayed.

Technology is expanding options to find food through e-commerce. This includes direct sales by the processer, retailer, Amazon, entrepreneurs and food hubs.

The Oklahoma Food Co-op is an example of a food hub. The customer places an order online, the vendors harvest or process products based on total orders and deliver to a central location or hub.

Individual orders are consolidated and delivered to a specific location each month for pick up. According to its website, the co-op expected to have about 5,000 products grown or made in Oklahoma available in September 2014.

Food trucks have come a long way from catering trucks that visited factories at lunchtime. Initially, they concentrated on value and quick service. A few years ago, I enjoyed an excellent tamale from the back of a pickup truck. I was getting my car serviced in Los Angeles and the mechanic said, “If you want to try the ‘world’s best’ tamale, you better get out front before the truck leaves.” Recently, I have experienced other great products prepared on board food trucks. A difference is few try to operate “under the radar” of applicable regulatory agencies.

As noted, food is available from many outlets. However, it is hard to explain what food should look like. Food usually does not look as good as pictures on a box or as in photos directed by a food stylist. It looks like what a particular culture expects it to look like or what one is familiar with.

When I first saw margarine, I thought, “This looks like lard.” At the time, margarine in Minnesota did not have yellow coloring. To get around this, margarine was packed in a plastic pouch with a color capsule. To add color, the capsule was broken and the pouch was kneaded to spread the coloring. The other option was to take a trip to Iowa to purchase yellow margarine. Our neighbor was a “margarine runner,” who made periodic trips to Iowa to supply local demand.

The picture of food becomes more confusing as various food movements push for “less processed, healthier, less bad and more good, sustainable and real” foods.

Companies often develop and promote products to fit these standards.

I consider “bad foods” to refer to “off condition foods.” I have experienced eating all the Halloween candy in one sitting and consider this bad practice and not bad food.

Good can mean the product tastes good, is good for you or is a good value.

When the man in the fiber gummy commercial says, “These are good,” I am sure he does not mean they are good enough to be served as a main course.

In his book “Food Rules, An Eaters Manual,” Michael Pollan makes some good points about food. His last rule: “Break the rules once in a while. Obsessing over food rules is bad for happiness and probably for your health too. Our experience over the past few decades suggests that dieting and worrying too much about nutrition has made us no healthier or slimmer; cultivating a relaxed attitude toward food is important.”

With the variety and sources of food available, it can become an adventure — enjoy.

By David Moe, food process consultant david.moe@okstate.edu

21

quality management

UNANNOUNCED ? y d a e r u AUDITSAre yo The Safe Quality Food Institute initiated its unannounced audit protocol for the Global Food Safety Initiative benchmarked SQF scheme on July 3, 2014.

SQF Code 7.2 states, “Within three (3) certification cycles the certification body shall conduct one (1) unannounced recertification audit of the supplier.”

One out of every three audits will be unannounced to the supplier. If the supplier refuses entry to the auditor at the start of an unannounced audit, then immediate suspension will occur.

SQF is the first GFSI scheme to require unannounced audits. British Retail Consortium, another GFSI-benchmarked scheme, has two options for unannounced audits that suppliers can request. The BRC unannounced audit is not mandatory at this time.

BRC Global Standard for Food Safety Issue 6 states, “The unannounced scheme is voluntary and the decision to participate in the scheme rests with the certificated company.”

BRC does recognize there are some customers requesting their suppliers to incorporate the unannounced audit program. It will not be long before BRC and other GFSI-benchmark schemes follow SQF. A letter dated Aug. 20, 2014, by Robert L. Garfield, senior vice president at SQFI,

22

and Frank Yiannas, vice president of food safety at Walmart, says, “We would like to ask all GFSI-benchmarked scheme owners to consider offering an unannounced option within your scheme by June 2015.”

Garfield states in his letter, “SQFI developed its unannounced audit protocol to prepare our clients for the future of third-party accredited assessments, which are in line with food-safety management expectations of industry stakeholders and consumers.”

Peanut Corporation of America

The recent decision to convict the owner of Peanut Corporation of America, Stewart Parnell, and two of his employees creates compelling evidence as to why customers are demanding an audit system with more transparency. The PCA owner and employees were convicted in connection with a foodborne outbreak that sickened hundreds and killed at least eight people.

According to an article published in The New York Times on Feb. 5, 2009, by Andrew Martin titled “Peanut Plant Says Audits Declared it in Top Shape,” “Each audit, conducted by AIB International, gave the Blakely plant a ‘superior’ rating.”

The audits at the PCA Blakely plant were announced audits. There is a perception by some consumer groups, govern-

ment agencies and customers that the announced audit does not mean anything, since the supplier can be spotless and records up-to-date the day of the audit. What does the facility and records look like on a regular day?

Announced audits

The food supplier knows days if not months ahead when the audit will occur.

It is human nature to procrastinate. What does it say about our food-safety system or food safety when we come in at 2 a.m. to get ready for the announced audit?

Preparing for a food-safety system audit is daunting and preparing for it the weeks and days prior to the audit is even more daunting. When should we prepare for the food-safety system audit?

We should not have to “prepare” for a food-safety system audit. Sanitation is not something extra we have to do, but it is part of the process. The implementation of a food-safety system should also just be part of the process.

Develop a culture of being ‘Audit Ready’ all the time

The unannounced audit is a better reflection of a company’s food-safety culture.

In the fapc.biz Fall/Winter 2011 magazine article about food-safety culture, I state, “Companies committed to a food-

quality management

FAPC’s Jason Young (middle) sits down with Blair Switzer (left) and Dale Beerwinkle (right) of Triple S Farms in Hydro, Okla., to discuss meeting Global Food Safety Initiative standards.

Photo/Mandy Gross

Unannounced Audit Scheme

safety culture have incorporated foodsafety priorities in their mission statement, business objectives, and goals for foodsafety continuous improvement. Management leads by example, implementing policies, procedures and record keeping at all levels of employment.”

In “Audits and Inspections are Never Enough: A Critique to Enhance Food Safety,” the authors state, “More effective audit systems incorporate unannounced visits along with supplemental information into their framework and require extensive documentation of internal audits, regulatory compliance, laboratory results and raw product certifications. Audits and inspections remain point-in-time assessments that represent a small fraction of foodproduction time and volume. If conducted properly and the results acted upon, audits can reveal strengths and weaknesses in a

food-safety program, but cannot guarantee future performance.”

The food-safety system needs to continually improve. Moving away from being audit ready during a small window of time to being audit ready all the time will demonstrate confidence in our food-safety system. Customers will be provided with the assurance that systems and procedures are in place every day.

GFSI continuously seeks ways to improve the food-safety system

The implementation of a comprehensive food safety system as defined by GFSI integrates risk assessments, policies, procedures, training and record keeping. The mission of GFSI is to “provide continuous improvement in food-safety management systems to ensure confidence in the delivery of safe food to consumers.”

British Retail Consortium states unannounced audit scheme provides companies an opportunity to: • Demonstrate their confidence in their systems and procedures to the extent they are willing to subject these to unannounced scrutiny.

• Provide their customers with an independent unannounced review of systems and procedures that demonstrates they are maintaining their systems in good order.

• Provide their customers with an opportunity to review the risk rating of suppliers and view suppliers in the scheme favorably depending on performance, and adjust the frequency of customer audit and other additional control procedures applied by the customer.

By Jason Young, quality management and GFSI specialist jason.young@okstate.edu

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Oklahoma State University Robert M. Kerr Food & Agricultural Products Center 148 FAPC Stillwater, OK 74078-6055

NONPROFIT ORGANIZATION U.S. POSTAGE PAID STILLWATER, OK PERMIT NO. 191

Adding Value to OKLAHOMA Division of Agricultural Sciences and Natural Resources Oklahoma State University 148 FAPC, Stillwater, OK 74078-6055 Phone 405.744.6071 www.fapc.biz