Symposium of Food Innovation & Development … of Food Innovation & Development INNOVA 2007 LATU, Montevideo, Uruguay Trazabilidad efectiva de productos: esencial en la respuesta a

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Effective Product Tracing:Essential in Response to

Foodborne Illness OutbreaksFrank Busta

Director Emeritus10 October 2007

Symposium of Food Innovation & Development INNOVA 2007

LATU, Montevideo, Uruguayhttp://www.ncfpd.umn.edu

Trazabilidad efectiva de productos: esencial en la respuesta

a brotes de origen alimentarioFrank Busta

Director Emeritus10 October 2007

Symposium of Food Innovation & Development INNOVA 2007

LATU, Montevideo, Uruguayhttp://www.ncfpd.umn.edu

Agenda

• Global food supply chain vulnerable & accessible• Multiple examples of supply chain complexity

– Most using U.S.A. current information– Most focused on food defense

• Food defense actions needed in response– Emphasizing product origin and traceability

Systems thinking is imperativePrinciples are fundamentally sameDetection at the local level

Sick peopleSick animalsDetection of tamperingFocus for prevention is localFarm/processing facility/warehouse/retailSame responders

Food Safety vs. Food DefenseCommon Themes

“Unnatural” contamination

Familiar agents in unfamiliar places

Need to think in a new manner

Role of law enforcement

Food Safety vs. Food DefenseImportant Differences Food & Agriculture Infrastructure

• The most complicated supply chain in existence– Globally dispersed– Privately held– Highly integrated– Flexible– Dynamic

• Innumerable potential points of disruption/contamination

• Inherently systems based

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Food Attack Impacts

• Both a significant public health and economic threat– Access to sufficient calories not a likely issue

in developed nations, could be one in poorer nations.

• Globally distributed target• Psychological impact of personal threat vector

for delivery of agents– “Will my cookie kill me” – as a Weapon of

Mass Destruction threat

Principles of Delivery

• The delivery of the food supply is highly dependent on the many facets of the food system and supply chain

• No longer a simple system

Illustrating Supply Chain Complexity:Basic Ingredients in a Cheeseburger

IngredientsCheeseburger

bleached wheat flour mono- and diglyceridesmalted barley flour diacetyl tartaric acid estersthiamine ethanolriboflavin sorbitolNiacin polysorbate 20folic acid potassium propionatereduced iron sodium stearoyl lactylateWater corn starchcorn syrup ammonium chloridesesame seeds ammonium sulfatesoybean oil calcium peroxideYeast ascorbic acidSalt azodicarbonamidecalcium sulfate enzymescalcium carbonate calcium propionate calcium silicate wheat glutensoy flour baking soda

USDA inspected beef

Milk milkfatWater creamsodium citrate saltsodium phosphate sorbic acidartificial color cheese cultureacetic acid soy lecithinEnzymes starch

SauceSoybean oil pickles distilled vinegarWater egg yolksHigh fructose corn syrup Sugaronion powder corn syrupSpice spice extractivesSalt xanthan gummustard flour Prop. glycol alginatesodium benzoate potassium sorbatemustard bran garlic powderhydrolyzed proteins caramel colorPaprika Turmericcalcium disodium EDTA

CucumberswaterVinegarSaltcalcium chlorideAlumnatural flavoringspolysorbate 80turmeric

Grill SeasoningSaltPeppercottonseed oilsoybean oil

Lettuce/romaine distribution chain

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Feedlot Scenario in the Panhandle of Texas

2.1 MillionU.S. Farms

? MillionForeign Farms

30,000 U.S.Processing Sites

94,000 ForeignProcessing Sites

19,000 DomesticPackers/Repackers

87,000 ForeignPackers/Repackers

935,000 RetailFood Outlets

224,000 RetailFood StoresU.S. Global

Food System:Strength and Risk

Imported Foods• ~ $60 billion in ag imports• ~ 150,000 foreign facilities

registered

• ~ 3% of imported food is inspected at the border

• Borders are porous

Over 90% of green onions Over 90% of green onions and 48% of cucumbers and 48% of cucumbers sold in the United States sold in the United States

were from Mexico in 2005were from Mexico in 2005Mexican trucks make about 4.5 million Mexican trucks make about 4.5 million

border crossings each year, according to border crossings each year, according to US government figures. DOT 6US government figures. DOT 6--2424--0505

U.S.Agricultural & Seafood Imports 2006

Bananas

CheeseGrains

Cocoa

Oils

SeafoodVegetables Juices

Fresh MeatProcessed Meat

Spices

Global Food Systems – Greatest Import Source

2005

Fruit

Edible Prep

Meat GrainsSeafood

Fats/Oils

VegetablesAnimal

Products

Dairy

Meat/FishPrepCoffee/Tea/Spices

Primary Origin of U.S. Imports

2006 USDA-FAS Data

Cocoa PrepVeg/Fruit Prep Bev

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Tracking U.S. Food Imports

Fruit

Edible PrepMeat Grains

Seafood

Fats/OilsVegetables

AnimalProducts

Dairy

Meat/FishPrepCoffee/Tea/Spices

Cocoa PrepVeg/Fruit Prep Bev

Cured MeatPoultry CrustaceansFish

FrozenBeef Offal

Sheep

Pork

Live Fish

The labels are on the country that is the single largest exporter to the U.S. of that item – Canada and Mexico the biggest source of food imports to the U.S.

Canada is also the largest source of meat products to the U.S. – including crustaceans in dollar terms

Tracking U.S. Food Imports

In weight terms, Thailand is the largest source of crustaceans, with over 100,000 tons/year

Dead ScallopsSnails

Rock Lobster

Shrimp

Cuttle Fish

Mussels

LobsterLive

Scallops

Live Fish

Oysters

Octopus

Dead Crab

Fresh Crab

AUSTRALIA DENMARK INDONESIA NICARAGUA SURINAMEBANGLADESH ECUADOR IRAN NORWAY TAIWANBELIZE EL SALVADOR ITALY PAKISTAN THAILANDBRAZIL FRENCH PACIFIC JAMAICA PANAMA TURKS & CAICOSBRUNEI GREENLAND JAPAN PERU UKRAINECAMBODIA GUATEMALA KOREA PHILIPPINES UAECANADA GUYANA MADAGASCAR PORTUGAL UNITED KINGDOMCHILE HONDURAS MALAYSIA SAUDI ARABIA VENEZUELACHINA HONG KONG MEXICO SINGAPORE VIETNAMCOLOMBIA ICELAND MOZAMBIQUE SPAIN YEMENCOSTA RICA INDIA NEW ZEALAND SRI LANKA

The range of countries that export shrimp is quite broad

U.S. Sources of Shrimp

Surprising Primary Exports to U.S.2006 USDA-FAS Data

• Azerbaijan juices• Bangladesh crustaceans• Cambodia crust. prep.• Chad gums• Georgia wines• Haiti dates• Indonesia crustaceans• Iran juices• Israel baked goods

• Kazakhstan prepared fish• Lebanon fruit/nut prep.• Mongolia honey• Pakistan rice• Sri Lanka tea• Sudan gums• Venezuela crustaceans• Yemen coffee• Zimbabwe sugar

Cocoa supply chain - real• 3/15 Chicago Manufacturer of hot chocolate mix receives

a purchase order from a U.S. product marketer.• 4/9 Manufacturer begins production of four flavors of

various hot chocolate mixes.• 4/23 Manufacturer loads full container – 20 pallets – with

hot chocolate mixes. • 4/30 Container received by Chicago rail-yard for

destination to Oakland, CA – 2000 miles away.

Cocoa supply chain - real• 5/7 Container loaded onto freighter.

Destination: Shanghai, China 6143 miles away• 6/4 Freighter arrives in Shanghai, container taken

off ship and picked up by truck• 6/11 Hot chocolate taken out of container for

product assembly. Pouches are hand labeled and placed in tins. Lid applied to tins.

– Tins sealed and placed three flavors to a gift pack. Gift packs placed in a merchandising display.

Cocoa supply chain - real

• 8/6 Pallets of completed merchandising displays loaded onto container and shipped to Shanghai loading dock - -Containers loaded onto freighter.

Destination: Oakland CA 6143 miles away• 9/3 Ship received in Oakland. Truck pick-up.

Destination: Wholesale club store warehouse in New Jersey 3000 miles away.

• 9/10 Product received at warehouse. Forwards two pallet orders destined for Chicago 1000 miles away

• 10/8 Chicago manufacturer receives order of cocoa gift packs to provide as customer Christmas gifts

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Cocoa supply chain - real• Hot Chocolate in gift packs traveled 18,286 miles before

being placed under a Christmas tree in U.S.A.

• Why so many miles? • Labor rates between $0.18 and $.30/hour resulting

in cheap assembly and materials costs of a fraction of those costs in U.S., Europe or Japan.

• Most of this cheap labor is in India, Pakistan and China

Source: Reinhart FoodService, LaCrosse, WI.

Source of Food Imports• U.S. imports 13% of total food consumed (USDA-ERS)• China accounts for 3.5% of food and agriculture imports

(USDA-ERS, dollars)• China is in the top five in imported Fish/Crustaceans

(#2), Vegetables (#3), Meat/Fish Preps (#3), Cereal/Starch (#4) & Vegetable/Fruit Preps (#2)

• Actual imports from China unknown due to ingredients & trans-shipments

Intentional Food Contamination in China

• 1997: China; Insecticide contaminated pork provided to villagers by another resident (44 ill)

• 1999: China; Nitric acid contamination of donkey soup by competitors to the food vendor (148 ill)

• 1999: China; Rat poison contamination of sweet rolls by competitors to the food vendor (48 ill)

Intentional Food Contamination in China

• 2001: China; Rat poison contaminated noodles by a competitor to the food vendor (120 ill)

• 2002: China; Rat poison contaminated school lunch (92 ill)

• 2002: China; Rat poison contaminated breakfast foods by a competitor to the food vendor (400 ill, 41 dead)

61 Students felled by rat poison in central ChinaMonday, September 29, 2003Dozens of elementary school students and teachers in Hunan Province were hospitalized after ingesting rat poison with their school breakfasts in an apparent deliberate mass poisoning, state media said Sunday.

Food Contamination History Food Attack Impacts

• China inspectors find one-fifth of goods substandard

Wed Jul 4, 2007 3:59PM BST

• Formaldehyde found in Chinese cookies The Associated Press Updated: 9:56 a.m. CT July 18, 2007

• China to build nationwide grocery-tracking system to ensure food safety

www.chinaview.cn 2007-09-18 10:57:32

• CHINA: 34 kids remain hospitalized for food poisoning

23.sep.07 China Daily.com

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Melamine in pet food

Diethylene glycol in cough syrup & tooth paste

E. coli 0157H7 in washed bagged spinach

Botulinum toxin in thermally processed chili topping

Salmonellae in peanut butter

E.coli in frozen ground beef

Recent Food Contamination History Food/Feed System Complexity:Tracking The Contaminant

China CoalPlant

GlutenPlant(s)

Xuzhou Anying Chem Nutra

Menu FoodsKansas

Menu FoodsNew Jersey

Menu FoodsCanada

Fish Farms Various PetFoods

Reclaimed/etc.Animal FeedPoultryFarms

SwineFarms

Dramatic Shift In Chinese Gluten Imports

$0.0

$5.0

$10.0

$15.0

$20.0

$25.0

2001 2002 2003 2004 2005 2006

Year

Whe

at G

lute

n Im

port

s Fr

om C

hina

($M

)

#7

#7

#7

#7

#4

Country/Food Vulnerability Assessments

• Combine country by country assessments with adulterated product information from agencies

• Tier products by susceptibility for economic vs. public health focused adulteration

• Develop decision grids to help focus private and public sector interventions

• Conduct cost/benefit analysis of decision grids

Explore Enhanced Product Movement Surveillance Strategies

• Understand what other collected data could be used to identify trading pattern shifts & anomalies

• Assess the cost/benefit of real time compilation and analysis of Oasis data

• Investigate how the current “equal to” inspection regime could be used to better capture product movement

• Work with the Private & Public Sector to develop improved supply chain verification tools

Explore Enhanced Inspection Strategies

• Based on variability of source/size/mode of shipment, analyze cost/benefit of varying inspection & analysis frequencies for relative reductions in vulnerability

• Research tools and protocols that might be employed in concert with trading partners for country of origin surveillance and detection.

OPIS=Offshore Pest Inspection system

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Modeling of food system contamination events for vulnerability assessment

Models of Food System Events• Presents realistic models of key event attributes

– Consumer exposure and outcome – Impact on public health infrastructure– Economic impact of an event – Impact of various interventions

• Demonstrates massive impact from food event • Requires extensive collaboration with private

sector, states and federal agencies to be relevant

Food Defense Plan

Objective: to develop a comprehensive program that will minimize the potential for intentional contamination of a specific food product/facility

Creating a Food Defense Plan

• Do Carver + Shock evaluation• Ensure ALL employees (CEO/President to

temporary employee, etc.) know and understand their role in the Defense Plan.

• Establish safety/defense partnerships with local, state, and federal official

• Develop mechanisms for identifying and referring suspicious incidents or site security breaches


• Is an emergency shut down plan in place?• Is an emergency evacuation plan in place?• Has a mitigation/recovery assessment been

conducted?• Has an appropriate recall strategy been

established?

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Components of a Food Defense Plan

• Personnel• Perimeter security• Facility security• Receiving/transportation• Ingredients• Process security


PersonnelObjective(s): to know and understand

employees and to foster commitment to safety and quality plant and product security

Creating a Food Defense Plan• Personnel

– Are all vulnerable areas adequately supervised?– Are personal items (medicines, packages, bags,

etc.) restricted from the facility?– Does senior management provide strong

support for security efforts?– Has responsibility for security management

been established?– Has defense awareness training been

conducted for employees and contractors?

Creating a Food Defense Plan• Personnel

– Are policies and procedures are in place to prevent and respond to workplace violence?

– Are background investigations conducted on new employees?

– Are service providers (janitors, temporary employees) required to provide background checks on their workers?

– Provide economic incentives for personnel to use products made in the facility


Perimeter SecurityObjective: to decrease the possibility of

unwanted access and/or successful attack on the facility in question


• Perimeter SecurityIs adequate perimeter protection in place?

• guards? signs? lighting?• fences? walls? gates? trenches?• intrusion detection systems?• in-bound material inspections?• parcel and mail inspections?• gate controls?

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• Perimeter Security– Install surveillance cameras that allow view

of complete perimeter– Install watch towers that allow for human

surveillance of complete perimeter– Use a single-point of access for entire facility– Inspect incoming/outgoing vehicles (to the

extent practical)


Facility SecurityObjective: to limit access to the facility

in question so as to inhibit potential delivery of a harmful agent


• Facility Security– Are critical utility and communication

equipment adequately protected?– Is bulk-unloading equipment (e.g. pipes,

augers, conveyor belts, hoses) secured when not in use?

– Are reception, production and office space areas arranged and controlled so that unescorted visitors are easily noticed and prevented from unauthorized access to the facility?


• Facility Security– Does the manager know (recognize) all

respective employees?– Are security guards on-site?– Are all keys accounted for at all times?– Are facility access control measures effectively

implemented?– Implement designated/assigned work area– Minimize the number of entrances to sensitive

areas

Creating a Food Defense Plan• Receiving/Transportation

– Is loading/unloading of shipments supervised?– Are shipments cross-checked against an invoice?– Do drivers undergo background checks?– Are seals/ID tags inspected?– Are damaged bags rejected?– Are only intact packages accepted?– Is a system in place to identify and track

products enroute to the facility and upon leaving the site?


IngredientsObjective: to ensure acceptance of

only high quality and safe materials

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• Ingredients– Is the number of approved suppliers limited?– Are lot numbers of incoming ingredients

verified?– Are incoming packages inspected?– Are only known/approved suppliers used?– Are suppliers required to have Food Defense

plans in place?


Process SecurityObjective: to eliminate or reduce (to a

non-deadly level) the impact of a potential intentional contamination of the product in question


• Process Security– Have detailed SOPs been implemented?– Are all areas supervised?– Control access to vulnerable points/restrict

access to essential employees only– Modify processing parameters to inactivate or

minimize impact of specific agents to which your process and product may be susceptible, where or to the extent possible

Food and Drug Administration• http://www.cfsan.fda.gov/~dms/defterr.html

United States Department of Agriculture• http://www.usda.gov/homelandsecurity/

FDA and USDA Guidance

Take-Home Message• Assess / minimize your vulnerabilities• Know your personnel• Understand your ingredient suppliers and their

security program• Understand your product formulation• Understand your processing• Understand your production/distribution

practices• Be able to trace ingredients to their origin• Be able to trace product to consumer

Defending the safetyof the food system

through research and education

Frank BustaDirector Emeritus & Senior Science Advisor

http://www.ncfpd.umn.edu

Documents

Symposium of Food Innovation & Development … of Food Innovation & Development INNOVA 2007 LATU, Montevideo, Uruguay Trazabilidad efectiva de productos: esencial en la respuesta a