Transcript (edited for length)
Food Processing: How have you seen food safety, sanitation and technology evolve over the past five or six years?
Jorge Izquierdo: As regulators and companies raise the bar for sanitation, workforce training must keep pace with new standards, best practices and tools. Food manufacturers have embraced Industry 4.0. We have seen greater adoption of predictive maintenance and remote access accelerated by Covid. Lastly, evolving regulations, consumer expectations and retailer preferences have everyone pulling to improve food safety, but not necessarily in the same direction. This poses greater challenges for manufacturers to align and comply with different demands.
FP: PMMI research that was just released recently mentions a 20% increase in food and beverage recalls since 2020. But what does the research ultimately say about food safety today?
JI: We were very curious about it as well. In our research, we asked OEMs and food processors, “What do you think was the reason?” Most responses from people with decades of experience suggested the industry has never been safer than it is today. For example, one respondent at a coffee roaster raised an interesting point. Years ago, coffee was a fringe food product subject to very few regulations or standards. Today all the standard requirements totally cover them for sanitation. And that’s true for many industries, where it’s much stricter these days than before.
FP: So how are companies adapting equipment design or operations to meet the increasing requirements of regulators and food safety?
JI: They’re looking for more clean-in-place equipment — which is not necessarily new, but it’s an investment. Toolless assembly is another in-demand feature, and so are features that ensure equipment can withstand high-pressure washdowns. Of course, hygienic equipment design with fewer crevices — harborage points for bacteria and contaminants — can make cleaning operations easier and shorter. And demand is rising for accurate record-keeping and reporting on the equipment sanitation for visibility and verification.
FP: What are some of the more exciting innovations or technologies being developed for the next generation of sanitation systems?
JI: We see growth in data handling and automatic report development to ensure that all that information is kept. This is especially important for labeling. There have been many recalls due to problems with labeling rather than the product. There has been significant growth in automation for clean-in-place. Operators also are taking advantage of sensors to verify the cleaning process. The guarding of electronics is still an issue, and so is ensuring equipment is much more intuitive — easier to operate, diagnose and troubleshoot. Processors want quick training solutions that can put the operator in front of the equipment, and whenever there’s a problem, technology will be able to assist the operator to solve 80% of the problems. The other 20% are left for remote access technologies or the service technicians to address. Further beyond the horizon, we’re hearing more robotics helping with the cleaning process and making sterilization easier and shorter.
FP: PMMI’s research highlighted labor shortages as a concern. How truly widespread is it, and what are the ultimate consequences to sanitation?
JI: The cleaning and sanitation process still requires manual labor, but not just anybody can do the job. Companies need someone who understands the process, how to report and log it, and manage the cleaning chemicals. It requires significant training. I would say it should be one of the hardest positions to fill at a food or beverage company given the necessary experience. Many hope to address the shortfall with great training and better technology.
FP: How are stronger cleaning agents and sanitizers impacting equipment durability, and how are manufacturers responding?
JI: To make the sterilization process shorter but effective, food and beverage manufacturers are using stronger chemicals for longer periods of time. That can create problems for the equipment. Sometimes machinery designed to produce one product is switched to another, and another specific cleaning procedure is necessary. But that can create problems with the seals, plastic parts or the equipment materials and components. Many OEMs are working to help processors here, but some chemicals are so aggressive that operators still need to be very careful. Managing equipment exposure is critical to the longevity of equipment. Each application is unique and requires specific recommendations.
FP: What actions is PMMI taking or planning to take in response to the findings of the research?
JI: On the Industry Services side of PMMI, we have the OpX Leadership Network, which has already put out a set of guidelines for hygienic design of packaging equipment. These guidelines were compiled by end users — food processors and other CPGs — to offer a starting point for specifying new new equipment or performing a factory acceptance check. We recently updated those best practices, and we are looking very close at all the recommendations on cleaning chemicals in use. The goal is to make things easier for operations to run smoothly, and to help OEMs close the loop on making these operations run more smoothly as well. In addition, innovation of all types — including food safety and sanitary, hygienic design — will be on display for attendees during PMMI’s Pack Expo Las Vegas, Sept. 29-Oct. 1, 2025, at the Las Vegas Convention Center. For anyone seeking solutions in these areas, the show is a great resource. Visit www.packexpolasvegas.com to register today.
