Training and scheduling are the keys to deriving maximum value from a facility’s staff. Managers should guide new hires through a facility orientation, emphasizing proper operating techniques and safe product handling. However, training should not be limited to the first few days on the job. “Staff should be continuously developed as changes to the operation take place or new customer requirements emerge,” suggests Aguilar.
Operating procedures in a fresh produce facility must be based on good manufacturing practices (GMPs). Adopting GMPs will help facilities conform to regulatory agency guidelines and ensure product does not pose any risks to consumers. The key principles include maintenance of hygiene at all times, creation of clear process definitions and controls, avoidance of cross contamination, and strong recordkeeping for traceability.
“Any kind of holding area for fresh produce needs to follow CFR [Code of Federal Regulations] Title 21, Part 110 [promulgated under the Food Safety Modernization Act],” recommends Gombas. “The important part for facilities is Subpart B related to full preventative control rules. This includes a food safety plan, a supplier approval program, environmental monitoring, and more.”
It is also sensible for supply chain facilities to promote food safety through a management system like hazard analysis and critical control points (HACCP). Companies must analyze and control the biological, chemical, and physical hazards that can harm product.
“You absolutely need to be HACCP compliant or HACCP certified,” states Treacy. Some of which goes into the very design specifications of the building, he notes. “Make sure you have the right setup so you support pest control, sanitation, and safety.”
OVERCOMING CHALLENGES
Production and distribution facilities are dynamic operations. Each day brings new challenges, varying customer requirements, and expectations for perfect order fulfillment. Chief among these challenges are proper sanitation, labor availability, and fluctuating demand.
As a former grocery distribution center manager, I fully recognize the many challenges related to maintaining sanitary facility conditions. Product spills, temperature excursions, and pest infestation are the tip of the iceberg. Fresh produce facilities must also control allergens, avoid product cross-contamination, and prevent opportunistic pathogens from causing foodborne illnesses. The solution is a strong commitment to proper cleaning, food safety training, and periodic audits.
“Sanitation is always going to be a problem, especially for a warehouse that is operating 24/7,” acknowledges Gombas. “But it’s important to find environmental issues like listeria and respond before they get entrenched in your facility.”
Regulatory compliance is another facility management issue. Nobody enjoys those unannounced government inspections that seem to happen at the most inopportune times. However, facility leadership must prepare for the unexpected by developing appropriate strategies, executing the plan, and maintaining operational controls to ensure a secure and safe environment. Internal audits and assessments are also beneficial.
Aguilar recommends that companies conduct scheduled facility risk assessments, both from an operational risk management perspective and from a food safety and food security perspective. “This will determine if the proper policies, procedures, and resources are in place for the facility to conduct its operations to the suitability of its stakeholders including management, customers, regulatory agencies, and employees,” she notes.
