Cold chain conference nov 7 2013 chicago

Exploring Vulnerabilities in the

Cold Chain

Practical Approaches

Nick PacittiChicago, IL7 Nov 2013

• Creating clear protocols and product standards

• Evaluating cold chains for trends and weaknesses

• Managing product/information flows at transfer points

• Minimizing cost while maximizing quality

Vulnerabilities in the Cold Chain

Description US UnitsPublic Blast Freezers 51,000

Private Blast Freezers 100,000Public Refrigerated/Freezer Facilities 12,800

Private Refrigerated/Freezer Facilities 114,000Public Coolers 1,600,000

Private Coolers 2,200,000

Restaurant Coolers/Freezers greater than 1K sf 4,000,000+

Public Refrigerated Trailers 30,000,000Private Refrigerated Trailers 9,000,000Public Refrigerated Railcars 31,000

Private Refrigerated Railcars 35,000Sources:International Association of Refrigerated WarehousesWorld Logistics OrganizationInternational Refrigerated Transportation AssociationInternational Association of Cold Storage Construction

Refrigerated distribution is huge…

Vulnerabilities in the Cold Chain

However, there are exceptions

Cold Chain Making National News

http://www.today.com/id/26184891/vp/44623239#44623239

http://youtu.be/0dNqUK6caAo?t=4m18s

7

Actual Examples of a Cold Chain in Action

Cumulative Average Temperatures

Another Example of Poor Cold Chain Performance

AdulteratedProduct

CompromisedProduct

DesiredProduct

45 to 50+

40 to 44.9

< 39.9

42%

12%

46%

88% of product delivered

had been compromised and

based on science should

have been disposed of

Cumulative Average Temperatures

Creating Protocols and Standards

Protocols and Product StandardsAn example of an actual Desired State for large shipper

• An optimal carrier base for chilled loads that properly balances service and cost

• Clearly defined carrier expectations for temperature control and rigorous carrier performance management

• Well defined processes, standard work and data sources for chilled product staging, loading and shipping; clear accountability at each step of the process

• Systemic data gathering around temperature abused loads across all chilled product categories

• Selection and application of temperature monitoring technology that expands data capture across chilled shipments

Required Component Description

Available cold chain policyProvides guidance and temperature thresholds on all the elements from pre-loading to loading , yard mgmt/trailer staging, monitoring through to delivery

Determine product limitsUsing real life operating environment simulate the effect of cumulative average temperatures on product stability and spoilage rates

Temperature range stipulations Based on spoilage rates develop trailer temperature protocol in monitoring temps and given thresholds

Defined temperature trigger points Based on defined thresholds develop stages of intervention and required decision points

End to end t monitoring - Rules based control and monitoring systems

Apply temperature and quality protocol in monitoring trailer temps during pre-chill, loading, staging, and delivery cycles

Suitable staff training Revise cold chain (HACCP and Quality Management System based) training for associates

Self and third-party audits Periodic monitoring of the system in assessing how the system is performing as planned and required

A formalized validation process assuring the process works

Actual monitoring, validation and quantification of how well the system works and what adjustments are needed in bringing system in line with established standards

Protocols and Product Standards

Initiative Now Next Later Impact

Fix what is wrong

Develop Cold Chain policy and product standards – how does product behave in real life operating conditions – for all seasons

Develop temperature performance index

Design and implement rules based temperature monitoring

Selected training at management and hourly levels

Review fleet utility and rationalize size – with a process in place and asset productivity improved other

Develop audit to validate index

Protocols and Product Standards

Temperature as a Quality Control Point

• Single point readings are irrelevant• Average temperature readings are irrelevant• Cumulative temperatures matter most

>50 A A A A A A50 C A A A A A48 G C C A A A46 G C C C A A44 G G C C C C42 G G G G G C

39 - 41 G G G G G G36 - 38 G G G G G G

Hours 2 4 6 8 10 12

Illustration Only

>50 A A A A A A50 C A A A A A48 G C C A A A46 G C C C A A44 G G C C C C42 G G G G G C

39 - 41 G G G G G G36 - 38 G G G G G G

Hours 2 4 6 8 10 12

Illustration Only

G = Good – optimal qualityC = Compromised – quality issueA = Adulterated – food safety risk

Protocols and Product Standards

Canary in the Mine

• Can’t focus on everything

• Understand sensitivities of selected products or product families

• Use one or two product families for guidance in determining thresholds or ‘cold chain specs’

Where is the Canary?

Evaluating and Assessing Trends

• There is often resistance to cold chain issues

• Once issues are identified…what to do?

• What is the cost-benefit in fixing

Cold Chain Evaluation

• Rising consumer complaints

• Need to set standards against product quality thresholds

• Need to monitor the standard

• Need for predictive capabilities in eliminating problems before they arise

• Capability to measure and control the cold chain

Cold Chain Evaluation

How to evaluate cold chains in assessing trends and weaknesses

Need to look at Cold Chains in Totality

How to evaluate cold chains in assessing trends and weaknesses

Understanding the entire cold chain doesn’t stop at delivery

How to evaluate cold chains in assessing trends and weaknessesEven with the best monitoring things can wrong without being noticed

If you could, would you have a manager ride along the cold chain, with a cell phone, reporting back critical operational data?

Who would be that manager?

Trailer Temperature Temperature Profile Product Quality Behavior Reefer Mode Reefer Set Point Supply Air Return Air Product Temperature Door Open or Close Reefer Alarms Location

Poor cold chain management has a direct influence on cost and product quality

Refrigerated trucks ready for loading

Refrigerated dock design to minimize energy and temperature loss

This is an excellent option in minimizing energy while maintaining product temps

Raising storage temperatures to save energy: Is it worth it in the long-run?

• Raising the holding temperature and reducing the heat gain through the walls due to a reduced temperature differential inside to outside.

• With 4” of insulation, raising the temperature will decrease the conduction into the facility by 2%.  The impact or change in effect of infiltration would be minimal with a 5 deg. change so was not considered at this time.

• Thus providing a 2% energy savings on a “peak differential day”• Raising the holding temperature, thereby allowing a reduction in compressor

suction temperature• if the compressor suction can be raised a corresponding 5 deg. then depending

on the system, there will be a reduction of 8-9% of required compressor brake-horsepower

• Kraft Foods engineers claim a 2% savings for every 1 psi increase.  At these temps we are about 4.5 psi increase, so this is a second validation of the 8-9% savings.

• Installing Variable Speed Drives• If the roofing is black, change to a reflective coating• This will reduce the heat gain through the roof• Can reduce the temperature of the air being drawn across the condenser coils

The focus on cold chain management improves the scientific basis for safety and control processes. Monitoring of temperature in a proprietary way is done by using indicators that can be measured easily, such as cumulative average ambient temperatures. This focus on measurable indicators provides a more cost-effective approach to control than product sampling and testing, which is more expensive and may not provide timely results. This is especially important for foodborne microbial pathogens, because their incidence is low and costs of testing are high.

To meet the goals of processors, retailers and the consumer, temperature standards must be set to accommodate accurate product behavior over extended periods. Once established, these standards can be measured in innovative ways that convert data into meaningful and actionable information in better controlling processes. Setting product temperature standards and measuring in innovative ways allow greater efficiency in meeting processors, retailers and public health goals.

Cold Chain management is evolving into a regulatory tool, but more importantly, into a supplier and retailer specific requirement. The reason is that it overcomes and solves for the high information costs of setting and enforcing standards for microbial foodborne pathogens. These information costs contribute to the market failure in food safety provision and make design of effective interventions difficult. Moreover, a cold chain standard has been proven to actually reduce food safety risks. It is an effective and useful performance standard.

Epilogue

The Integrated Food Chain Research Center

Thank You

Nick Pacitti – [email protected]

330-217-8005

www.ifc.scl.gatech.edu

www.sterlingsolutions.net