Food Safety Matters

Episode 181 | Guest: Johanna Velez: Dedicated to a Culture of Consistent Improvement

Date: November 12, 2024
Host: Food Safety Magazine Editorial Team (Stacey Acheson, Adrienne Blum, Bob Ferguson)

Main Theme & Overview

This episode centers on cultivating a culture of consistent improvement in food safety, featuring an in-depth interview with Johanna Velez, Vice President of Quality Assurance at Monin Americas. Velez shares her experience overseeing food safety and quality programs in the specialized sector of flavorings and colorings, discussing Monin’s modernization processes, quality control enhancements, and the unique challenges of operating as a global supplier. The episode also covers current key food safety news and trends, including outbreak updates, FDA priorities, and insights on the international technology revolution in food safety.

Key Discussion Points & Insights

1. Industry News Segment

McDonald's E. coli O157:H7 Outbreak Linked to Taylor Farms Onions

• Details & Response
  • An E. coli outbreak sickened at least 90, resulted in one fatality across 13 states.
  • Source: Slivered yellow onions from Taylor Farms Colorado Springs, not beef as first suspected.
  • McDonald's and several other fast-food brands halted use of Taylor Farms onions from that location, while a recall and investigation continue.
  • Traceability Success: Taylor Farms demonstrated strong traceability, limiting the scope and duration of the recall.
  • Potential Root Cause: Focused investigation on the slivering process/machinery as slivered but not diced onions were implicated.
  • Quote:

    "It sounds like there's something unique about the slivered onions... wherever that machine is in the plant, and you may find that is what the cause was." – Bob Ferguson [05:46]

FDA Human Foods Program (HFP) Reorganization & Priorities for 2025

• Vision: "The food supply is a vehicle for wellness."
• Mission: "Protect and promote the health and wellness of all people through science-based approaches."
• Focus Areas:
  • Microbiological food safety (pre-harvest water rule, traceability, genome tracking)
  • Chemical food safety (premarket reviews, contaminants, PFAS exposure)
  • Nutrition (infant formula market resiliency, consumer labeling)
• Expert Commentary:
  • Some industry experts (Frank Yiannas) find priorities uninspiring, calling for more boldness.
  • Hosts note that transition and steady progress may be prudent in the face of internal changes and reorganizations.
  • Quote:

    “The reorg... was billed as a 'once in a generation opportunity.' But the 2025 priorities do not rise to that characterization. They're a bit light and there really isn't much new.” – Citing Frank Yiannas, via Helena Botmiller Evich’s Food Fix [11:40]

  • Quote:

    "Turning the battleship at a reasonable speed is probably the right way to go." – Bob Ferguson [15:57]

Trends in FDA Food Recalls (2002-2023)

• Key Findings:
  • 76% of recalls due to microbiological contamination or allergens.
  • Listeria (45%) and Salmonella (38%) led recall causes.
  • Allergens account for 28% of recalls, mostly from undeclared milk/whey.
  • Over half the recalls were Class 1 (most serious).
  • Quote:

    "Listeria and Salmonella are the big two that people are looking out for." – Bob Ferguson [18:13]

FDA & Purdue University Environmental Salmonella Study

• Focus: Salmonella distribution/survival in Indiana's cantaloupe-growing region to inform mitigation and safe growing practices.

2. Food Safety Insights Column Highlights – Bob Ferguson

Global Tech Adoption in Food Safety

• International Survey Results:

  • 75% have adopted rapid testing for microbiology or allergens.
  • Emphasis is on technologies that support cleaning, sanitation, and rapid response—not adopting tech for its own sake.
  • Practical, result-driven approaches prevail globally, regardless of region or resources.
  • Quote:

    "I did not see anybody adopting technology for technology's sake ... All of it was very practical, which I took as a very good sign." – Bob Ferguson [24:50]

• Why the Need for Rapid Testing?

  • Not just about newness: it's about making timely, informed decisions, especially for plant sanitation.
  • Companies value in-plant rapid tests (e.g., QR, lateral flow strips) to clear lines for production after cleaning.
  • Quote:

    "It needs to be fast and good enough." – Bob Ferguson [26:14]

• Regional Nuances:

  • International companies perform more on-site testing than US/Canada due to fewer accredited labs nearby.
  • Illustration:

    "One company has an accredited lab on their island. The other one doesn't ... shipping it off the island and waiting for the results just doesn't work." – Bob Ferguson [27:28]

3. Feature Interview: Johanna Velez, VP of Quality Assurance, Monin Americas

(Interview Begins: ~30:04)

3.1 Special Food Safety & QA Considerations in Flavorings & Colorings

• Evolving regulations, technology, and consumer expectations demand adaptability.
• Customer demand for consistency and transparency, especially from a multi-facility, global brand.
• Quote:

  “We know that [customers] expect consistency. They want a product that's transparent. They want to feel reassured that the product they're consuming is safe.” – Johanna Velez [30:38]

3.2 Leveraging International Knowledge & Lifelong Learning

• Emphasizes open-mindedness, ongoing education, and collaborating with Monin teams globally (Asia, Europe) for shared best practices.
• Quote:

  "By combining my knowledge with their knowledge and their feedback and that collaboration, it helps us maintain our high quality standards." – Johanna Velez [32:15]

3.3 Modernizing & Digitizing Quality Control

• Digitized all quality documentation for transparency and efficiency (moving away from spreadsheets).
• QR code-based maintenance: Operators and QA can quickly access equipment history, file work orders, and see real-time data with a scan.
• System allows proactive management and “working smarter, not harder.”
• Quote:

  "We digitized a lot of our documents ... helps me make better decisions. So then I know that something's not going the way we plan and maybe I need to spend more resources into that particular area." – Johanna Velez [33:20] "You can scan that QR code ... you can see the history of that equipment ... do it right there on the line." – Johanna Velez [33:52]

3.4 Proficiency Testing for Continuous Improvement

• Quarterly proficiency tests keep staff sharp, identify training needs, and foster growth.
• Tactics include: equipment calibration checks, shadowing, and sensory evaluation "challenge rounds."
• Creates friendly competition and boosts engagement.
• Quote:

  "Doing the proficiency test is a really good way to measure their skill set, also ensure consistency, see where there are gaps, and see if we need to tailor the training to their needs.” – Johanna Velez [37:22]

3.5 Positive, Blame-Free Approach to Non-Conformances (“QUIP” System)

• Nonconformances reframed as “Quality Improvement Process” (QUIP) to foster problem-solving, not blame.
• Involves cross-functional teams—IT, Marketing, R&D—to address and prevent repeat issues.
• Digitization extends to manufacturing clean records for easier audits.
• Quote:

  "When something does happen, we need to take the approach of being blameless problem solvers. It's not as who did what, who did not do what they were supposed to do. Something happened. Okay, let's work together ... we call it now Quality improvement process.” – Johanna Velez [40:14]

3.6 Achieving and Sustaining SQF & Organic Certification Excellence

• Monin’s Clearwater & Sparks facilities: consistently above 95% on SQF; organic certification at both sites.
• Commitment comes from intensive staff training and involving all departments in audits and certifications.
• Policies and procedures reviewed annually to exceed, not just meet, standards.
• Quote:

  “We scored above 95% every time ... we do that because we spend a lot of time training our staff.” – Johanna Velez [42:55]

3.7 Embedding a Culture of Consistent Improvement

• Leadership models quality-first behavior; food safety is part of employee onboarding, facility signage, and daily operations.
• Employees are empowered, recognized via “Moanin Connect” platform and “high five” shout-outs for contributions that catch issues before shipping.
• Cross-departmental support and collaboration (e.g., marketing pitching in on housekeeping).
• Quote:

  “It does need to come from the top down. ... One of the values that is listed on our mission is that we have a passion and commitment to quality and we never compromise our standards.” – Johanna Velez [45:55] "At the end of the day, our employees are going to take that product home and they're going to share with family and friends, and I know they're not going to take anything that they don't feel is safe." – Johanna Velez [48:10]

3.8 Working with Suppliers as Partners

• Robust onboarding process ensures suppliers meet GFSI standards and value alignment.
• Open, collaborative communication builds long-term relationships; suppliers viewed as “part of the Monin family.”
• Quote:

  “Our suppliers are partners and they play a very critical role in the success of the business. If we're successful, they… also do well.” – Johanna Velez [49:39]

3.9 Unique Food Safety Aspects in Flavorings/Ingredients Sector

• Quality assurance involves working side-by-side with line operators, not just QC staff, for mutual responsibility.
• Emphasizes joint effort in process controls (e.g., label checks, equipment codes).
• Quote:

  "It's that working hand by hand that is really important... It's a mutual understanding that working together really ensures that we meet our customers' expectations..." – Johanna Velez [52:11]

Notable Quotes & Memorable Moments

• “We found one [digital tool] that fits our needs best. … It’s something that we wanted to bring on board that everyone was going to welcome and be part of that change.” – Johanna Velez [35:28]
• “No one wins alone … It takes a family, it takes a village, having a strong culture to get all this accomplished.” – Johanna Velez [53:39]
• “Sometimes it’s the simple things that make the biggest difference.” – Johanna Velez [48:54]

Timestamps for Key Segments

• [03:28] News: McDonald’s E. coli outbreak with Taylor Farms onions
• [06:59] News: FDA Human Foods Program vision, mission, and priorities debate
• [14:18] Comments: Perspectives on FDA’s new approach and organizational change
• [16:47] News: FDA recall study and Salmonella study partnership with Purdue
• [19:55] Bob Ferguson’s Food Safety Insights: Global tech revolution in food safety
• [30:04] Featured Interview: Johanna Velez, Monin Americas

Recurring Themes

• Collaboration: Both internally across teams and externally with global partners and suppliers.
• Digitization: Modernizing all records and maintenance systems for efficiency and traceability.
• Empowerment & Training: Staff engagement through testing, friendly competition, and positive reinforcement.
• Continuous Improvement: Quality and food safety are dynamic, requiring ongoing evaluation and adaptation.

For Listeners

This episode offers a comprehensive look into how a leading flavorings and ingredients manufacturer sustains a top-tier food safety culture. Johanna Velez’s insights are practical, emphasizing technology adoption, robust training, and the importance of an empowered, collaborative workforce. The episode also provides context for ongoing regulatory discussion and trending issues in the broader food safety sector.

Links to referenced articles, studies, and news are available in the episode’s show notes.