Shay Hannon shares how the National Prepared Consumer Food Centre is helping Irish businesses navigate food safety
Qualifying with a degree in Environmental Health, Shay Hannon’s career in the food industry began in quality and product development. He worked in Newbridge Foods for three years, progressing through the company before moving to Lily O’Brien’s Chocolates where he spent eight years, rising to become Head of R&D and Technical: “I led the quality function, and the technical and research function, the area I was keen to develop in.”
In 2017, the National Prepared Consumer Food Centre at Teagasc Food Research Centre at Ashtown in Dublin was established by the Department of Agriculture, Food and the
Marine in consultation with Teagasc, Food Drink Ireland’s Prepared Consumer Food company members, Enterprise Ireland and Bord Bia. The role of the centre is to support
research, development and innovation in the Prepared Consumer Food sector through specialist expertise and state-of-the-art facilities. Shay joined as Centre Manager in 2019 and his enthusiasm for his job is evident. “It’s a dream job, especially for someone like me who is interested in food research and development. The team and I are exposed to a lot of high-level science, and we pass on that knowledge to the wider food industry where we can.”
Collaborative approach
Shay and his team are currently working with approximately 120 Irish food companies, supporting them in a variety of ways. Client companies can use the facility for training, on equipment such as a mixer for example, or use the test kitchen facilities. “We could be involved in a more in-depth research project that might include a series of product trials over weeks or months.” One aspect of his role is helping companies to understand what is involved in shelf-life analysis and sensory analysis. “We can run trials in real-life conditions in a humidity chamber or light cabinet as you would fi nd in a retail store. We can do indepth sensory analysis in our laboratory to understand how long a product will last and how it’s going to obtain its optimum quality.” While microbiological testing is essential, the sensory side of shelf life can, at times, be forgotten. “We really stress with food companies that it is about running both in tandem: You have to check the quality and sensory attributes of your food product in conjunction with the food safety aspects.” Shay often finds himself on the road, visiting a client’s factory or premises. While on-site, he focuses on lean manufacturing. “Sometimes you need to stand back and see if your process is efficient: Could you buy a better piece of equipment or add a different ingredient? Could there be savings, perhaps from an energy perspective?”
Novel processes
One such process that Shay would like to see implemented by an Irish food company is non-thermal processing. “Heat treatment of food products is historically the optimum way of extending shelf life and guaranteeing a food product is safe. In the last ten years, there have been massive technology advances in non-thermal processing such as high-pressure processing (HPP). Another example is pulse electric field technology (PEF) where the product is subjected to pulsed electrical currents. It’s widely used in other countries for the pasteurisation of fruit juice and that’s an area we want to tap into with Irish manufacturers. They could potentially install that technology and it could cost a fraction of a heat treatment system. It also uses very little energy. A big win for us would see an Irish company adapt that technology because of the work we have done here.”
Market trends and forces
Much of the work undertaken at the centre is led by consumer trends, Shay says, citing the rising interest in plant-based products, beverages, and meat alternatives over the last
year. “Covid presented a unique set of challenges, but it also presented opportunities, such as immune boosting and fortified foods. A lot of the products we have worked on in the
last couple of months have some degree of added nutritional benefit and how companies are incorporating those benefits into their standard product: how to infuse vitamins and
minerals into a product.”
In the food business sector, which was heavily impacted by the pandemic, Shay’s team helped companies in the chilled ready meal category to increase their products’ shelf-life capability. “We did a number of trials and advised several companies on how to extend shelf life, and what packaging to use. That’s grown business opportunities for those companies which they have retained post-covid.”
Global challenges are ongoing for food companies and the war in Ukraine is an example of how external forces can impact a small food business: guaranteeing the supply chain. “When you aren’t guaranteed supply of a product, it can potentially open the market to adulteration. I believe that what has been implemented at European level over the last ten years has safeguarded against that, but it is always a concern, particularly for smaller clients.”
Advice and guidance
There is an advisory side to the role, too, and Shay works closely with the Food Safety Authority to offer guidance to businesses, particularly those in the start-up phase. “We help
them decipher legislation and regulation, particularly in terms of shelf life. It can be complex, and simple things such as what goes on the back of the pack. We have to help them to develop a safe process and help them to understand that the product has to be safe. It’s the foundation for every food product.” He would encourage food companies to visit the centre to discuss potential projects and see the equipment and technology available. “The centre can be utilised in a number of ways: for our expertise, where I or a member of our staff goes to a site to do an assessment of the product or process or work alongside a company to develop a product, trial or process.”
Additionally, companies can rent a facility at the centre, and use the equipment with training and guidance from Shay and his team. “Once the product is developed, we guide them through the analysis required: safety analysis, nutritional analysis. If the client wants to make a nutritional claim, we decipher the legislation for them and send the product for accredited analysis and then inform them of what they can and cannot claim. It’s a complex area for small companies to understand, legally, what you can say on your pack and label.”
Industry challenges
Understanding the requirements around shelf life and labelling are the key challenges for small food businesses and, he says, the biggest mistake a company can make is rushing product development and launching before the product is ready. Shay would urge companies to do all their due diligence, testing, sensory analysis, and even consumer trials before going to market. “Making a claim that isn’t legal, such as ‘high in protein’, when it isn’t, is a key issue. We are wary of claims such as ‘highly nutritious’, or ‘good for you’. I tell every company: it has to be ‘Ronsealed’: it has to do what it says on the tin and if it doesn’t, the claim can’t be made. We have a brilliant reputation in Ireland for producing high quality, safe food and it’s the responsibility of, not just Teagasc and the centre, but of every food company to guarantee that.”
The best part of the job, he says, is seeing the finished product. “The thrill for me is seeing a company leave here with a product or process and knowing that we have helped them on that journey. Sometimes I flick through the Aldi or Lidl or some other retailer magazine, and I see a client’s product and that gives me great pleasure. Ultimately, what we are doing here is helping to create jobs and businesses.”
Comments