Setton Farms Steps Up Safety Program

Following up on their voluntary recall this past spring, Setton Farms, called a town hall meeting in late June in Visalia, Calif., for their growers, and others, to explain what they did during the recall. Company officials also outlined their new food safety program now in place.

“The recent recall was a watershed event for the entire pistachios industry and required complete re-examination of all assumptions,” said Mia Cohen, Setton Farms Chief Operating Officer, adding, “The event could have happened to anyone.”

“We need to raise the bar in terms of food safety in pistachios, and keep the pathogen level as low as possible,” said Jeff Gibbons, Setton Farms Grower Relations Manager.

“Salmonella was not something we thought much about,” said Mia. We were not looking for it because we did not know it could exist in the roasted pistachio product. But we have learned that it does exist in a very small percentage, about one percent, the same as in almonds,” she said.

The company’s new corporate focus increases the commitment in becoming an unparalleled leader in food safety. “It’s a moral obligation for our customers,” said Mia. “Our consumers eat our product, and we want that product to be safe.”

The voluntary recall has concluded, with little product still coming back, and all effectiveness checks have been completed. The recall was conducted with full cooperation from the Food and Drug Administration (FDA) and California Dept. of Public Health.

Setton Farms recalled about 14 million pounds, with approximately 12 percent being returned. (Most of the product that had been shipped had already been eaten by the time the recall was announced.) There has never been any conclusive links between Setton Farms pistachios and illnesses. Company officials noted that during the recall, expert ex-FDA communications firm was successful in keeping pistachio media coverage light and brief. In all, the pistachio recall was well managed, professionally executed and short in duration.

Lee Cohen, Setton Farms’ General Manager, outlined the company’s new food safety program that is now in place. “Our approach from the beginning was that this was all about science,” he said. “We left no stone unturned to identify the science to educate our growers and the industry.

“We made a major shift in assumptions, and realize that we need to kill the bug where it," Lee said.

Many changes were made during a complete shutdown of Setton’s Terra Bella, Calif. Facility during the late spring. “We conduced a deep-cleaning and sanitization of the entire facility,” Lee said. “We made a major change in the product flow. We completed a total segregation of raw pistachios, and roasted/ready-to-eat products.

The company also:

Eliminated common surfaces, equipment and cross traffic, dedicated separate equipment such as bins, pallets, utensils, forklifts and some mechanics for exclusive use in areas handler ready-to-eat products.

Changed airflow patterns to ensure that air flows from ready-to-eat to the raw production.

Upgraded physical structure, sanitation equipment and roaster equipment.

Scientifically validated roaster as a microbial kill step by a third party process authority firm, and

Certified dry and oil roasting capability, which achieves pasteurization level while maintaining product freshness.

Setton Farms business resumed operation on June 1, after their production process was validated. “Customers are receiving roasted product, or raw product that will be roasted later,” said Gibbons.

Gibbons explained the Setton is reviewing all Good Agricultural Practices (GAPS), and will be communicating with all growers regarding “Best Practices” and to avoid the use of techniques, which could increase field and tree microbial activity.

“Setton will be working proactively with growers to review their operations to ensure GAP compliance with quality and food safety standards,” Gibbons said.

Mia Cohen noted that consumers judge the pistachio industry as a whole; so all processors will need to enhance their own food safety program.

To help maintain the new strict guidelines at Setton Farms, the company has hired Carl Scrucon, as the Quality Assurance Manger. He comes to Setton, after serving many years in other major segments of the food industry.