While an effective pest control plan is crucial in all industries, it is especially important for companies that handle food. For food and beverage processors, ensuring that pest control methods are as up to date and comprehensive as possible is paramount for the safety of staff and customers.

Several new and evolving pest control technologies can help improve the effectiveness of existing pest control plans and strategies by providing real-time data on hot spots and trends, reducing invasive treatments, and improving targeted pest management for treatment and removal. These technologies can help support an existing integrated pest management (IPM) plan to support your facility.

New and Evolving Pest Control Technologies

Part of forming a comprehensive pest control strategy is to regularly implement new and evolving technologies at your facility that continuously improve your existing pest control plan. In recent years, several technologies have emerged that can help improve the effectiveness of pest control, as well as the safety of food processing facilities and the goods they produce.

• Remote rodent monitoring: This involves the use of wireless sensor networks to collect data on pest activity. These sensors can be strategically placed in key areas to monitor temperature, humidity and other environmental factors that influence pest behavior. By collecting this data, pest control providers can focus on prevention by better predicting and analyzing pest behavior to find the root cause of the pest issue.
• LED insect light traps (ILTs): These traps are designed to emit light in specific spectra that are attractive to target pests while minimizing attraction to non-target species. This makes them more efficient and environmentally responsible compared with traditional insect light traps. LED ILTs consume less energy than conventional fluorescent lamps, reducing operational costs. They also have a longer lifespan, reducing the frequency of bulb replacements.
• Advanced application equipment: Improvements in the equipment used to apply chemical treatments include changing power sources from gasoline engines and direct electric power to battery-driven devices. This reduces environmental impact and allows for better control over the output of products, making a more effective application service.
• Insect monitoring and counting technologies: Many manufacturers are in the development stages of producing ILT devices that can count the number of insects captured and use artificial intelligence (AI) to identify types of insects captured. This technology will provide more accurate analysis of pest activity trending around your facility.
• Redesigning rodent management: Legislative changes in some parts of the United States are driving a change to managing rodent populations. Moving away from dependence on traditional rodenticides and using carbon dioxide or carbon monoxide instead to help reduce populations in burrow systems is becoming more common.

These new pest control technologies can help protect your food processing facility by maximizing preventive tactics to help minimize pest issues.

Integrated Pest Management

Now that you understand some of the newest technological advancements in pest control, it’s important to establish how these can fit into the overall pest control strategy. Integrated pest management (IPM) programs employ a comprehensive and sustainable approach that combines proactive pest prevention, regular monitoring, and targeted interventions to minimize the use of chemical treatments and help effectively manage pest populations in your facility. In an all-inclusive, ongoing, proactive cycle focused on prevention for your facility, providers will implement the most effective customized pest control measures to benefit the needs of the facility. Providers then continue to monitor the program’s effectiveness and perform check-ins as needed to ensure the facility is cared for.

With a focus on innovation and prevention, IPM is one of the most promising ways to bring in new technologies regularly and intentionally. A successful IPM program:

• Is environmentally responsible and intentional in its measures;
• Involves the entire staff in the operation through group training and instruction;
• Keeps detailed records of all pest activity and pest control operations;
• Educates and partners with facility managers to understand the business operations comprehensively;
• Addresses pest hot spots inside and outside the facility; and
• Inspects the property and focuses on exclusion techniques that help keep pests out of the building.

For optimal partnership with your pest control provider, always provide documentation of pest sightings and spotting trends in your facility. Implementing a process for staff to report any signs of pest activity can help keep employees aware. Always maintain open lines of communication with your pest control provider and communicate the importance of preventive measures internally.

Navigating pest control in your food processing facility requires looking toward the future and investing in new and innovative pest control technology to help develop the best possible protection and treatment plan for your facility. By fostering an environment of collaboration and forward thinking, you can help safeguard your facility, which in turn protects your customers and employees, preserves your business’s reputation, and helps you deliver the best possible product.

Meek is a technical services manager for Rollins, a pest-control company. He is a board-certified entomologist and a 35-year industry veteran in the field of pest management. Reach him at FMeek@rollins.com.

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Many parts of the United States are in for a blistery cold winter season this year, which brings new challenges for pest management in food processing facilities. One of the most notable challenges these facilities face is increased pressure from rodents who seek out food and shelter in extreme weather. These issues are amplified by erratic weather and extreme snow, to which many areas have become accustomed. A rodent infestation could shut down a food processing facility and lead to a loss of product and profit. Additionally, these pests can transmit diseases to employees.

Rodent infestations are extremely dangerous to the health and safety of employees who work in the facilities, as these pests can transmit Salmonella, which can also contaminate food manufactured in the facility. In fact, rodents are known to contaminate or consume about 20% of the world’s food supply.

To prevent infestations, it’s very important for facility managers and their employees to have some baseline knowledge of the different rodent species they could be facing. The most frequent invaders found in the U.S. are deer mice, house mice, Norway rats, and roof rats.

• House mice. These are the most commonly encountered rodent in the U.S. and, despite their name, they are the most common invader of commercial facilities. They usually nest in dark, secluded areas such as storage rooms and basements. These pests can cause serious property damage by chewing through drywall and wires, which can then spark electrical fires. House mice also pose a significant threat to food processing facilities, contaminating food products and spreading disease. House mice have been implicated in the spread of Salmonella through their feces.
• Deer mice. These mice typically live in rural, outdoor areas and are less common in urban areas; however, this does not reduce the risk they pose to food processing facilities located in more rural settings. They will often prepare their nests in old fence posts, tree hollows and log piles but will also seek shelter in commercial buildings, storage areas or vehicles. Deer mice present serious medical concerns as they can be carriers of hantavirus, a characteristically influenza-like illness which can be accompanied by kidney, blood, or respiratory ailments and is potentially fatal.
• Norway rats. Similar to house mice, Norway rats often nest in basements, in piles of debris, and in other undisturbed areas and materials. They especially like burrowing into soil underneath sidewalks, slabs, or low-growing shrubs. Norway rats have a propensity to gnaw through almost everything, including plastic and lead pipes, which can damage food processing machinery and spark dangerous electrical fires. Norway rats are also carriers of serious diseases including rat-bite fever, leptospirosis, trichinosis, and salmonellosis.
• Roof rats. Named for their tendency to find shelter in the upper parts of buildings, roof rats not only damage materials by gnawing through them, but they also contaminate stored food and serve as vectors of dangerous diseases. Roof rats are willing to eat practically anything available to them; however, their preference to feed on seeds, nuts, fruits, and berries which may draw them to food processing facilities. Roof rats secured their place in history by spreading the highly dangerous bubonic plague. Though transmission is rare today, there are still a handful of cases in the U.S. each year.

Signs of an Infestation

To keep their facilities safe, food processing facility managers need to regularly inspect the building and machinery for signs of an infestation. Here are the top signs of a rodent infestation facility managers should keep an eye out for:

• Droppings: Mouse or rat droppings found around the facility are some of the most common signs of rodent infestation. These pellets are often left behind in places where food is stored, as well as under sinks, inside chewed cardboard boxes, along baseboards, and on top of wall beams.
• Gnaw marks: Rodents can cause serious property damage by chewing through almost any type of material—including plastic and lead pipes—to obtain food or water. House mice and Norway rats are also known to gnaw on wires behind walls, sometimes causing fires.
• Nests: Rodents prefer to nest in dark, secluded areas where there is little chance of disturbance. House mice, specifically, like to build their nests out of shredded paper products, cotton, packing materials, wall insulation, and fabrics. If facility managers find these materials scattered around guest rooms or common areas, it might be a sign that rodents are nearby. Norway rats typically nest in underground burrows, often near building foundations, while roof rats may nest in ceilings or attics.
• Tracks or rub marks: Rats tend to leave dark grease or dirt marks along walls and floorboards as they follow a trail through the building between their nest and food sources. Facility managers should keep an eye out for these rub marks, which are caused by the rat’s oily fur.
• Strange noises: Getting complaints that employees are hearing strange noises in the walls? Chances are these sounds can be attributed to rodents scurrying about the facility, between the walls and up in attics. Rodents are especially fond of storage spaces because they prefer dark, secluded spots.
• An actual rodent: Mice can breed rapidly, so if a facility manager or a customer spot one mouse in the building, it’s likely there are others playing hide and seek. In fact, a female house mouse can give birth to a half dozen babies every three weeks, producing up to 35 young per year.

Rodent Prevention

Food processing facilities are likely required to work with a licensed pest control company for ongoing pest inspections, routine maintenance visits, and treatments as needed. Working with a qualified pest control company is essential to ensuring your food processing facility remains pest-free. Your pest control partner will work with you to implement an integrated pest management (IPM) plan. An IPM plan is a comprehensive pest control method that that focuses on three basic techniques: inspection, identification, and treatment by a pest control professional. This method will help to ensure that pests are properly controlled and deterred as well as to ensure that your facility is clean and compliant.

In addition to working regularly with your pest control partner, facility managers should implement these prevention tips to avoid unwanted rodent run-ins:

• Trim back trees and foliage close to the foundation;
• Seal any cracks or holes on the outside of the building;
• Repair any broken vent covers, loose siding, or shingles;
• Keep storage areas clean and organized to eliminate any potential nesting grounds;
• Properly ventilate storage areas and machinery to prevent moisture buildup that can attract pests;
• Keep food products sealed and stored properly in air-tight containers;
• Clean high-volume areas often, including employee break rooms, bathrooms, and lobby areas where crumbs and trash accumulate daily; and
• Dispose of garbage regularly and store in sealed receptacles placed at a distance from building entrances.

Rodents will be a continued threat to food processing facilities, but facility managers can ensure they’re prepared through proper education, prevention, and—most importantly—a partnership with a reliable pest control professional.

Dr. Fredericks is senior vice president of public affairs for the National Pest Management Association. Reach him at jfredericks@pestworld.org.

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Warm temperatures spur an uptick in pest activity, making the spring and summer months peak seasons for pest threats. The abundance of food, water, humidity, and places to hide in food processing facilities make them the ideal sanctuary for pest populations, which means it’s imperative that proper pest control be a top priority for food processing facility managers.

Threats to Pest Control

Understanding the pests that frequently invade food processing facilities and the threats they pose can help facility managers identify and address any issues that may arise before an infestation has a chance to take hold. Food processing facilities present the perfect conditions for various pests, including rodents, flies, cockroaches, and stored product pests, such as Indian meal moths and merchant grain beetles to thrive thanks to an abundance of food, shelter, and moisture. In the spring and summer, food processing facility structures are also susceptible to termites.

These pests can cause serious issues for food processors because they contaminate food with their droppings and are known to spread many diseases to humans, including E. coli and Salmonella. Rodents are also known for chewing through wiring, which can result in electrical fires and damage to essential machinery. While pantry pests do not transmit disease, they can still infest ingredients, resulting in the contamination of food products made in these facilities. The main threat posed by termites is their ability to cause extensive property damage. They cause $5 billion in property damage in the United States each year, which can be extremely costly to your business.

Pest Prevention

The most important step managers can take to ensure their facility is protected from pest threats is partnering with a licensed pest control company to perform regular inspections and implement an integrated pest management (IPM) plan. IPM is a holistic and customized approach to pest control that comprises three steps: inspection, identification, and treatment to help ensure that commercial facilities are clean, compliant, and pest free. By enlisting the help of a professional, you can rest assured, knowing your facility is well protected from pests year-round, allowing you to instead focus your time on delivering quality products safely and efficiently.

In addition to recommending that mangers partner with a professional, the National Pest Management Association recommends that they add the following steps to their maintenance checklists to protect their facilities from pests:

• Ensure employee kitchens and eating areas are clean by wiping down countertops and sweeping floors to remove crumbs and residue from spills;
• Vacuum and clean all areas regularly, including offices, hallways, lobbies, and public bathrooms;
• Routinely check under sinks and machinery for areas of moisture, and repair any leaky pipes or clogged drains;
• Store all food products in sealed containers, and organize empty boxes to prevent harborage areas;
• Keep trash in sealed containers inside the building and remove from the facility regularly. Ensure dumpsters are far away from any building entry points;
• Inspect the exterior of the building to ensure there are no entry points; pay close attention to areas where pipes and utilities enter the building, and seal any gaps or cracks in the foundation;
• Install door sweeps on exterior doors to seal the gap between the floor and the door where pests can enter;
• Remove debris from gutters and direct water away from the building through properly functioning downspouts, gutters, and splash blocks; and
• Ensure that grounds surrounding the facility are properly maintained, because overgrown vegetation can attract pests to the property.

The spring and summer seasons are exciting times of year that can quickly be ruined by a pest infestation. Help keep your employees and products safe this season and year-round by following these tips and working with a trained pest professional.

Mannes is senior vice president of public affairs for the National Pest Management Association (NPMA).

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Food processing facility managers know the importance of product quality and run a tight ship to meet regulatory requirements, while delivering goods on time and without issues. Third-party food safety audits help ensure that operators are practicing food safety measures, and proper preparation for these visits, whether they occur in person or are held remotely, is essential to your success.

While the COVID-19 pandemic has required changes to the way audits are conducted in food processing facilities, third-party audits remain a priority to ensure that food safety standards are upheld. Unfortunately, understaffing and limitations to interior pest control service may have provided the perfect conditions for pests to enter and multiply in facilities, unnoticed. Whether your facility has continued to participate in audits as usual, has adjusted to a hybrid version, or has paused in-person audits during the pandemic, remaining prepared is crucial. Operating a food processing facility is a demanding job already, and the last thing you want to do is fail an audit due to preventable pest issues.

A poor audit score—or worse, a failed audit—could have damaging effects on your business, ranging from tarnished reputations to canceled orders and lost profits. With the pest control portion of your audit accounting for up to 20% of your final score, it’s important to have a reliable pest control provider who understands your business and your industry’s requirements for food safety and pest control. Additionally, your provider needs to be aware of the various audit schemes that in are use and what their specific, individual requirements are.

Your Pest Control Program

Because food processing facilities provide ample resources needed for survival—shelter, water, ideal temperatures and food—they will always be prone to pests. Although operators in these facilities have strict sanitation and safety measures in place, pests such as cockroaches, rodents, and stored product pests can still disrupt operations.

An integrated pest management (IPM) program, which focuses on preventive techniques rather than reactive treatment for pests, is one of the best ways to make sure your facility is prepared. Partnering with your pest control provider to assess your facility’s pest pressures and maintaining a proper sanitation and cleaning schedule are key steps to a successful IPM program.

Maintaining proper documentation is also necessary to ensure IPM success, as well as an essential part of the pest control portion of your food safety audit. Keeping documentation updated is important because, even with a pest-free facility, you could still lose points on an audit due to insufficient or poor documentation.

Your auditor doesn’t just want to see pest monitoring devices and a pest-free facility. They want to see an ongoing commitment to upholding food safety measures. The following documents can help demonstrate that commitment.

• IPM plan: This documentation includes your written IPM program, pest management food safety rules, and your risk assessment. Make sure these documents are kept updated (at least annually), and address any recent changes to your IPM program or facility.
• Pest sighting log: Facility managers and staff should have this available and updated at all times. Entries should include the date of the sighting, type of pest, location, and the actions taken to prevent future occurrences.
• Service documentation: These are reports of your pest control provider’s visits and will provide the auditor with more details about any pest findings, pest pressures specific to the facility, and whether any corrective measures taken by your facility were successful.
• Pesticide documentation: While the use of pesticides in food processing facilities is often limited, your pest control provider should keep a record of any pesticides used, along with labels for the products and safety data sheets. These will show your auditor that you’re maintaining a safe and environmentally friendly facility.

Be Prepared

Now that you know what information is needed for your food safety audit, be sure you stay prepared. Audits can be unannounced, so staying ready will help prevent any unpleasant surprises. The goal is to be ready every day for an audit.

To make sure you’re prepared for an audit:

• Communicate with your pest control provider on an ongoing basis throughout your partnership. While they are the expert when it comes to pests, you know your facility better than anyone. Taking a proactive role in the partnership will help prevent pest issues in the long run.
• Involve your entire staff in the IPM plan; they know the most about your facility and may spot pests or other issues before you do.
• Conduct annual assessments, regular inspections, and risk assessments with your pest control provider to ensure your IPM plan remains effective and proper.
• Make sure you’re aware of any changes to your pest control service, and be sure to document them. The pandemic altered the way many facilities were able to work with their pest control providers, so document any changes prior to your audit.
• Don’t wait until the last minute to get your documentation in order, because it takes time to compile the information. Your pest control provider should have hard copies of all the essential reports and paperwork, but keeping them digitally is also a good idea. Most pest control providers have digital systems for documentation that even provide trend reports and analysis your auditor will appreciate. It’s also easier to share documentation digitally when there are so many required items.
• Your pest control provider should have proof of their training available for your records as well.

In this time of heightened public health concern, food safety audits shouldn’t be ignored in an effort to keep the supply chain moving at all costs. Even if your audit is conducted virtually due to social distancing requirements, your documentation still will be required. Working with the right pest control provider for your business and being a proactive partner will help ensure that your next food safety audit is a success.

Meek is a technical services manager for Rollins and a board-certified entomologist with 30 years in the field of pest management. Reach him at fmeek@rollins.com, or visit www.orkincommerical.com for more information.

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Choosing the right pest management provider for a food manufacturing or processing plant is a necessity, because the presence of pests can be costly. Neglecting to contract with a trusted provider who can meet the needs of your company can affect your operations, reputation, and bottom line. A major pest problem, whether it is from a gap in preventive care or an inability to handle a situation that unexpectedly arises, can create numerous challenges. In some cases, your company could be responsible for expensive product recalls or other regulatory action.

With such stakes on the line, companies need knowledgable and trusted pest management providers. Identifying whether a pest control provider fits the needs of your facility, however, can be a challenge in itself. With so many options to choose from, it can be daunting to choose the most qualified provider for the job. Needless to say, when you set out to find the best pest control fit for your company, it is easy to become overwhelemed.

As you balance myriad responsibilities at your company, the last thing you should have to worry about is whether the pest management provider you hired is doing its job. Rather than wait to endure the potential consquences of a less-than-ideal partnership, consider orienting your decision process around the key qualities of a good pest management provider.

A good pest management provider should be able to offer you a comprehensive integrated pest management (IPM) program with preventive measures that can reduce the risk of a pest problem, but their program should not stop there. The right provider should produce a plan that meets all applicable audit standards, as well as your other specific company needs.

To better understand what to look for in your potential pest management provider, consider using these five key criteria as decision-making guidelines:

1. Extensive Food Industry Experience

The food manufacturing and processing industry is an incredibly specialized area of service, and the work is completely different than that of industries such as restaurants or multi-family services. When choosing a provider, note that their expertise may not transfer across these industries, because the food manufacturing and processing industry has distinct and stringent protocols. Your provider should be well-versed in the food processing industry, including safety regulations, audit compliance, regulatory compliance, and more. This expertise can help mitigate the likelihood of costly mistakes that could stem from being less familiar with the industry’s needs. Each niche of service proposes its own tasks and struggles, and hiring someone who either specializes in or has experience in food processing can directly influence the effectiveness of the pest management in your facility down the line.

2. Technical Knowledge

Your pest management provider should serve as your go-to source for up-to-date information. From rules and regulations to the latest technology, your provider should be a wealth of knowledge, not only for your organization, but for the food processing and manufacturing industry as a whole. In fact, to utilize the best pest control practices for the food processing and manufacturing industry, they should follow industry updates. For a strong partnership, your provider should be able to communicate these ideas and updates to you and your employees. Your provider should also be readily available to answer questions and offer any other helpful insights related to pest prevention. Your provider’s ability to share this knowledge and make it more accessible will further reinforce your IPM efforts. This mutual understanding and guidance, in all cases, will greatly bolster the preventative steps your facility takes.

3. Geographic Coverage and Consistent Service

Consider the location of your facility when choosing a provider, because different providers treat different regions. With each region come different pests due to variances in landscape and climate. Should your company operate in multiple locations, as many food manufacturing and processing companies do, be sure to research whether your potential provider typically covers the scope of your locations. This will ensure that your provider knows the pest risks associated with the area and can addresses each location’s needs. In fact, it is best to make sure potential providers have the ability to service all of your locations. By utilizing the same provider across locations, you can simplify operations at all of your facilities and always know exactly who to call when you have a question or need support. The result will be a timely response, which is necessary if a crisis arises. Continuity and rapid response can make a noticeable difference when it comes to pest management.

4. Applicable Credentials

In the same way your company needs proper certifications and licenses to operate in the food processing and manufacturing industry, pest control providers need proper credentials. These will vary depending on a person’s role, but the correct credentials from everyone involved are crucial. From the technician who services your facility to the inspector who reviews the effectiveness of your IPM, each acting member from your pest management provider needs to be appropriately trained to complete their job effectively. Higher levels of management in pest control should hold certifications and, when applicable, additional certificates and degrees. Technicians and field workers should also hold appropriate certifications and should have completed the proper training. All providers must be certified and licensed by their state’s appropriate regulatory agency. You should ask your provider whether or not their licences are up to date.

5. Reporting and Trending

As the customer, you should be able to follow your site’s pest management status at a glance whenever needed. This includes knowing when your provider last serviced your facility and what they accomplished during their visit. With access to these updates, you can have confidence in your provider, knowing there is an added layer of accountability. A reputable provider understands that readily accessible reports help to provide transparency, both strengthening your partnership and helping you monitor the status of your facility. This can prove crucial for your company in the event of an audit as well. During an audit, your providers must be able to offer detailed reporting to you for documentation purposes. Any pest management company that does not offer reports and access to your records and status when you request them should raise a red flag.

As a decision maker in charge of selecting your company’s pest management provider, you have a great responsibility, and the choice you make could be crucial for the long-term success of your operations. From audit compliance to reputation to your company’s bottom line, who you choose as a provider can affect your business positively or negatively for years to come.

Knowing what key factors to look for when choosing a provider can help narrow down your options to the one that meets all of the needs of your company. Utilizing these five tips as a roadmap and researching your options as you determine which companies could serve as your pest management provider will help simplify your decision and set you on the path to success.

Dobesh is a director of technical services at IFC. She has spent the last 16 years as an extension specialist at Kansas State University, and she holds an MS in entomology and a BS in crop protection-entomology. Reach her at sdobesh@indfumco.com.

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The one phrase you’ll never hear an experienced pest management professional utter is, “Now, I’ve seen it all.” Nothing can be further from the truth when it comes to eliminating pests from food processing, storage, and distribution facilities.

Why is that phrase so far-fetched? It’s simple: pests. Rodents, cockroaches, flies, and stored product pests are animals and their behavior can be unpredictable. When you add the human element to the mix, you need to be prepared for anything when it comes to pests.

An experienced pest management technician will see evidence of pests in areas of a food processing facility that no one ever thought possible, or uncover structural, cultural, or sanitary conditions that no one would think could contribute to a pest infestation.

The bottom line is that, when it comes to designing, implementing, and measuring the effectiveness of a pest management program, nothing is off the table. Anything is possible, so expect the unexpected.

Be Awake to All Possibilities

It may sound like a daunting task to prepare your facility for every possible pest, and the reality is, that it isn’t possible. No QA manager, plant sanitarian, or facility manager can think of everything when it comes to pests.

That’s why developing strong partnerships with your pest management service provider and outside vendors (e.g., cleaning crews, transportation companies, etc.) is essential to safeguarding your facility, products, employees, and customers from pests and the harmful bacteria they can transfer to food products.

A collaborative and proactive approach to establishing consistent cleaning, sanitation, inventory management, product and ingredient inspection, and maintenance protocols is the first step toward effective pest management. Learning from experiences, both good and bad, when it comes to pest prevention and management is a critical part of the process. With these protocols in place, the chances of coming across an unwelcomed pest surprise are mitigated, but never eliminated.

Here is a collection of real-world tales that illustrate the point that effective pest management involves expecting the unexpected, being proactive and innovative, and leveraging all your intellectual and technical assets to arrive at a solution.

Tale No. 1: Digging Deep to Solve a Phorid Fly Infestation

A technician was having a problem getting an intense phorid fly infestation under control at a new food plant. The problem had been going on for a few months and the client was getting impatient.

The technician and technical staff met with the plant’s management team to explain the biology of the species and point out that the flies are usually associated with compromised drains, but management did not want to listen. They wanted a bioremediation treatment performed, pesticide injections in the drains, and weekly fogging treatments to eliminate the flies.
Even though it was explained that these approaches would only provide short-term relief, the technician did what was asked. The plant’s maintenance staff even filled the facility’s hollow block walls with foam and called another pest control company to drill into the slab floor and perform a termite treatment, both of which did not solve the problem.

The client finally followed the original recommendation and had the drains scoped by a plumber. It was discovered that the drainpipes were not connected, and water was accumulating underneath the building slab, providing ideal conditions for a fly infestation.

The Takeaway: When it comes to pests and drains, have a plumber scope the drains to see what’s really going on down there. Yes, drain repairs can be costly, but what’s the price of a product recall or a failed audit? If the client had followed the initial recommendation, the problem would have been solved much faster and at a lower cost.

Tale No. 2: That Sucks—Fungus Gnats in a Food Plant

A production factory was experiencing an intense fungus gnat infestation in its employee break room. The infestation was so severe that it started to migrate to the plant’s production area where it potentially could contaminate product.

A technician conducted a thorough inspection of the facility. Since he understood the behavior and biology of the fungus gnat, he took the time to look at the air intake on the plant’s roof. Sure enough, the filter was so full it was collapsing, allowing small flies to be sucked into the building.

Adding to the misery, it was the dead of summer and there was extensive security lighting on the exterior of the building. These lights, which were located above the entrance and loading dock doors, shined brightly and attracted small flies to the building.

The Takeaway: Staying on top of basic maintenance practices is a critical element in any pest management program. If your maintenance crew has too much on their plate, consider outsourcing certain tasks; it’s worth the investment. Additionally, when conducting an inspection, make sure it covers all areas, from the roof to the basement. When it comes to building lighting, switch to low sodium vapor bulbs and determine which lights must be on for safety and security. Consider putting lights on poles in the parking lot and shining them on the building to draw pests away from the building while still meeting security needs.

Tale No. 3: A Fly in the Soup—Cheese Soup

A large manufacturer was experiencing a drain fly problem, something it had never faced before. After several weeks, the problem intensified and, during a follow-up inspection, the primary culprit was identified: a missing p-trap on a drain.

The drain was in an area on the production floor that was very difficult to access. There was large machinery in the way and the area was very warm and wet from the constant use of water in production. The missing p-trap was lying on the gravel under the slab and water was falling freely to the ground.

Repairing the drain was a challenge, as the floor in the older plant needed to be jacked up to safely allow workers to get underneath to perform the work. In the interim, a bioremediation treatment was performed to knock down the fly infestation. It took several weeks from initial identification until the pipe was fixed.

An interesting aside to this situation is that a few days following the inspection, the city’s wastewater department called and said gravel was showing up in their facility about a mile away from the plant. So much water was being put down the broken drain that it was washing gravel all the way to the wastewater building!

The Takeaway: Drains must be cleaned on a consistent basis and on a specific schedule. If that had been done in this case, the broken drain would have been noticed sooner and a solution would have been reached more quickly. The type of food you are producing should dictate the frequency for drain cleaning. For example, dairy and beverage facilities are at the highest risk as they use a lot of water in production. For that type of product, monthly drain cleanings are recommended.

Tale No. 4: Don’t Get Snake Bitten

An employee at a food processing plant kept pet snakes in his office (a non-production area). One day he put too many feeder mice into the snake’s aquarium enclosure and needed to remove some.

To safely remove the mice, one of the plant’s multi-catch rodent devices was placed into the enclosure. The trap caught several of the mice, but instead of keeping them for a future feeding he put the trap—with the mice in it—back where he found it inside the plant.

You can probably imagine the technician’s surprise when he opened the trap while performing the next scheduled service and found four dead white mice in the trap. The employee shared his mistake and the technician explained the importance of not keeping any pet animals in a food plant.

The Takeaway: Just when you think you’ve “seen it all,” a story like this comes along. While not a typical example of pests in a food plant, it illustrates the need to be prepared for any possibility. What if an auditor had discovered the mice first? It wouldn’t have mattered that they were feeder mice instead of a sign of an infestation. It would have led to a failed audit and a real headache for the plant.

McCoy is director of quality and technical training for Wil-Kil Pest Control in Menomonee Falls, Wisc. Reach him at smccoy@wil-kil.com. Wil-Kil is a member of Copesan Services, a national network of pest management professionals specializing in commercial pest control and food safety services.

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Many of you probably heard the old joke: “What’s worse than finding a worm in your apple?” The answer: “Half a worm”—implying you’ve ingested the other half of the critter.

As a culture, Americans are quite squeamish when it comes to insects, especially spiders, roaches, and earwigs. (Older people might remember the earwig story in Rod Serling’s “Night Gallery” television show.) And most people certainly don’t want bugs in their foods, although I wager many of you found something in your food over the course of your life—say, a grasshopper in canned green beans. It’s unsavory and unappetizing, but at least the insect is now commercially sterile.

Bugs: It’s what’s for dinner.

This is one reason why food processors are so conscientious when it comes to pest management. They want to keep flying and crawling insects out of their food plants and out of their food. What’s ironic is there’s currently a movement to incorporate insects into our diets—including crickets, mealworms, and others. Will a processor who is making mealworm powder need a pest management program? Will it be an issue if a few crickets end up with the mealworm powder? We shall see as this new industry and trend grows.

But how did this transpire? Why are we looking at bugs as a food ingredient? The answer is the environmental movement. It takes a great deal of food and water to fatten up a cow or hog for slaughter, whereas bugs grow quickly and rapidly produce biomass that’s high in protein. But really, how many people want foods made from insects? Most non-vegetarians would rather opt for a beef burger than a bug burger.

I’ve had the opportunity to travel throughout the world, sharing foods with people in many different places. And I must admit that some of what I have been served included insects—yes, bugs were on the menu. I was served deep-fried cicadas and deep-fried scorpions in Asia. The cicadas were nice and crunchy, however, once was enough for the scorpions. Scorpions are full of formic acid, which dominated the taste.

My sense is it will be quite a while before insects make a dent in the market, although, there have been some tongue-in-cheek advertisements about insects in our food. One of the major breweries ran an ad years ago featuring a table of appetizers at a party that included a dip located under an insect electrocuter…the party-goers really liked the crispy things in the dip.

Richard Stier
Co-Industry Editor

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A common catchphrase in pest management is, “If it’s not documented, it didn’t happen.” This is true of the steps a pest management technician takes while serving a facility, but it’s also true of the steps QA or plant managers must take to plan and implement good sanitation protocols.

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Picture this: A dad hands his daughter a box of morning cereal, which she rips opens in excitement. While grabbing the toy out of the box, she drops it and screams, spilling cereal all over the floor—there are bugs in the cereal!

It’s easy to see how pest problems in a food processing facility can turn into a big problem. Pests can directly hurt your bottom line by contaminating products or equipment, causing you to either throw out and/or replace costly shipments. If products make it all the way to the consumer with pests, it could have a devastating impact on your brand, especially with today’s social media connectedness.

Food safety plan. The food safety plan is the most important piece of documentation. Because this is a larger, overarching document, focus on the pest management portion and what can be done to update and improve it for now. While a food safety plan should cover all aspects of the facility and products, for pest management specifically the plan should include details about all activities done to proactively ensure products are protected from pests. Make sure to incorporate all potential hazards, preventive controls, and corrective actions implemented to reduce risk. It’s also important to include monitoring and verification procedures. If possible, include information about suppliers and their programs. A crucial part of ensuring pest issues are traceable is to show that incoming and outgoing shipments are being inspected, as this will help catch pest issues before they get further down the supply chain.

List of service changes. Every IPM program needs to adapt and change as pest pressure does. No two facilities are the same, and pest pressure can shift from year to year depending on a variety of external factors, like nearby construction driving rodents from their homes. Anytime changes are made to the program, note how and why the changes have been made. At a minimum, review the plan at least once per year.

Annual assessments will help uncover recurring problem areas and hot spots around the facility to better address concerns.

Monitoring devices/traps. The best food safety plans include a map noting monitoring equipment, traps, and any other devices used in and around the facility to minimize pest populations. For each device, record the locations and activity levels. The trend report from the collected data will give insight as to what issues need to be addressed immediately, helping to make management decisions. Pest management professionals should note activity each time they come out, and many already have systems in place that can pull together trend reports. Including this information will show any inquisitive auditor you mean business when it comes to proactive food safety.

Annual assessments. Review your IPM program and how it relates to the food safety plan every year. Specifically, look at the facility’s pest problems and talk through how to resolve and prevent them with a pest management provider. These annual assessments will help uncover recurring problem areas and hot spots around the facility, allowing you to better target the plan to address those concerns. Also, auditors will be looking for these yearly assessments.

Sighting reports. Pests and evidence of pests spotted within the facility should be recorded in a logbook. Typically referred to as a “pest sighting log,” this will help a pest management professional refine their investigation and better target the areas most plagued. The report should include information about the location of the pest problem within the facility, who found it, and the number of pests spotted. Capturing the pest is ideal, but it’s not always feasible to do so. In that case, photo evidence helps with identification, so obtain a close-up picture of the pest(s) if possible. Usually, employees will be the first to see pest problems, so make sure they know what to do when it happens!

It takes team effort to have a traceable, proactive IPM program. Typically, it’s recommended that employees keep an eye out for pests in areas most relevant to their job title and where they work. Don’t make it too difficult for employees to complete assigned inspections or else they won’t do it.

These documents can help trace when and where pest issues began so businesses can work on a customized solution to resolve problems. Openly sharing news about documented pest issues with supply chain partners can prevent pests from sneaking into shipments and contaminating product.

Making It Work

To make this all work in reality, first, hold a training session in partnership with the pest management professional and get as many employees there as possible. Discuss the most common pests around the facility and where they’re most likely to be found. Then, arm employees with an action plan they should use when a sighting does occur. Everything should be recorded in the logbook, which will help ensure issues are resolved quickly. Make sure employees know where to find it, and consider having a few logbooks at different, convenient locations around the facility.

Next, give some basic assignments to employees. For example, the forklift operator in charge of moving products into a warehouse could keep an eye out for stored product pests. Meanwhile, the employees working around the assembly line could be tasked with inspecting and wiping down equipment at the end of each day, which will help minimize attractants.

There are a lot of ways to diversify roles and make sure employees keep an eye out for pests. If unsure about how to go about this, talk to the pest management professional. For starters, employees need to know the signs of pests.

Stored product pests. Although there are many different species of stored product pests that can affect a food processing facility, all are adept at thriving in and around products undetected. The Indian meal moth, for example, has small, cream-colored larvae that will eat just about anything. Tiny and right at home in product packaging, these pests will wreck a batch of products and then move on to the next. Pheromone traps can help with detection, so make sure employees know what they are and why they are there.

Rodents. Rats and mice can carry disease-causing pathogens, which can rub off onto any surface the rodent comes into contact with. Both rats and mice are capable of fitting through tiny gaps (mice can fit through a hole the size of a dime, while rats can fit through a hole the size of a quarter), so any gaps on the exterior of a building serve as a doorway. If rodents are suspected but haven’t yet been spotted, look for droppings and yellowish-brown grease marks around corners and along baseboards. Search for gnaw marks around gaps and openings in walls and on products too. Remember, rodents want to be out of sight. That’s why they skitter along walls and stay away from humans as much as possible.

Cockroaches. One of the most resilient and persistent pests around, cockroaches can get through miniscule gaps and will feed on just about anything, quickly becoming a terror for food processing facilities. If they’re not promptly removed, cockroaches can reproduce rapidly. A few cockroaches can create an infestation in a matter of months, especially with an abundant food supply. If a cockroach is seen during the day, it’s a good sign it’s time to act quickly. Cockroaches are most active at night, so spotting one during the day likely means others are lurking behind the scenes.

To obtain this trend data and see the hot spots around a facility, monitoring devices are likely necessary. Whether using pheromone traps to reduce stored product pest populations, bait stations to trap rodents, or fly lights to capture flying pests, these tools identify what types of pests and how many are lurking behind the scenes.

Pests are resilient and persistent. They’ll do whatever it takes to get to the food, water, and shelter needed to survive.

Pest pressure doesn’t just disappear overnight. Consistent improvement and effort are necessary to reduce it. But keeping track of pest population trends around the facility can help you and your pest management professional keep a pulse on the pests plaguing your business.

If your facility is affected by pests and you haven’t implemented proactive, traceable policies, you’re going to have a tough time finding and removing pests. Protect your brand from negative publicity and your facility from costly shutdowns by keeping tabs on the pest populations and then do everything you can to keep them out.

The best time to implement a proactive approach to food safety was yesterday. The second-best time is now.

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Hartzer, a technical services manager for Orkin LLC, is a board-certified entomologist and provides technical support and guidance across all Rollins brands in the areas of operations, marketing, and training. Reach her at mhartzer@rollins.com.

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From production to processing, distribution to preparation, each step of the food production chain presents a unique set of food safety challenges. One challenge, however, is universal across all facets of the food industry—pest control. Technologies may advance, supply chains shrink, and food trends evolve, but the pest control battle wages on, with rodents often leading the charge for the opposition.

Rodents eat or contaminate at least 20 percent of the world’s food each year. Their ability to contaminate on such a large scale is due in part to their “nibbling” habits, wherein they come into contact with far more than they actually consume. In addition, in just one year a rat can shed more than half a million body hairs, and a mouse can produce up to 18,000 fecal droppings. In that same year, a pair of rats can produce over 1,200 descendants. Within three years, that can grow to half a billion descendants! Rodents have been linked to asthma and transport fleas, lice, and ticks. The CDC also points out that they carry diseases including rat bite fever, hantavirus, leptospirosis, salmonellosis, murine typhus, and even the bubonic plague.

These are just a few of the disturbing statistics that highlight the importance of preventing infestations before they occur. Once rodents are inside, it is already too late. USDA Sanitation Performance Standards require that “establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.”

The use of chemical rodenticides in the food industry is impractical, ineffective, and often highly dangerous. Exclusion—the method of creating physical barriers against rodents and pests to prevent them from entering a building in the first place—is preferred among industry professionals as the safest and most effective pest management strategy available. Fundamentally, it involves the elimination of cracks, crevices, and other spaces that allow rodents to gain entry. The CDC lists “sealing up holes inside and outside the home to prevent entry by rodents” as its number one suggestion in preventing rodent infestations. The New York City Department of Health and Mental Hygiene recommends “sealing all cracks, crevices, and holes in walls, cabinets, and doors” as its top guideline for controlling conditions that promote pests.

Rodent exclusion is fundamental to food safety. Keep the rodents out—plain and simple. Or is it? These tenacious pests are relentless in their pursuit of food and shelter. A mouse can squeeze through an opening the size of a dime, and a rat through an opening the size of a quarter. Rats have the ability to gnaw through plastic, wood, aluminum, brick, cement, and even lead. They can climb wires and rough surfaces, swim considerable distances and tread water for several days, making them a worthy opponent to say the least. But with a comprehensive exclusion plan and employee diligence, it is entirely possible to keep rodents at bay.

Safeguarding Your Building

Specialized, rodent-proof products, like Xcluder fill fabric, are fundamental to proper exclusion.

Building access points are not difficult for rodents to find. The most obvious, and therefore the most critical to protect, are exterior doors. Without proper exclusion, rodents will literally walk through the door and compromise food safety. Personnel doors, garage doors, and loading dock doors are all at risk. Exterior doors should remain closed whenever possible, and sheet iron flashing should be installed at the base of wooden doors, which are susceptible to rodent gnawing.

The gap beneath exterior doors is a very common access point. Any clearance below the door must be smaller than 1/4 inch. It is a common misperception that standard rubber or bristle door sweeps are sufficient to protect this area. While rubber sweeps may help keep out the elements, they provide little to no protection against rodents. Even the smallest of rodents can gnaw through a bristle or rubber door sweep in the course of a single night. Metal brush seals pose a larger obstacle for rodents, but overtime they dent and deform leaving gaps that rodents can exploit to gain entry.

Specialized, rodent-proof door sweeps are perhaps the single most important exclusion tool available. Xcluder Rodent-Proof Door Sweeps, for example, feature reinforced rubber gaskets lined with Xcluder fill fabric—a blend of stainless steel and poly-fiber that has been tested and proven effective against rodents by USDA/APHIS. The reinforced edge prevents rodents from gnawing on the sides of door sweeps, and the fill fabric’s sharp, coarse fibers cannot be gnawed through by rodents. This type of specialized, rodent-proof product is fundamental to proper exclusion. Rodent-proof seals should be installed on all dock levelers, garage doors, and overhead doors. Vertical side seals are also important for dock doors because rodents will not stop at ground level attacks.

A simple method for testing door frame vulnerability is at night. Turn on the brightest light in the room or warehouse and step outside to see if any light is escaping around the door frame. If light can get out, pests can get in.

Additional rodent entry points that need protection include places where electrical, water, gas, sewer, and HVAC lines enter the building, beneath roofing tiles, and through small cracks in the foundation. The Mallis Handbook of Pest Control offers a practical set of exclusion guidelines for those tasked with protecting a building against rodents. Here are a few examples.

• Ventilator grills and windows should be protected with proper exclusion materials, ensuring any voids or cracks are filled.
• Defective drain pipes provide a transportation pipeline for rodents. A perforated metal cover should be cemented over the drain pipe, and any small openings surrounding the drain where it enters the building should be patched or filled with proven exclusion materials.
• Large sidewalk cracks should be sealed, as these crevices allow rodents to access a restaurant’s foundation and search for entry points. Foundation walls can be protected with barriers of metal, concrete, or brick around and below the foundation.
• Circular rat guards should be placed around all vertical wires and pipes.
• Ensure that cracked or broken roofing tiles are replaced as needed and utilize exclusion material to fill any voids.

The Right Tools for the Job

A comprehensive exclusion plan—one that identifies potential access points with a fine-tooth comb and constantly monitors for changes and weaknesses—is the most effective approach to protecting a building from invading rodents. A diligent plan, however, is only as effective as the barrier products installed. Caulk, mortar, and spray foam are occasionally recommended as exclusion tools. While appealing, given they are inexpensive and easy to install, these products offer little to no protection against rodents. A creature that can gnaw through lead pipes will certainly not be deterred by spray foam. Steel wool is another popular exclusion material. Though stronger than caulk and foam, steel wool faces rusting and decomposition over time and therefore requires regular replacement. Copper mesh, a more expensive solution, is effective against rodents when properly installed. However, this is not an easy task as a tight seal is difficult to secure, and the mesh often becomes loose over time. It is also a softer metal, lacking the sharp texture that discourages rodent gnawing.

Consider specialty exclusion products as a solution. Xcluder fill fabric compresses during installation to “spring back” once in place and creates a permanent seal, and the stainless-steel poly-fiber combination won’t rust or degrade over time. This type of proven, specialty product offers permanent protection against rodents, and the peace-of-mind that goes along with it.

Repellents and sonic devices should not be considered viable pest control solutions. Chemical repellents, designed to discourage rodent presence without harming them, are both unsafe for use in the food industry and ineffective overall. Repellents cannot be used near food products, and though the chemicals may cause rodents some amount of discomfort, the resulting distress is not nearly strong enough to deter them from their pursuit of food and shelter. Sonic devices producing ultrahigh or ultralow frequency sounds to deter rodents have been deemed ineffective by the scientific community.

The Importance of Sanitation for Pest Control

A discussion of exclusion best practices would be incomplete without mentioning the wider tenets of integrated pest management, including monitoring and sanitation. The following suggestions from The Mallis Handbook of Pest Control highlight the critical role of sanitation in the fight against rodents.

• Trash must be disposed in clean, tightly-sealed containers and stored as far from the building as possible. Trash removal should be frequent enough to ensure the containers are not a reliable rodent food source, ideally two or more times per week.
• Standing water attracts rodents, especially rats. Gutters should be free of debris and channel water away from the building. Leaky faucets, pipes, and air-conditioning units should be repaired or replaced. Water should not be left standing in sinks overnight, and storage rooms and basements should be dry and well-ventilated.
• Avoid clutter as much as possible—boxes left on the ground are popular nesting grounds for rodents. Cabinet bases, storage shelving voids, and the tiny space behind appliances are also prime targets.
• Storage areas containing bagged or powdered food should be monitored consistently with stock rotated frequently. Whenever possible, store food products away from the walls to reduce the risk of contamination.
• Store food properly in sealed, rodent-proof containers made of metal or hard plastic. Any spills should be addressed as soon as possible.
• Regularly clean and sanitize appliances, equipment, food contact surfaces, and all floors to eliminate any sources of food for rodents. High volume areas where crumbs and trash are likely to accumulate must be cleaned frequently.
• Train employees to notice and report evidence of pests (e.g. rodent droppings in undisturbed areas), which should be addressed immediately.

The battle against rodents is not easily won. But a thorough, well-supported exclusion plan is the most effective tool in keeping rodents out, and absolutely critical in upholding food safety standards. Seek out pest management professionals who understand and support exclusion methods, and work with them to carefully identify and protect all building weaknesses. Do not underestimate the strength and resilience of these tenacious pests; take every precaution necessary and insist upon specialized, rodent-proof product solutions. Encourage all employees to report signs of rodent activity and remember that constant upkeep and monitoring are critical to long-term protection against rodents.

McFadden, the director of research and marketing for Xcluder Pest Control Products, has been serving the commercial and residential pest exclusion industry for many years, touching all levels of the food supply chain from production to retail. Reach him at drewf@gmt-inc.com.

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