A matter of will

WHILE THE MEATPACKING INDUSTRY sought to block implementation of a science‑based inspection system, the owner of the Jack in the Box chain, Foodmaker, Inc., struggled to recover from the bad publicity surrounding the outbreak. Robert Nugent, the president of Foodmaker, had waited a week before acknowledging that Jack in the Box bore some responsibility for the illnesses. His first instinct had been to blame the chain’s ground beef supplier and Washington State health officials. He claimed that Jack in the Box had never received a thorough explanation of why hamburgers needed to be fully cooked. Nugent soon recruited Jody Powell, President Jimmy Carter’s former press secretary, to help improve the company’s image and hired David M. Theno, a prominent food scientist, to prevent future outbreaks.

Theno had previously helped Foster Farms, a family‑owned poultry processor in California, eliminate most of the Salmonella from its birds. He was a strong advocate of Hazard Analysis and Critical Control Points (HACCP) programs, embracing a food safety philosophy that the National Academy of Sciences had promoted for years. The essence of a HACCP program is prevention; it attempts to combine scientific analysis with common sense. The most vulnerable steps in a food production system are identified and then monitored. Stacks and stacks of records are kept in order to follow what went where. Theno quickly realized after arriving at Jack in the Box that the chain relied upon the safety standards of its suppliers – instead of imposing its own. He created the first HACCP plan in the fast food industry, a “farm‑to‑fork” policy that scrutinized threats to food safety at every level of production and distribution. Assuring Jack in the Box customers that their food was safe not only seemed the right thing to do, it seemed essential for the chain’s survival. In the years since the Jack in the Box outbreak, David Theno has emerged as a fast food maverick, applauded by consumer groups and considered “the Antichrist,” he says, by many in the meatpacking industry.

Theno insisted that every Jack in the Box manager attend a food safety course, that every refrigerated delivery truck have a record‑keeping thermometer mounted inside it, that every kitchen grill be calibrated to ensure an adequate cooking temperature, and that every grill person use tongs to handle hamburger patties instead of bare hands. An almost fanatical devotion to microbial testing, however, became the key to Theno’s food safety program. He discovered that the levels of contamination varied enormously in ground beef supplied by different meatpacking companies. Some slaughterhouses did a fine job; others were adequate; and a few were appalling. The companies that manufactured hamburger patties for Jack in the Box were required to test their beef every fifteen minutes for a wide range of dangerous microbes, including E. coli 0157:H7. Slaughterhouses that continued to ship bad meat were eliminated as suppliers.

Jack in the Box now buys all of its ground beef from two companies: SSI, a subsidiary of the J. R. Simplot Company, and Texas‑American, a subsidiary of the family‑owned American Food Service Corporation. Theno gave me a tour of the Texas‑American plant in Fort Worth that makes hamburger patties for Jack in the Box. We were accompanied by the plant manager, Tim Biela. Much of Biela’s work involved testing things repeatedly and maintaining records of the tests. “You can’t manage what you don’t measure,” he said more than once. His records contain not only the date and time when a case of hamburger patties was produced, but also which employees worked that shift, which slaughterhouse provided that beef, and which feedlots sent cattle to the slaughterhouse that day. The hamburger patty plant looked new and clean. I saw huge vats of beef scraps – some shipped all the way from Australia – stacked high in a cooler. The beef was dumped from the vats into shiny stainless steel machines. It was ground into fine particles by giant augers, mixed into exact proportions of lean meat and fat, stamped into patties, perforated, frozen, passed through metal detectors and then sealed in plastic wrap. The frozen hamburger patties that came out of the machines looked like little pink waffles.

David Theno would like the meatpacking industry to adopt a system of “performance‑based grading.” Slaughterhouses that produced consistently clean meat would received a grade A. Plants that performed moderately well would receive a grade B, and so on. Microbial testing would determine the grades, and the marketplace would reward companies that ranked highest. Plants that earned only a C or a D would have to do better – or stick to making dog food.

Some people in the fast food industry resent the idea that Jack in the Box, which was involved in such a large outbreak of food poisoning, has assumed the mantle of leadership on the issue of food safety. Theno’s support for tough food safety legislation in California made him unpopular with the state’s restaurant association. The meatpacking industry is not fond of him, either. Theno says that the industry’s long‑standing resistance to microbial testing is a form of denial. “If you don’t know about a problem,” he explained, “then you don’t have to deal with it.” He thinks that the problem of E. coli 0157:H7 contamination in ground beef can be solved. He has an optimistic faith in the power of science and reason. “If you put in a score‑keeping system and profile these meatpacking companies,” Theno says, “you can fix this problem. You can actually fix this problem in six months… This is a matter of will, not technology.” Despite the meatpacking industry’s claims, the solution need not be enormously expensive. The entire Jack in the Box food safety program raises the cost of the chain’s ground beef by about one penny per pound.