How to organize your “snake pit” with consolidation and valve banks
Jun 13, 2019
Breweries and distilleries can be infamous for their “snake pits,” the areas of the facility where transfer hoses can become a tangled mess.
Flow panels and hoses are widely used to route product and cleaning solutions through brewery and distillery piping systems, and they are a cost-effective initial investment. However, as a facility grows, so do the number of connections — and that can quickly get out of control.
These snake pits can pose serious problems for your facility’s efficiency and the safety of your workers. Let’s examine five major risks associated with snake pits, and what you can do about them.
May 9, 2019
You’ve likely heard a lot about Industry 4.0 and the impact of predictive and prescriptive maintenance on the food and beverage industry. It can sound overwhelming, but it doesn’t have to be. In fact, a few basic investments and the right partner can help streamline the way your facility operates and communicates
Food manufacturing facilities are complex and have various ecosystems operating at different levels, including:
- Raw materials and receiving
- Processing and KPIs
- Monitoring (HMIs, PLCs and networks)
- Inventory and work orders (ERP and PRM)
- Packaging and distribution
- Quality, process safety management (PSM) and safety
But all of these systems don’t always talk to each other. In many facilities, an equipment failure triggers a lengthy domino effect: Maintenance staff has to assess the problem, create a work order, check if a replacement part is available and so on.
Does this scenario sound familiar?
Feb 14, 2019
As more food and beverage processing moves from mechanical to automated, it’s important to hire the right people who can operate and troubleshoot from the plant floor. Once you have qualified technical staff in place, transferring knowledge about your automation and controls systems to them is crucial.
At Stellar, we often help food manufacturers configure new facilities, so we understand the process and what it takes to make it go smoothly. When it comes to training your plant personnel on the automation and controls, follow these tips for an efficient startup at your next facility.
Dec 6, 2018
A growing number of food and beverage processing facilities are investing in robotics and automation, as the technology continues to advance and costs continue to normalize. These tools can be a game-changer for many businesses, offering benefits such as reduced operating costs, upped throughput and increased food and worker safety.
That said, such a significant investment requires careful implementation. Before incorporating robotics into your facility, consider these important best practices to ensure you invest wisely and efficiently.
Jun 14, 2018
There’s never been a better time to invest in capital expenditures for your business. Recent tax reform has freed up cash and created more incentives for corporate entities to spend on new equipment and infrastructure.
Plus, the combination of mergers and acquisitions, advances in technology, and evolving consumer demand is spurring innovation. The speed-to-market food and beverage industry is only moving faster.
So it’s a great time to invest in your company’s growth, but what exactly is the best move? Considering the current industry climate, there are some forward-thinking options worth prioritizing.
Nov 2, 2017
How old is the control system at your facility? In most processing plants, the control system consists of field instruments that are wired to I/O cards which feed to a central PLC controller. Operators communicate with the PLC through a human machine interface (HMI) computer.
While the lifespan of an HMI computer is about the same as a typical desktop computer, the instruments, field wiring, I/O boards and PLC controllers last a lot longer — and the mentality of most operators is: “if it ain’t broke, don’t fix it.” Upgrading a control system is a costly investment, and, as a result, many facilities have field hardware that is decades old.
So, when is it worth upgrading your control system? And what options do you have?
Minimize the top food safety risks in your food and beverage facility
Sep 22, 2016
Ask any food manufacturer or processor if they are committed to high safety and quality standards and their answer will, of course, be yes. But even with the strictest standards, thousands of recalls are still issued each year in the U.S. In 2015, the FDA recalled 9,178 products, a 12-percent increase over the previous two years. If you weighed the amount of goods the USDA recalled last year alone, it would be as heavy as 52 Boeing 747 airliners. That’s a lot of product gone to waste.
Lessons from Food Engineering's 2015 Fabulous Food Plant winner
Dec 17, 2015
As today’s home-brewing coffee drinkers continue to seek convenient alternatives to coffee shops, the demand for delicious instant coffee has risen. However, it’s not always easy for processors to produce high-quality instant coffee, as there are many moving parts that must come together to put a tasty cup of joe on the kitchen table.
Dec 10, 2015
Total automation may be an ideal for most food processors, but it can be difficult to determine how to connect every system in a food plant—or if they should even be connected at all. To optimize ROI, it’s important to learn which areas of your food processing facility are best suited for automation. Below are five tips for improving your plant’s automation capabilities.
Oct 1, 2015
Today, our team is settling back into the office after exhibiting at PACK EXPO in Las Vegas. While packaging is fresh on our minds, let’s examine some fascinating packaging research released by The Association for Packaging and Processing Technologies (PMMI) earlier this week.