May 16, 2019
Managing total package oxygen (TPO) can be a challenge for beer producers looking to grow their output. TPO is the total concentration of oxygen (O2) present in packaged beer at the time of packaging. When beer comes into contact with air, it begins to oxidize — and too much oxygen can negatively affect the beer’s flavor.
The ultimate goal is to reduce the amount of oxygen allowed in during packaging to prevent oxidation and maintain product quality and taste. However, this can be easier said than done, especially if you’re transitioning from a smaller-scale production with manual processes to greater throughput with increased automation.
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?
May 2, 2019
If you’re a decision maker in the food manufacturing space, ask yourself these questions:
- Does your company value sustainability and transparency in its processing?
- Is your boardroom as diverse as your customer base?
- Are your company’s leaders listening to those customers to anticipate what they want?
- Is your company taking tangible steps to be innovative, or does it just say it is?
If you want to thrive — not just survive — in today’s market, you must be answering “yes” to these questions… or at least taking actionable steps toward a “yes.”
The food and beverage industry is changing more than ever before thanks to disruptive innovation, the internet, evolving customer values and more.
Don’t be the next Blockbuster, Kodak or Myspace. The key is to be proactive, not reactive. Where should you begin? Consider these leading trends shaping the industry.
The best eco-friendly investments that also generate ROI
Apr 25, 2019
Most food and beverage companies aren’t against being more eco-friendly — it’s just that achieving sustainability in a food processing plant can be easier said than done.
The upfront investment associated with energy-efficient solutions, such as “green” building materials and equipment, can be difficult to justify. How do you know which energy-efficient options will provide the best return on investment?
As we observe Earth Day this week, let’s look at ways to invest in your food plant that are both good for the planet and provide a solid return on investment (ROI).
Feb 21, 2019
For more than 120 years, Royal Cup Coffee & Tea has been rooted in its hometown of Birmingham, Alabama. Over the past century, Royal Cup has grown from selling coffee out of a horse-drawn wagon to a major international importer, roaster and distributor of premium coffees and teas.
Recently, in an effort to meet the demand of its rapidly growing consumer base, Royal Cup consulted with the Stellar team on how it could revamp its 40-acre campus to increase production as well as set the industry standard for safety and efficiency.
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.
Jan 31, 2019
You don’t need to build a brand new facility to meet modern-day food safety standards. The reality is that most companies don’t have the budget to build from scratch as often as they’d like, but that doesn’t mean your decades-old plant can’t be a shining example of food safety.
Let’s look at five things you can do now to ensure your older facility is up to today’s food safety standards.
Aug 23, 2018
Photography: Robert Pepple
When Starbucks engaged Stellar to design and build a soluble coffee manufacturing facility, they set the goal of creating the most functionally and technologically advanced plant in the United States. To say they achieved that objective might be an understatement, as the award-winning facility has set a new standard in the industry.
From food safety practices that adhere to the rigorous British Retail Consortium Food Safety Standard to features designed to meet LEED Gold certification requirements, the Starbucks soluble coffee plant in Augusta, Georgia, is a modern marvel. Nowhere are the facility’s many innovations more on display than on its processing and packaging line.
Aug 16, 2018
Photography: Robert Pepple
In response to the growing demand for home-brewed instant coffee that delivers true “coffee shop” flavor, Starbucks came to Stellar wanting to build a unique soluble coffee plant. The award-winning facility in Augusta, Georgia, was designed to produce the company’s VIA® instant coffee products, and it’s cutting-edge in every sense of the word.
Among the plant’s many innovations, food safety was a top priority. There are several lessons food and beverage manufacturers can learn from how Starbucks addressed this critical issue.
Aug 9, 2018
At Stellar, we construct a lot of cold storage facilities and distribution centers. In fact, over the years we’ve designed and built more than 10 million square feet of public refrigerated warehouse space.
My point? We notice patterns in consumer demand, common challenges and external factors that influence the market as a whole.
Here are six of the top things affecting the cold storage construction industry right now.