How quick chilling works, improves pork product output
May 12, 2016
There are more than 68,000 pork producers in the United States alone—competition is fierce. So how can your hog facility remain competitive? By producing the highest quality product possible for consumers, efficiently. And an effective chilling system is key to facilitating the most premium product for your consumers: a flavorful cut of meat with appealing color, firmness and moisture levels. The faster a carcass is cooled after slaughter, the better quality the meat will be. Quick chill systems, specifically, reduce chill time and produce a better cut of meat. While they may be a significant upfront investment for your food plant, this method offers significant advantages and long-term ROI.
An in-depth look at how to safely produce gluten-free products
Apr 14, 2016
Stellar recently exhibited at the American Society of Baking’s (ASB) annual BakingTech conference in Chicago. “Gluten-free” continues to be a topic on the rise among the attendees. This isn’t surprising, as more and more companies are incorporating gluten-free products into their offering arsenals. However, a common challenge for food manufacturers going gluten-free is preventing cross-contamination, whether it’s modifying existing plants or embarking on greenfield projects. Gluten-free products also require specific distribution and processing considerations that may differ from what manufacturers are used to, from mixing methods to storage. So, how do you safely integrate gluten-free manufacturing into your bakery plant?
Mar 24, 2016
Your food processing facility’s commitment to safety starts with being prepared. How do you prepared to be… prepared? With your food plant’s emergency action plan (EAP): a required Occupational Safety and Health Administration (OSHA) document that defines employer and employee actions during workplace emergencies. While emergency action plans that meet minimum requirements may include emergency information and procedures, they still may not contain enough detail to ensure the safest response to dangerous situations. Your plan must be comprehensive, eliminating all confusion and hesitancy in case of an emergency. A non-comprehensive plan — one lacking extensive instruction or failing to address each emergency — may add confusion to the situation.
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.
Reviewing the FDA's newest food safety rules for food processors
Dec 3, 2015
The FDA recently released new final Food Safety Modernization Act (FSMA) rules. These rules are the result of amendments made to the original proposals, based on comments and criticisms in public forums. Below are important details of two rules. You can find a full explanation of each new rule here.
Final part in our worker safety series
Nov 19, 2015
In last week’s post, I introduced you to the behavior-based approach to worker safety. While ergonomic design and regulatory compliance remain critical to worker safety, behavior-based safety strategies incentivize employees to take ownership of their own safety. Employees proactively identify potential hazards, helping prevent them from ever happening in the first place.
Below, I outline in more detail three reasons you should integrate a behavior-based approach into your food plant’s worker safety practices.
Make your 'recorded incidents per man hour' work for you
Nov 12, 2015
Worker safety is a critical element in every food plant, regardless of the type of products manufactured. And while creating a safe, ergonomic work environment is a must, sometimes it’s not enough to ensure the safety of your most important asset—your employees.
In a recent Food Engineering article on ergonomic practices, I discussed how a behavior-based approach can enhance your plant’s worker safety. With behavior-based safety training, workers are incentivized to proactively look for potential hazards, creating a safety-oriented workforce.
Avoid discrepancies by providing details about utilities, food safety and more
Nov 5, 2015
At this time of year, many food processors are planning next year’s capital expenditures, which often means piecing together budgets for upcoming food plant construction projects. It is important to create the most accurate budget possible: a tricky task. Frequently, food processors prepare budgets without the assistance of an experienced design-builder. By doing so, they make assumptions that can skew their entire budget.
Strategic planning for food processors series
Oct 22, 2015
A manufacturing plan is a key piece of your food business’ overall strategic plan. Your manufacturing plan is a clear set of actions driven by gaps and discoveries from your manufacturing analysis, or the analysis of your business’ manufacturing processes.
Strategic planning for food processors series
Oct 14, 2015
A manufacturing analysis is the portion of a strategic plan that focuses on all the processes and materials related to manufacturing. A situation analysis is a major focus of the manufacturing analysis, serving as an in-depth look at the physical layout of the facility. The goal of situation analysis is to ensure that the technology and strategy you plan to implement are feasible in the physical space of your facility.