Whether you’re building a new facility or upgrading an existing one, it’s vital to have a well-designed drainage system throughout your processing areas. In fact, the North American Meat Institute (NAMI) lists the prevention of liquid accumulation as one of the top three principles of sanitary facility design.
Poor drainage in a food and beverage facility can impede the sanitation process and greatly affect overall food safety. Meanwhile, proper drainage design speeds up cleaning and reduces health and safety risks for both workers and production.
When done incorrectly, your facility’s drainage system can contaminate ingredients and products that then must be discarded, directly impacting your bottom line. In addition, recalls caused by product contamination can damage both your company’s reputation and your product category.
A clean-in-place (CIP) system is a cost-effective and time-saving tool that rinses and washes the inside surfaces of food processing piping and equipment without mechanical disassembly. When designed well, a CIP system improves sanitation and enhances food safety while both simplifying the cleaning process for plant operators and reducing downtime. It automates what has traditionally been a laborious and time-consuming manual process of disassembling the piping, hand-cleaning each component and reassembling equipment.
In addition to lost revenue from halted production, improperly cleaned equipment can spread foodborne contaminants from batch to batch, which is dangerous to consumers and can lead to recalls that directly impact a company’s bottom line and reputation.
If you’re considering investing in a CIP system for your facility, it’s important to ensure you’re getting a design that is reliable and up-to-date. Your process design team should consider the overall needs of your operation, including changeover efficiency, water conservation and how the design will affect the complexity of the system.
It’s no secret that working in a food processing plant can be quite dangerous. In fact, the Bureau of Labor Statistics (BLS) has listed the food manufacturing industry as one of the most hazardous. A big contributor to workplace accidents is improper lockout/tagout (LOTO) procedures.
When production in a food processing plant is halted for the installation, servicing or maintenance of machinery and heavy equipment, there must be a LOTO procedure in place to prevent the machine from turning back on and injuring a worker.
The U.S. Department of Agriculture (USDA) is renewing its commitment to strengthen critical supply chains and address long-standing challenges within the food production and processing industries.
“As the pandemic has evolved and Russia’s war in Ukraine has caused supply chain disruptions, it has become clear we cannot go back to the food system we had before,” said the USDA in a press release.
The USDA aims to make the industry more competitive, equitable and resilient by investing billions of dollars in the food system. These investments are designed to build on a framework of similar legislation introduced in 2021 and could make the industry even more competitive.
Food and beverage companies have seen a major increase in demand for their products in the past few years. The COVID-19 shutdowns changed consumer habits: Instead of dining out or ordering takeout, consumers spent more money having their groceries delivered, making their own meals at home and discovering new food and beverage products.
This increase in demand is driving many food manufacturers to consider automating their packaging processes to improve efficiency. However, choosing the right level of automation takes time and research. There is no one-size-fits-all approach, since the level of implementation will impact your initial costs as well as your return on investment.
The flooring systems in food and beverage processing areas are an essential component of the facility’s daily operation. Whether you’re evaluating flooring in a food production, storage or welfare space, the floor’s cleanability, resilience, durability and surface characteristics are integral to the space’s sanitation and safety.
Selecting the appropriate flooring system for each area is an important and nuanced operational and budgetary decision, especially in a highly regulated industry like food processing. The decision requires careful consideration in the earliest stages of the design and construction process.
Americans have been quitting their jobs in record numbers since the onset of the COVID-19 pandemic. The so-called Great Resignation is significantly impacting the food and beverage industry. In response, many industry leaders are focusing on ergonomics strategies to improve employee comfort and safety, and in turn, retention.
“If the workplace is designed to meet peoples’ needs, it demonstrates the employer’s commitment and enables employees to be fully engaged in the workplace,” says Jeff Sanford, an ergonomics expert at VelocityEHS, a provider of environmental health and safety (EHS) solutions.
Sanford recently spoke at a webinar hosted by Food Processing magazine, in which he shared best practices for improving ergonomics and employee safety within the food and beverage industry.
The goal of ergonomics is to prevent soft-tissue injuries and musculoskeletal disorders (MSDs)caused by sudden or sustained exposure to force, vibration, repetitive motion and bad posture. This is especially important in the U.S. food and beverage industry, which has the highest lost-workday incidence (LWDI) across all industries with a rate of 6.5 injuries and illnesses per 100 full-time workers, compared to the standard of 3.3.
These numbers especially matter in today’s competitive labor market. A recent study on ergonomics cited in the webinar found employee turnover dropped anywhere from 23% to 49% within companies that employed an ergonomics strategy. Meanwhile, the same study found absenteeism dropped between 42% and 116%. These statistics could help some processing facilities justify the cost of implementing ergonomic changes.
What can facility owners and plant managers do to improve employee ergonomics? Below are some common issues and solutions shared during the webinar.
Food processing facilities have come a long way since pre-industrial days. Each year, food and beverage companies rely more heavily on automation, high-tech building management systems, remotely accessible machine sensors, modern data collection and the latest technology. While these innovations can help facilities run more smoothly, they can also leave them vulnerable to data breaches and cyberattacks.
In 2020, the average cost of a cyberattack was approximately $3.86 million,according to the Association for Packaging and Processing Technologies (PMMI). When computer intrusions happen, cybercriminals are typically seeking out a company’s intellectual property or customer and client data that can be exchanged for digital currencies, like passwords, protected health information, personal identity information and credit card information.
Every company will be targeted by a malware or ransomware attack at some point. It’s just a matter of when, so it’s vital to have a robust cybersecurity plan that protects your assets and information.
Signing on a new construction or renovation project presents an exciting time for food manufacturing owners ready to embark on the next stage of their business plan. A commissioning partner who uses a vertical start-up model can help ensure a smooth project handover.
Traditionally, commissioning occurs as construction nears completion when engineers begin installing and testing equipment to guarantee production lines will run properly. However, my experience is that waiting until the end to conduct system integration, simulations and automation can prolong start-up and cost owners valuable time, money and resources.
Applying best practices for commissioning and coordinating with owner equipment manufacturers (OEMs) early on can ensure facilities achieve full performance much faster and at a fraction of the cost compared to traditional methodologies.
Business intelligence (BI) and data analytics empower and enable organizations to quickly make fact-based decisions that improve the efficiency and effectiveness of their operations.
Successful BI and analytics strategies are only possible when the database where information is stored is properly maintained. If any member of your team inputs incorrect or incomplete data, you’ll ultimately get inaccurate results, which could end up costing your facility money and time.
