Stellar Food for Thought

April 14, 2022September 1, 2022 Views: 2931

Struggling to Staff the Third Shift? Combat Labor Shortages with These Automation Solutions

As labor market woes continue, adopting some degree of automation is no longer optional for companies looking to remain agile and equipped to meet future consumer demands.

Even industries that historically haven’t struggled with labor shortages are now finding it challenging to hire staff. With a peak record of 11.3 million jobs open in January 2022 and not enough workers available, more manufacturers are turning to robotics to fill the gaps.

In fact, U.S. factories ordered a record 29,000 robots during the first nine months of 2021, a 37% increase from 2020, according to data from the Association for Advancing Automation (A3).

The good news? Automated systems are getting cheaper to implement and improving technology is making systems more reliable. At Stellar, we’re constantly monitoring developments and best practices for leveraging robotics in our clients’ facilities to help them improve efficiency and productivity — not to mention combating that growing labor gap.

Let’s review some modern automation tools and the many ways robotics can be implemented into the food manufacturing process.

March 31, 2022March 8, 2023 Views: 3586

4 Strategies for Mitigating Supply Chain Disruptions in Your Next Construction Project

Construction firms are fighting an uphill battle to maintain project budgets and schedules as the industry grapples with global supply chain disruptions.

The Associated General Contractors of America (AGC) reported that material prices for nonresidential construction soared 21% from February 2021 to February 2022, and analysts predict costs will continue going up. Additionally, logistical bottlenecks such as overseas shipping delays and shortages in the transportation sector are drastically impacting project lead times.

Stellar’s industry veterans are discovering there are ways to mitigate supply chain disruptions and their effects on construction projects — but only if construction firms are willing to shift their paradigm and use a different approach when working with their clients.

Here are four ways our teams are navigating the waters.

March 24, 2022November 30, 2023 Views: 842

Your Checklist for Updating Your Facility’s Risk Management Program

Facilities, including food and beverage manufacturers, that use certain flammable and toxic substances in amounts that exceed threshold quantities must have a documented Risk Management Plan (RMP) per Environmental Protection Agency (EPA) requirements. Companies must update and resubmit their RMP at least every five years.

The EPA requires each facility to review all sections of their RMP, update where appropriate, and certify that the entire RMP is accurate and complete.

According to the EPA’s checklist, here are the key elements that should be reviewed for resubmission:

March 3, 2022March 15, 2022 Views: 780

Low-Impact Development: From Eco-friendly Trend to Industry Standard

Environmentally conscious construction sites have earned praise over the years as the world’s priorities have shifted to address growing climate concerns.

The World Green Building Council (GBC) estimates the building and construction sector is globally responsible for 50% of the world’s resource consumption, 36% of energy consumption and 38% of energy-related carbon emissions. Keeping this in mind, any time a building or facility can feature sustainable design, it’s a win for the planet.

Expectations are changing, however. What was once seen as the “cherry on top” of a construction project is quickly becoming standard practice.

A prime example of this is the evolution of the use of low-impact development (LID).

February 17, 2022February 17, 2022 Views: 1999

Factors to Consider Before Using a Spec Building for a Food and Beverage Facility

If you’re considering sites for a new facility, you may come across listings for speculative (“spec”) buildings. Developers often construct these basic, pre-engineered buildings in anticipation of a future tenant, and they can be attractive for owners looking for a new space.

Upfront, spec buildings offer to reduce costs by cutting out design and construction steps from a tenant’s to-do list — but there’s a catch. Food and beverage manufacturing has unique needs and it’s impossible to guarantee a spec building will meet them without retrofitting. Although leasing a spec building may be attractive to manufacturers who want to ramp up production quickly, there is the potential that they will incur additional costs the owner wasn’t anticipating.

It can be a valuable option in certain situations, but there are factors to consider before making a final decision.

February 3, 2022March 15, 2022 Views: 1405

Food Safety: 7 Pest Hotspots to Monitor

It’s no secret that food processing facilities, warehouses and distribution centers must maintain high standards to ensure food safety. If pests infiltrate a workspace, every area of production is at risk. Not only can pests carry diseases that threaten health and safety, an infestation could also lead to product loss, product recall, reputation damage, product liability lawsuits and a facility’s shutdown.

The Centers for Disease Control and Prevention (CDC) estimates nearly 48 million Americans get sick from foodborne diseases every year, while thousands more are hospitalized or even die from them.

Understanding the threats, developing a robust pest prevention strategy and recognizing when it’s time to call for help are vital to protecting your operations, staff and customers.

January 20, 2022January 26, 2022 Views: 2088

5 Coffee Trends to Watch in 2022

Nearly two years after the onset of the COVID-19 pandemic in the United States, consumers continue to rely on daily comforts for moments of normalcy in uncertain times. Coffee is at the top of that list.

For years, coffee has earned a top spot among America’s favorite drinks. In a recent national study, the National Coffee Association found 60% of respondents had a coffee in the past day, more than any other beverage — including water!

While it’s a safe bet that coffee will continue being the beverage of choice for many Americans, how they drink it is constantly changing, and the food and beverage industry needs to stay on top of these evolving trends to stay competitive.

We’ve pulled together some of the hottest trends to watch in 2022.

January 6, 2022January 30, 2023 Views: 1274

Does your PSM compliance training meet the latest OSHA requirements? [infographic]

Industrial refrigeration managers know that their personnel must undergo Process Safety Management (PSM) compliance training — but how do they know if their current training meets with the latest requirements from the Occupational Safety and Health Administration (OSHA)?

For example, did you know that simply sending your refrigeration team off for generic training at another facility is not enough? OSHA 1910.119 mandates being trained on your specific equipment and process.

December 16, 2021December 14, 2021 Views: 2003

The Stage-Gate Approach and Why it’s at the Root of Successful Project Development Strategy

Process-related project development can be a lengthy, expensive and unnecessarily complicated process without a solid plan to guide the project from start to finish.

Imagine investing in a large, complex piece of equipment or component for your facility without first confirming the question of how it will be integrated into your existing controls/automation system. If it doesn’t easily “connect” (plug-and-play), then you may need to reengineer the system(s), buy additional hardware/software, and/or delay the project timeline to resolve an issue that should have been identified prior to the purchase. The same holds true for other questions, such as when this equipment should be installed. If it does not align with your overall business objectives and strategy, then there could be negative consequences.

The AIA stage-gate process (also referred to as the phase-gate process) is a project management technique that breaks down complex projects into structured phases to mitigate risk and ultimately minimize (ideally eliminate) the consequences of poor planning.

In this article, we will address the stage gate approach and how it pertains to the process equipment integration portion of a project.

December 2, 2021December 1, 2021 Views: 1234

Choosing a Systems Integrator (SI) to Advance Your Automation Strategy

The use and development of industrial robotics and automation technology has accelerated in recent years, and that growth remains at full speed ahead. According to a recent ABI Research report, more than a half million mobile robots will be shipped to warehouses globally by 2030. That’s a Compounded Annual Growth Rate (CAGR) of nearly 40% in the next decade — and that’s just for distribution warehouses, not to mention manufacturing and processing facilities.

Many large food and beverage manufacturers have in-house engineering teams that provide automation and system integration services to their various facilities. However, most small- and medium-sized processors don’t have that capability, meaning they must often partner with an outside systems integrator (SI) to advance their automation strategy and bring new systems online.

With so many available options in the vast field of automation and robotics, selecting an SI can seem like a daunting endeavor — but it doesn’t have to be.