Views: 6198

Industrial Automation: Is It Time to Upgrade Your Control System?

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?

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Views: 6159

What is Total Package Oxygen in Beer?

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.

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Views: 6075

Should You Renovate Your Food Plant or Build a New Facility?

Should you renovate your existing facility or build a new facility? This question isn’t an easy one to answer and is, of course, dependent on capital expenditure. However, your answer should also be driven by your company’s strategic plan to ensure that your decision aligns with your long-term needs and goals.

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Views: 5686

The Food Industry Is Being Disrupted. What Should You Do About It?

The food industry is in the eye of a hurricane named Disruption.

Sweeping consolidation has turned the traditional food industry on its head, leaving major companies like Heinz, Kraft and Unilever feeling under siege. Other major players are working to “redefine” themselves before they become acquisition targets. Taste preferences have evolved and weekday sit-down meals are no longer a mainstay as families are increasingly on-the-go. Therefore, convenience is the name of the game.

Big companies are being challenged by upstart brands: Chobani challenged Yoplait and Dannon, long-time leaders in the yogurt market, and KIND bars have become one of the fastest-selling snack bars on Amazon. Neither company existed at the beginning of the 21st Century! Is the “slow and steady wins the race” mantra of the food industry on the way out?

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Views: 5640

Industrial Refrigeration: Your Options as R22 Refrigerant Is Phased Out

This is the last year that R22 can be manufactured in or imported to the United States.

As a reminder, here’s the timeline according to the EPA final rule: 

  • On January 1, 2018, R22 production dropped 30% from the 2017 supply to 9 million pounds
  • On January 1, 2019, production dropped 55% from the 2018 supply to 4 million pounds
  • On January 1, 2020, R22 will be phased out completely with no new or imported R22 allowed in the U.S.

If your refrigeration system uses R22, you have some decisions to make — and the clock is ticking.

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Views: 5437

Eco-friendly Packaging in the Food and Beverage Industry: Types & Benefits

Food for Thought is celebrating its two-year anniversary this month, and one of our very first blog posts is one of the most popular to-date. In April of 2013, I wrote a piece titled “Food Companies Go Green With Eco-Friendly Packaging,” discussing its different types and benefits. Eco-friendly packaging is something that’s only gained more steam as time has passed.

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Views: 5379

RFID vs. Barcodes: Advantages and Disadvantages for Food Traceability

Barcodes have long been the standard for tracking products throughout the food and beverage supply chain. But technological advancements have introduced RFID as another option across a variety of industries. What’s the difference?

What is RFID?

RFID, short for Radio Frequency Identification, is the use of radio frequency waves to wirelessly transfer data without contact. Tagging items with RFID tags allows users to automatically and uniquely identify and track inventory and assets.

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Views: 5358

Eliminating Noxious Plant Odors Through Incineration: A Case Study

Odor complaints from those who live and work near food processing plants have been making headlines lately, resulting in bad press and poor community relations for the manufacturers. The Environmental Protection Agency’s (EPA) Clean Air Act was created to reduce emissions of hazardous and odorous air pollutants and outlines specific requirements for food processors.  Subsequently, odor control should be a part of any food processing plant’s Good Manufacturing Practices (GMP) program.

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Views: 5254

5 Ways to Reduce Water Use in Your Food Processing Plant

Food and beverage manufacturing facilities are notorious for how much water they consume. While water is central to your plant’s operations, there may be ways you can operate more efficiently and be smarter about how your plant uses water.

Optimizing your water consumption is not only better for the planet, but it may save you in utility costs as well. Let’s look at five basic ways to reduce water consumption in a facility.

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Views: 5178

3 Key Areas to Examine in Your Manufacturing Analysis

What’s the best way to remain competitive in the food processing industry today? A strategic plan. It equips your business with the knowledge, tools and strategies necessary to evolve and adapt to changing marketing conditions and consumer demands. In fact, we’ll be hosting a Food Engineering webinar June 23, 3 Key Elements in a Successful Strategic Plan for Growth to dive into strategic plans even further. Last week, we discussed the first step in developing a strategic plan: developing a business plan. This week, we’ll discuss step two: conducting a manufacturing analysis.

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