Stellar Food for Thought

June 17, 2021July 26, 2021 Views: 4279

4 Ways Site Location Can Affect Construction Costs

Building anything right now can be daunting and expensive, much less a large industrial facility. In the wake of the COVID-19 pandemic, the cost of construction materials has skyrocketed, labor is scarce and demand is surging. But that doesn’t mean the food supply chain can stop.

Food manufacturers and distributors still have customers to serve — and, for some, that still means investing in a new facility. At a time when construction costs are high, a company might make up for it in savings by reconsidering where the facility is built.

June 3, 2021June 23, 2021 Views: 1820

4 Tips to Get Your New Process Facility ‘Off the Ground’

Facilities that support process operations produce some of the most expensive and complex buildings in the world. And they run the gamut: “Process operations” can range from baking desserts such as cakes to processing raw meat for grocery operations, to manufacturing parts and components for U.S. Navy submarines.

So what do facilities across such diverse markets have in common besides being founded on their process? For one, the costly and painful struggle of getting the project started. Many times, important early stages are executed out-of-order or even too late. Let’s look at four recommendations that may seem obvious, but if executed properly, will take some of the pain out of beginning your next process facility.

May 20, 2021June 29, 2021 Views: 2917

How Blockchain, IIoT and AI Make the Global Supply Chain More Resilient

The Suez Canal blockage in March 2021 pointed out a major pinch point — for lack of a better term — within the global supply chain. One ship getting blown off course during a predictable sandstorm halted 12% of global trade — an estimated $9.6 billion per day. While the Ever Given was freed after six days, the ripple effects of the event will be felt for months due to the thousands of ships delayed in those six days.

Witnessing the magnitude of what a single ship mishap can do to interrupt global trade makes it obvious that safeguards need to be put in place to prevent such events in the future. If an accident put a stop to 12% of global trade, what kind of damage could an intentional act inflict?

May 6, 2021October 11, 2022 Views: 1569

What Is Your Maintenance Program (or Lack of One) Costing You?

For many manufacturers — especially in the food and beverage space — the COVID-19 pandemic has ushered in new challenges and increased demand, all at the same time. This has many corporate leaders under the gun and pushing production to the max in order to keep their pipeline filled. To meet this demand, many are working overtime, plants are reluctant to shut any lines down and smaller maintenance jobs have dropped lower on the priority list.

But, none of that matters if you’re rushing in the wrong direction. Ignoring maintenance or only fixing things when they fail (a reactive approach), has long-term consequences. The continual deferment of maintenance will ultimately result in failure.

April 22, 2021June 29, 2021 Views: 2338

Automated Storage and Retrieval Systems: Advantages and Considerations for ASRS Warehouses

E-commerce retail is at an all-time high, according to the U.S. Census Bureau’s latest quarterly report. Total e-commerce sales for 2020 were estimated at $791.7 billion, an increase of 32.4% (±1.8%) from 2019.

While this isn’t exactly unexpected, the COVID-19 pandemic has only sped up e-commerce trends that were already taking place. And that means distribution warehouses — and the workers and technology that power them — are in the spotlight.

This has more companies considering how to best capitalize on this demand, and automated robotics are taking the storage and distribution game to new heights — literally.

April 8, 2021May 6, 2021 Views: 1955

Flexible Food Manufacturing: 5 ‘Blind Spots’ That Can Hurt Your Ability to Adapt to the Market

You could argue that flexibility in food manufacturing has never been more important: new generations of consumers are craving more variety, the internet is reshaping how food is packaged and purchased and a global pandemic just reminded us all of how crucial (and fragile) the supply chain can be.

With some speculating that history could (at least somewhat) repeat itself for another post-pandemic “Roaring Twenties,” how can food and beverage companies prepare for sustainable success in the decade ahead?

March 25, 2021May 6, 2021 Views: 1228

Food Traceability: 5 Business Benefits When Switching from Manual to Digital Recordkeeping

In a recent post, I summarized the new traceability requirements recommended by the U.S. Food and Drug Administration (FDA). The proposed rule would require additional recordkeeping for those who manufacture, process, pack or store foods included on the FDA’s new Food Traceability List.

The thought of new government regulations can often elicit groans from manufacturers, but rather than view this as another hoop to jump through, food and beverage companies should take a long view: It’s really an opportunity to improve product quality, boost efficiency and reduce manufacturing costs.

March 11, 2021January 30, 2023 Views: 1300

The FSMA Proposed Rule for Food Traceability (in a Nutshell)

The U.S. Food and Drug Administration (FDA) is proposing additional traceability recordkeeping requirements for those who manufacture, process, pack or store foods included on the Agency’s new Food Traceability List. The proposed rule is a key component of its New Era of Smarter Food Safety Blueprint and would implement Section 204(d) of the Food Safety Modernization Act (FSMA).

The additional recordkeeping requirements would apply not only to foods specifically listed on the Food Traceability List, but also to products that contain these foods as ingredients. Let’s look at what’s included:

February 25, 2021March 17, 2022 Views: 1162

Don’t Put Off Upgrading Your PLCs: 3 Red Flags and a Cautionary Tale

“If it ain’t broke, why fix it?”

It’s a question we’ve all heard before, but when it comes to older programmable logic controller (PLC) installations, it’s not an answer you want to find out the hard way. While some components can be found and purchased online, if your primary source for replacement parts is a site like eBay or obsoletePLCparts.com, it’s likely time to upgrade your system.

February 11, 2021May 6, 2021 Views: 2152

Should You Change Your Packaging to Meet Grocery Delivery Demand?

In the wake of COVID-19, online grocery delivery has taken off. According to the 2020 Food Packaging & Consumer Behavior Report, 61% of survey respondents said their purchasing habits acquired during the pandemic will influence the way they shop in the future, and 51% reported using third-party grocery delivery apps within the past three months.

In light of this trend, food manufacturers may have to adapt their packaging to meet the requirements of grocery delivery. Instead of packages being stretch-wrapped onto a pallet to be unloaded by grocery store workers, they’ll be boxed and sent directly to consumers’ doorsteps.

That means outgoing packages must be sturdy enough to withstand the increased vibration and movement across a courier’s distribution chain. Some items may be shipped as is or they will have to be sent inside another shipping box padded with extra dunnage (air bags, crinkled paper, bubble wrap). Products packed in glass, cans or other rigid packaging may have to be rethought.