Automation is an integral component of a modern facility’s competitive advantage. In addition to enabling rapid throughput, robotics and automation solutions can help minimize production issues stemming from fluctuating factors like labor availability, supply chains and material prices.
Historically, hefty price tags have acted as the main bottleneck to investments in cutting-edge manufacturing technology. The good news is technology is getting cheaper and easier to implement, making it harder for plant owners to ignore the long-term return on investment (ROI) of upgrading their facilities. However, plant managers face another challenge in today’s market: What happens when these sophisticated systems need maintenance or repairs?
The food and beverage design-build process demands attention to detail and a high level of expertise to navigate a maze of regulations, adhere to strict food safety guidelines, stay within budget and guarantee the facility is well-equipped to meet long-term production goals.
Effectively coordinating different disciplines, vendors and subcontractors to ensure timely and on-budget execution is an ongoing challenge in construction projects that requires careful planning and communication.
As an owner, you’re in the driver’s seat and play a pivotal role in the overall success of the project. Here are some key things you can do to support your design and construction teams and help streamline the process.
This past year has been a big one in the food and beverage industry, with new technology rolling out and (some) supply chain constraints waning. While new trends and practices are already appearing for 2023, it’s critical for manufacturers to reflect on 2022’s challenges and successes when planning for the one ahead.
That’s why we’re revisiting the topics our readers found most useful this year. From coffee trends to labor availability to cyberattacks, here are the five most popular Food for Thought posts of 2022.
Designing the processing system for a food and beverage facility is a lot like doing a jigsaw puzzle. You can probably force many of the pieces to fit into various spaces. However, if you do not find the perfect fit, you’ll ultimately wind up with holes and weaknesses in your finished puzzle — or in this case, elevated food safety and quality risks that may cost your business valuable time and money.
To make an educated decision about valve selection, owners and their construction partners should consider the different types of valves available in the market and how they will interact with other components in the individual facility’s production lines.
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.
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.
