Selecting the Best Drainage Systems for Food & Beverage Processing

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.

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Choosing the Best Flooring Material for Food & Beverage Processing Areas

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.

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How Ergonomics Affect Employee Wellness (and What Manufacturers Can Do to Improve it)

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.

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Cyberattacks, Hacking and Phishing Scams: the Food Processing Industry’s Multimillion-Dollar Problem

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.

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6 Ways Vertical Commissioning Can Benefit Your Next Food Facility Project

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. 

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Best Practices for Building an Enterprise Data Warehouse from Scratch

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. 

Building an enterprise data warehouse can offer many benefits for food and beverage manufacturers and their construction partners, including improved safety, budget certainty, warranty tracking and knowledge management. 

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.

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How to Leverage Construction Data to Level Up Your Next Food Plant Project

Modern data collection and analytics have created infinite opportunities for businesses to leverage information to their advantage. Even the simplest piece of information can prove incredibly valuable to an operation when organized and used correctly.

However, storing data to let it sit collecting dust is a waste of time and resources. This is especially apparent in the food processing and construction industries because every moving piece can be cataloged and therefore analyzed to the user’s benefit. 

When used strategically, streamlined and actionable data integration can fuel effective and efficient decision-making at every stage of the design, construction and business management processes.

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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.

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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.

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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).

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