As explained in this previous post, food processing operations require substantial energy. While utility costs are unavoidable, various factors can enhance efficiency and achieve long-term cost savings, including a facility’s water heating system. Considering your production specifications and overall environment, there are specific systems available that can effectively minimize energy consumption in your food or beverage production. Thus, it’s important to explore these systems and understand their differences. So, what are these systems, and how do they vary from one another?Continue Reading “Boilers vs. Direct-Fire vs. Glycol: Water Heating Systems to Consider for Food and Beverage Plants”
Compressors play a vital role in industrial refrigeration systems, serving as indispensable components. As time passes, both compressors and their bearings undergo degradation, posing a potential threat of facility downtime and consequent negative impact on your financial performance. To guarantee the consistent and efficient operation of this equipment, the implementation of a rigorous maintenance program becomes imperative.
Staying on top (or even ahead) of maintenance will prolong the compressor’s life and avoid a shutdown. In fact, 82% of manufacturing companies have experienced unplanned downtime, costing as much as $260,000 an hour, according to one study.Continue Reading “5 Common Oversights in Industrial Refrigeration Compressor Maintenance (and How to Combat Them)”
As any industrial engineer will tell you, screw compressors play a vital role in the food and beverage industry, where temperature control is critical to ensure product safety and quality.
They’ll also tell you that these compressors require a lot of oil to work properly. This oil serves several functions, including sealing the rotors, lubricating the bearings and cooling the discharge gas. Because of this, nearly all food processors and beverage manufacturers will be in the market for a refrigeration compressor rebuild or replacement at some point or another.
And while regular maintenance can help, designing a system with the proper oil-cooling technique can also extend a compressor’s lifespan by thousands of operating hours — but how do you determine what method makes the most sense for your system?Continue Reading “Choosing the Right Oil-Cooling Method for Your Industrial Refrigeration Compressor”
A food processing operation requires more energy than some may realize. Unless you’re the plant owner paying the electricity bill, you might not have considered how much energy is needed to keep things running. Food production (agriculture, transportation, processing and handling) accounts for nearly 20% of all fossil fuel use in the United States, and 16% of that energy is used for food processing alone.
While utility costs are inevitable, there are strategies to make food and beverage plants more efficient and save money in the long run — though they often require an upfront investment. Energy savings are a long-term payback; it’s important to keep that in mind when building a plant or modifying a current one.Continue Reading “5 Energy Conservation Strategies for Food and Beverage Plants”
Building information modeling (BIM) technology is a revolutionary tool used by architecture, engineering and construction (AEC) professionals. It improves overall project collaboration and communication across disciplines by transforming 2D paper-and-pencil concepts into virtual 3D models that decision-makers and end-users can interact with.
When renovating or designing a new food and beverage facility, one of BIM’s most beneficial applications is its ability to define scope in detail.
It’s difficult to determine exact cost estimates early in a project due to supply chain volatility, material costs, labor wage rates, site conditions and other variables. However, BIM software’s granular capabilities can significantly improve the accuracy of those forecasts and track decision impacts throughout the process.Continue Reading “The Advantages of Using BIM for Project Cost Estimating”
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.Continue Reading “Building a Food Plant: 5 Ways to Prevent Schedule Delays”
A clean-in-place (CIP) system is a cost-effective and time-saving tool that rinses and washes the inside surfaces of food processing piping and equipment without mechanical disassembly. When designed well, a CIP system improves sanitation and enhances food safety while both simplifying the cleaning process for plant operators and reducing downtime. It automates what has traditionally been a laborious and time-consuming manual process of disassembling the piping, hand-cleaning each component and reassembling equipment.
In addition to lost revenue from halted production, improperly cleaned equipment can spread foodborne contaminants from batch to batch, which is dangerous to consumers and can lead to recalls that directly impact a company’s bottom line and reputation.
If you’re considering investing in a CIP system for your facility, it’s important to ensure you’re getting a design that is reliable and up-to-date. Your process design team should consider the overall needs of your operation, including changeover efficiency, water conservation and how the design will affect the complexity of the system.Continue Reading “7 Best Practices for Designing a Clean-in-Place System”
A sustainable revolution is underway and industrial/commercial buildings in the U.S. are lagging behind. Almost a quarter of U.S. greenhouse gas emissions come directly from industrial sources, such as manufacturing, food processing, mining and construction, according to the Center for Climate and Energy Solutions (C2ES).
“If direct and indirect emissions are combined, the industrial sector is the largest emitting sector in the U.S. economy, responsible for 29.6% of total emissions,” according to data provided by C2ES.
While you may be familiar with Building Information Modeling (BIM), it’s often underestimated and pigeonholed as merely a design and construction tool. However, when implemented strategically, BIM is the key to turning industrial facilities into long-term sustainability powerhouses and providing transparency and a sense of order to what has historically been a nebulous process.
A building’s design, construction and operation produce data that comprise a complex puzzle — BIM helps solve it.Continue Reading “Think You Know BIM? Think Again: How Building Information Modeling Boosts Sustainability”
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:Continue Reading “Your Checklist for Updating Your Facility’s Risk Management Program”
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.Continue Reading “Factors to Consider Before Using a Spec Building for a Food and Beverage Facility”