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? Boilers Boiler ..read more

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 ..read more

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 mai ..read more

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 faciliti ..read more

When using ammonia refrigeration in a facility of any kind — whether it be meat or poultry processing, frozen food production or cold storage — compliance with ammonia safety standards is a must. The International Institute of Ammonia Refrigeration (IIAR) is a membership-based technical society focused on ammonia refrigeration advocacy, education and standards. As an accredited American National Standards Institute (ANSI) Developer, IIAR establishes the minimum requirements for safely inspecting, testing and maintaining closed-circuit ammonia refrigeration systems. IIAR 6-2019 was published in ..read more

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 facili ..read more

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 equip ..read more

It’s no secret that working in a food processing plant can be quite dangerous. In fact, the Bureau of Labor Statistics (BLS) has listed the food manufacturing industry as one of the most hazardous. A big contributor to workplace accidents is improper lockout/tagout (LOTO) procedures.  When production in a food processing plant is halted for the installation, servicing or maintenance of machinery and heavy equipment, there must be a LOTO procedure in place to prevent the machine from turning back on and injuring a worker.  The Occupational Safety and Health Administration (OSHA) maint ..read more

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) s ..read more