“Improved performance through sustainability,” the achievement lauded by ProFood World’s Sustainability Excellence in Manufacturing Awards, sounds like a lofty goal. Yet after listening to the presentations of this year’s winners at PMMI’s PACK EXPO (Sept. 27-29), what struck me wasn’t so much the success of each company’s sustainability initiative (all quite impressive and detailed here), but the common threads that led each to make changes that enhanced their operations while respecting the environment.  

The five companies that came away with this year’s awards were Smithfield Foods, B&G Foods, Conagra Brands, Liffey Meats, and Graphic Packaging International (in the Processor/Supplier Partnership Category). Whether striving to reduce air, water, greenhouse gas emissions, or packaging material waste, each company was intentional, critical, and collaborative in its efforts. Here’s a simplified version of what all processors can learn from their success:  

Proceed with intention: Realize that there’s always room for improvement. Companies that want to make things better have a can-do mindset. Set a goal and move forward. 

Critique your operation: Spend time on the plant floor. Watch operations, talk with personnel, ask them where improvements can be made and listen to their concerns and suggestions. Such efforts frequently reveal inefficiencies. Examine time spent on tasks, the amount of waste leaving the facility, current energy use and water discharge, even the packaging materials you’re using. Where can changes be made?  

Welcome collaboration: If the pandemic has taught the food industry one thing, it’s that we work better when we work together. If you want to make your operation more sustainable, you need to actively welcome input from workers and operators, involve them in goal setting, and keep them updated on the results. Some companies have created internal competitive teams to help them reach their goals and encourage teamwork, providing incentives and rewards for the most successful group. Consider also reaching outside of your facility for help. For example, a partnership with Graphic Packaging International led to more sustainable product packaging for Liffey Meats.  

And of course, collaborating with a design and engineering firm to streamline your processes or improve the layout of the plant can lead to energy savings and a more efficient overall operation. If you would like help, contact ushere. 

We had leftovers for dinner last night. Turkey sandwiches and salad.  

Normally, that would be an unremarkable statement, but I find it extraordinary that fresh, wholesome food is still available despite the events of the past two years. That is no small feat. And it is past time that we recognized the extraordinary resilience of food producers that have managed to feed us in an environment that is increasingly difficult.

We can debate the issues behind higher food prices-particularly meat prices—as is the chatter today. Certainly, various responses from the industryto current White House criticism and the plan to address this issue are worth exploring.  

But that’s not the point of this post. Here, we note that our nation’s food producers really have done a remarkable job pivoting and persevering to keep food on grocery shelves. And they deserve credit for that.

Our firm’s engineers, architects, designers, and construction specialists see what the average consumer does not. We get the calls from processors desperate to increase capacity to meet their customers’ needs. We are in the plants and on construction sites helping them figure out how to manage while they wait for everything from equipment to ingredients.

Faced with a workforce that was already limited, these businesses—many of them family-owned for generations—have invested in expansive facility changes and advanced technologies to keep staff healthy during this pandemic while continued waves of illness, changing governmental requirements, and other economic factors hinder their efforts. To keep your food safe, the working environment in these facilities is often cold, sometimes wet, and always noisy. Operations do not cease for holidays, and those at the helm of these businesses work 24/7.

And they keep going because people need to eat.

So, thank you to ALL of you behind the scenes for your efforts. We appreciate you.

(Green Bay, Wisc.) – Foth Production Solutions, LLC (Foth), a science and engineering firm headquartered in Green Bay, Wisc., will acquire  Food Plant Engineering, LLC and Food Plant Construction, LLC, an architecture, engineering, and construction firm based in Cincinnati, Ohio. This strategic acquisition significantly enhances the capabilities and reach of both firms within the food and beverage manufacturing sector.

The food and beverage market continues to see unprecedented evolution of consumer preferences for health conscious, variety, and private label offerings. Food Plant Engineering’s history of supporting this dynamic sector of the market is a strong complement to Foth’s existing partnerships within the consumer-packaged goods industry.

Over the last 72 years, Food Plant Engineering has created innovative solutions to the unique production and facility challenges of food processing companies. This expertise includes facility planning and design, process planning and design, facility construction, and process installation for forward-thinking organizations that are reshaping the pace and direction of the industry. Food Plant Engineering’s location also allows Foth to more quickly and efficiently serve clients throughout the Ohio River Valley. In addition, their architectural service offerings will contribute to greater efficiencies for design-build project delivery.

The acquisition will provide Food Plant Engineering’s existing clients with a broader range of services, addressing the increasing demand for integrated, multi-disciplinary expertise. By leveraging Foth’s extensive experience with mission-critical capital projects, deep bench of knowledgeable employee-members, and vast network of contractors, we can deliver more comprehensive solutions, specifically in the areas of food, beverage, paper, and industrial manufacturing and automation; civil design and engineering; and environmental services.

Together, we are uniquely positioned to deliver the speed, flexibility, and full-service solutions manufacturing clients need to thrive in today’s rapidly changing environment.

Employees of both firms will benefit from enhanced professional growth opportunities. The combined resources and expertise will create a dynamic and supportive environment for innovation and career development. This acquisition underscores Foth’s commitment to investing in people and fostering a culture of continuous learning and advancement. 

“We are proud to announce that we have combined our resources and expertise with those of Food Plant Engineering to more broadly serve new market segments and emerging companies within the food and beverage manufacturing sector,” said Foth CEO Randy Homel. “We look forward to welcoming our new employee-members who have demonstrated a proven track record of success as designers, builders, and creators for sustainable food production facilities.”

Food Plant Engineering President Mark Redmond reiterated that, “Joining Foth is a tremendous opportunity, not only for our FPE team but, most importantly, for our clients. We are proud of what we’ve accomplished alongside some of the best food manufacturers, and I’m excited to enhance their access to an even wider range of capabilities.”

About Foth:

Founded in 1938, Foth is an employee-owned science and engineering consulting firm that delivers technical solutions for public and private clients around the globe. Professional services are focused in the areas of production manufacturing engineering, infrastructure, and environmental science and engineering. Foth is headquartered in Green Bay, Wisconsin, with more than 700 employee-members across 30 locations. For more information, visit foth.com.

How to unleash production when the bottlenecks clear

Supply chain woes may have limited your ability to meet a rising demand for your product. And labor shortages—already a problem pre-pandemic—have worsened the situation for everyone in the food industry. As you scramble to obtain everything from ingredients to packaging materials, it’s likely that your focus on immediate needs has left little time to think about tomorrow. Expanding or upgrading your facility may seem like an impossible dream now.

But at some point, this will end.

And when it does, food processors that have planned will be ready to move forward and ramp up production, even if labor remains scarce. Here’s how to prepare:

Set Goals

Manufacturers are frequently in a hurry. “What is your timeline?” is often answered with “Yesterday” by those seeking engineering and professional design assistance. If you’re grappling with a recall or a food safety threat, the need is urgent, indeed. But if you’ve been putting off a renovation, struggling with consistent operational inefficiencies or waiting for the perfect time to automate a process, the time to start the planning phase of your project is now, while the world is waiting for the ships to come in (truly).

Planning provides the roadmap for your project. When you have made important decisions in advance, what follows is a much smoother process. Given the uncertainties of today’s supply chain, this planning step is even more important. The following are among the many issues you’ll need to address:

• Identify what you want to achieve:
• Increase production by 25%?
• Introduce an automated process?
• Reconfigure your space?
• Make room for a phased expansion?
• Set a timeframe. Ideally, when would you like to have your project completed?
• Look beyond tomorrow.
• Are your goals realistic if labor remains scarce long-term?
• What steps can you take to prepare for a future without the same level of hands-on labor you had before the pandemic?

Get Real

Take stock of your internal resources and expertise. Ask and answer these questions:

• Do you have an internal engineering team that can lead your project?
• If so, are these individuals aware of the materials and processes required to maintain a safe and sanitary food facility?
• Can they handle the design of the intricate systems necessary to operate the equipment you need?
• Do they understand what it takes to meet today’s regulatory requirements?
• Can you afford an interruption in your operation as you take on a construction project? If not, do you have the knowledge and time to manage a construction project while managing your day-to-day operations?
• Do you have access to a design/build team with extensive experience building food processing facilities? Note: Constructing a food processing facility is NOT the same as building a restaurant or a warehouse, so don’t be fooled by a local contractor into believing these are similarly complex.
• Do you have a budget in mind? While the cost of goods and services may vary with the economic outlook, your budget is your budget. Know what you can spend.

Proceed to Plan

After you’ve done the above, it’s time to get down to the nitty gritty. If you can tackle your entire project internally, dig into that planning now. If you need help with process planning, master planning, site planning or facility planning, reach out to an experienced design firm to gauge if your expectations and resources are realistic. You can contact us here.

Regardless of the path you choose, having a plan puts you at the front of the line when the supply chain congestion eases. You’ll be ready to install that line, receive that equipment, initiate that automated process, or even break ground on that new building, so you can move forward to meet or exceed your production goals. 

The 2022 International Production & Processing Expo promised the usual: technology, equipment, supplies, and services galore, all revolving around egg, meat, and poultry processing. Boasting on its website that IPPE is “the world’s largest annual poultry, meat and feed industry event of its kind,” the annual show at the Georgia World Congress Center felt like something more this time around. 

It felt… dare I say… more “normal” than we’d expected. Few masks were worn, handshakes were freely offered, and local eateries were crowded (though, most restaurants visibly struggled to provide services). Ditto hotels. The chatter among processors and suppliers was predictable: automation desperation coupled with supply chain frustration. These issues are constraining an industry that otherwise could be thriving.  

Trade shows are always an interesting gauge of the industry’s health. It’s clear from IPPE that the meat and poultry business is very much alive, though it needs to regain some lost energy. The supply chain should improve over time, but businesses are going to have to be strategic to manage labor losses. Improving inefficiencies in operations by streamlining processes, adding automation where appropriate, and improving facility layouts can help. These efforts, while not a panacea for all pandemic-triggered woes, will move us closer to normal more quickly. 

If you need assistance getting more out of your operation,connect with us here.

“Please keep your seat belt fastened in case we experience unexpected rough air.” Anyone who travels by plane is accustomed to this announcement.

Heading into the International Poultry & Processing Expo (IPPE) in Atlanta, I expected to hear similar proclamations from attendees. It’s time to buckle up; the food industry is headed for a rough ride. Avian flu has been painful, and the price of eggs is high. Feed costs are soaring. Labor is non-existent, and the supply chain is still in disarray. Overall, the economic outlook is murky. Yes, a little hesitancy about the future would be understandable.

Yet, among the processors and suppliers visiting with us, it was full speed ahead because product demand is still growing. Food must be produced, and processors are stretched to meet demand, making plans to expand, renovate and build. Pragmatic attitudes seem to be prevailing. Maybe we can ease up on that buckle a bit.

Should we be worried at all? What does the food industry radar indicate? Are there storms in our path we just aren’t seeing? Or are we, by expanding and improving efficiency now, buckling up and getting ready for the future?

Our instinct leans toward the latter.