[vc_row][vc_column][vc_custom_heading source=”post_title” tag=”h1″ size=”sz-l”][vc_column_text]In this blog, we explore the importance of finding the right partners whether you are considering the installation of a new line, or the extension of an existing one, or for the replacement of obsolete equipment. We think it is essential to think of any suppliers that you work with as partners, because if you are not working together to find solutions that meet your top-level business objectives, as well as stringent industry regulations, the relationship is likely doomed from the start.<\/p>\n
Before embarking on the selection process, you will need to ensure that prospective partners can provide precisely what you need to produce your product so that it meets industry and customer requirements. To do this you will need to carefully assess exactly what it is that you want to achieve. If you are looking at entering a new market, you will need to consider the the nature of the ingredients, packaging and labelling requirements, the desired speed of the line, how you will clean and maintain it \u2013 and much more.<\/p>\n
Or you may wish to modify or extend an existing line in a bid to grow market share. In these circumstances, you may need to bear in mind space issues, which could have a knock-on effect on health and safety.<\/p>\n
Once you have agreed on your production line requirements, the next step is to draw up a set of designs and specifications. Many food manufacturers seek help from external experts when it comes to formulating designs and specs, but before you begin drawing up a shortlist of potential design partners there are many things to consider, and these are just a few:<\/p>\n
While you need to be thorough at the planning stage, beware of over-specifying what you need your equipment and project management partner to do. This may seem a good, future-proofing idea, but it could lead to increased costs and the choice of a partner that is not the best fit.<\/p>\n
However, once you have agreed your plan<\/a>, you\u2019ll need to ensure you have buy-in from all the key stakeholders in your business.[\/vc_column_text][vc_single_image image=”9737″][vc_column_text]<\/p>\n Having decided on the types of equipment you need, you will face the challenge of identifying suppliers that offer the right type of machinery and line solutions<\/a>. This stage will likely involve a great deal of research \u2013 but it\u2019s worth it.<\/p>\n You may find that you can get all the components you need from one partner or that you need to engage several partners. The advantage of working with one provider is that you will have a single point of contact for your project management<\/a>. This will simplify your planning process.<\/p>\n However, you may find that one supplier does not offer everything you need. If you are working with multiple partners, make sure that the machinery they are individually supplying is compatible with the other equipment on the production line, to ensure efficient and accurate results.<\/p>\n This is one of the most complex parts of the process and it requires input from established food manufacturing experts. We will discuss this later in the blog.<\/p>\n When comparing different equipment partners, you need to carefully consider the specifications of the machinery they offer. It is also vital to check that their equipment provides the right level of accuracy, speed,\u00a0IP rating<\/a>\u00a0and any additional features that will help your business stand out against your competitors. You also need to ensure that their machines meet strict industry standards and regulations.<\/p>\n In the UK, you need to comply with\u00a0Food Standards Agency<\/a>\u00a0and\u00a0British Retail Consortium Global Standards<\/a>\u00a0(BRGS), the\u00a0Groceries Supply Code of Practice<\/a>\u00a0(GSCOP), as well as\u00a0EU directives<\/a>\u00a0and global standards such as the\u00a0Global Food Safety Initiative<\/a>. You should also check out local laws and any requirements relevant to the sector you operate within, such as\u00a0HACCP (Hazard Analysis and Critical Control Points)<\/a>\u00a0and GMP (Good Manufacturing Practice).<\/p>\n Diligent equipment suppliers ensure that their equipment is industry compliant and are always innovating to launch new and improved equipment<\/a> to help their customers achieve the best possible results.<\/p>\n This stage also needs forensic investigation, as the best equipment suppliers seek to improve product specifications as often as they can. So before signing on the dotted line, ask the manufacturer if it is working on a new, better version of the machine you like, how long it will be until the upgraded version is available to purchase and are there any upgrade paths for buyers. It is best to avoid acquiring machinery that may soon go out of production, so always check this before you purchase or you could find yourself having to find cash for a replacement much sooner than makes commercial sense.<\/p>\n You must choose a partner with the right type of experience for your food processing business. They need to be able to demonstrate an understanding of the kinds of equipment required at every stage of your manufacturing process and which equipment is best suited for which products.<\/p>\n Because it is generally the case that food processing production lines are made up of machinery and equipment made by a multitude of suppliers, you must ensure that each machine-maker is comfortable working collaboratively with other suppliers \u2013 who may themselves be potential rivals.<\/p>\n In more complex situations, where you are having to deal with many different suppliers, with different work cultures, working practices and personalities, it would be wise to appoint a first-rate project manager<\/a>.<\/p>\n The project manager plays a crucial role in getting your operation up and running, to maximum productivity, while meeting regulatory and customer demands. They need to be able to negotiate equipment prices on your behalf, so you must feel you\u2019re able to trust them. Ask them to provide case studies and testimonials. Check that they have good relationships with suppliers \u2013 but that they don\u2019t have allegiances with any particular suppliers. They also need to be flexible and adaptable. Production line installations can take many months to perfect, so your partners must be able to demonstrate endurance, patience, and an ability to be very flexible and adaptable as a lot can change along the way.<\/p>\n They also need to be present, whether that be in a physical sense or regularly emailing and calling suppliers and fitters to ensure they stay on track to deliver your project on time.[\/vc_column_text][vc_single_image image=”9780″][vc_column_text]<\/p>\n With food production lines becoming increasingly speedy and complex, having to cope with multiple raw material inputs, absolute accuracy in terms of weights, measures, packaging and labelling, not to mention the elimination of any contaminants<\/a>, the need for integrated solutions to cover the feeding, weighing, checkweighing, dispensing and inspection of your products requires a carefully calibrated and streamlined process.<\/p>\n The food production industry is also highly regulated, with food safety at the heart of the regulations, so it\u2019s vital that food manufacturers seek out the right advice for their production lines. Existing and potential new customers want manufacturers to be fast, efficient, productive and agile. Manufacturers must show that their lines are hygienic, safe and able to pass regulatory scrutiny.<\/p>\n To satisfy all these demands when installing equipment, it\u2019s crucial to engage a project manager capable of recommending impeccable equipment suppliers and managing the project from inception to completion. Ideally, food manufacturers need a project manager who can be a single point of contact from start to finish. This will simplify the process and free up management time for the day to day running of their business.<\/p>\n A good project manager will begin by gaining a deep understanding of the manufacturer\u2019s operations, their goals and objectives. They will then work with the food manufacturer from the design stage, the identification of compatible and efficient equipment, installation, testing and commissioning<\/a>. Some project managers are also able to provide training and ongoing support.<\/p>\n The essence of exemplary project management is the ability to work well with everyone who is contributing to the job \u2013 from the designers, equipment suppliers and engineers, to the client\u2019s management team and those who will be operating the line, maintaining it and cleaning it \u2013 and so on.<\/p>\n In other words, not only must your project manager be an expert in your particular field of food manufacturing, they must also be highly personable, persuasive and possess a \u2018can-do\u2019 attitude.<\/p>\n It is also worth considering the range of services your partner offers. Beyond providing you with the equipment you need, you will also want a partner that can assist with fitting the equipment and ensuring that all the parts work together smoothly<\/a>.<\/p>\n An expert project manager, with a verifiable track record, will know and understand the full range of equipment that each client needs. Once they have detailed knowledge of a manufacturer\u2019s individual needs, whether it be to produce fresh meat or fish, fruit and vegetables or cereals, snacks, ready-meals or dairy \u2013 and the list goes on \u2013 a full qualified and experienced project manager will be able to recommend a bespoke range of the very best equipment from verified suppliers.<\/p>\n Food production project managers will work within your budget to recommend the best machinery you can afford, to maximise the chances of avoiding equipment failure and consequent downtime.<\/p>\n One of the most important project management roles is to ensure that the various machines operating in your production line are compatible with one another. They will take care of every aspect of line installation, organise a dry run to check that all the machinery is working as it should be and that all the electricals are generating the correct signals and functioning properly.<\/p>\n Expert project managers can quickly identify any part of the production line that is not operating at maximum productivity levels. Once they are certain that all the equipment is running smoothly, they will ramp-up the speed and introduce the products. The ramp-up, or commissioning period, must be done with caution, so that if there are any issues, damage to other equipment can be avoided.<\/p>\n Once the ramp-up and the commissioning period has been completed, your experienced project manager will arrange a Site Assessment Test (SAT) to ensure equipment functionality. A good project manager will also recommend that a PUWER<\/a> assessment is carried out to ensure the equipment is suitable and safe for its intended purpose.[\/vc_column_text][vc_single_image image=”9781″][vc_column_text]<\/p>\n One of the main challenges for the food processing industry is to reduce manufacturing costs and waste. The best way to achieve this is to incorporate real-time analysis into your production line. This means you need to check that prospective partners can provide the tools and systems which enable continuous analysis and control of processes, including real-time sensing and analysis of both raw materials and in-process materials. This way, the product quality is controlled during processing and not determined after production.<\/p>\n The latest x-ray inspection machines<\/a> offer real-time analysis of potential contaminants so it is worth checking whether your partner can equip you with these if needed.<\/p>\n The gold standard here is to find a partner that is capable of providing instant live data collection that can be analysed by line, product, shift and site. This provides manufacturers with the all-important audit records that will help them avoid mistakes in the future. This increases efficiency, accuracy and productivity.<\/p>\n Given the demand of supermarket customers and the highly regulated nature of the food manufacturing industry, real-time data provides accurate production monitoring ensuring compliance to customers\u2019 specifications. Additionally, product performance reports help improve line productivity and drive down wastage.<\/p>\n It\u2019s also essential to choose a partner that can provide maintenance and servicing solutions as this will reduce the risk of downtime. Also, are they able to carry out repairs<\/a> on-site and how quickly can they do so? This will give you peace of mind that you have the right help in place during the lifetime of the project, including if anything should go wrong \u2013 and this can lead to a great partnership. In addition, it allows you to reduce the total cost of ownership.<\/p>\nHow do I find partners that are capable of doing what I need?<\/h2>\n
Do the equipment suppliers offer the right specifications?<\/h2>\n
Do the partners have sufficient experience?<\/h2>\n
Why is a project manager needed?<\/h2>\n
What is the role of a project manager?<\/h2>\n
What can a project manager do to help avoid errors?<\/h2>\n
Provide detailed advice on the best equipment<\/strong><\/h3>\n
Be able to work effectively to budget <\/strong><\/h3>\n
Ensure the installation goes smoothly<\/h3>\n
Run tests with the product present to eradicate any product\/machinery glitches <\/strong><\/h3>\n
Sign-off<\/strong><\/h3>\n
Data analysis<\/h2>\n
What about maintenance and servicing?<\/h2>\n
What about spare parts?<\/h2>\n