Mastering all the P’s in food chain productivity

Food safety specialist Fortress Technology examines why working smarter not harder is critical to safeguarding the future of global food security, naming performance, product, people, process and profit as the top 5 productivity priorities in UK food manufacturing. 

The food chain plays a significant part in our economy. In 2022, it accounted for approximately eight percent of the Gross Value Added of the UK non-financial business economy. Although productivity may have long eluded the other sectors in UK manufacturing, the Office of National Statistics reports that in 2022 three of the four food chain sectors had a higher productivity than in 2021, with UK food and drink manufacturing rising by 2.7 percent.

Maintaining this upward productivity curve will be reliant on the sector continually innovating and adapting to production and sustainability trends as they emerge, reports Phil Brown, Sales Director at Fortress Technology Europe.

POPULATION PROJECTIONS

Balancing all aspects of food security – now and in the future – is intrinsically linked to productivity. The United Nations projects that food production from plants and animals will need to increase 70% by 2050 to compensate for rapid population growth and food demand. Industrial food production will need to adapt to keep pace.

Considerable advances in food manufacturing technology have made it possible to produce higher volumes of safe food produce, despite the decline in available land for agriculture and manufacturing facilities. However, the present state of the food industry will be insufficient to maintain or exceed the current levels of food quality and availability required for future food security. Automated technologies, optimised production systems and stricter food safety standards must be adopted by the global food industry to ensure food products remain safe and in sufficient supply.

Globalised trade is set to increase alongside population growth. If not managed correctly, this could potentially result in unsafe food products entering the global marketplace. Utilising smart inspection equipment in tandem with automatic testing and digital data reporting can boost transparency throughout the supply chain, build trust between suppliers and consumers, and ensure each stage of production is performing its due diligence to comply with international food safety protocols.

“Technological advancements and advanced food safety equipment will be crucial in the pursuit to feed the entire world population by 2050,” states Phil Brown.

OPTIMISATION AT ALL LEVELS

To gain a competitive advantage as a food manufacturer in this turbulent market requires the ability to predict, plan, adapt and adopt new processing methods. One of the most valuable ways to contribute to a safer, more secure and sustainable food supply chain, as well as gain a competitive edge in the industry, is through process, performance and operational optimisation.

This can be accomplished by adopting lean manufacturing principles that focus on maximising value and minimising food and packaging waste. For example, streamlining processes can reduce the risk of contamination and ensure consistent quality. Additionally, implementing automated technology and digital tools can aid in identifying inefficiencies and increase responsiveness.

DISPELLING PEOPLE PRODUCTIVITY MYTHS

The most common fear when approaching food factory optimisation and productivity is exploitation. Workers may fear they’ll be overworked and underpaid to achieve greater output or lose their jobs to automated processes. However, when productivity is done right, these apprehensions rarely materialise.

Automation and digital tools which assist boosting productivity rely on human-machine interactions to function and evolve. Predictive analytics and AI tools rely on feedback from humans to generate valuable data sets and information. In other words, optimisation cannot exist without human input.

In fact, a food factory focused on operational efficiency can actually experience greater employee engagement, championing further process improvements.

5 PRODUCTIVITY-BOOSTING BENEFITS

Productivity establishes the important correlation between effort, efficiency, effectiveness and profit. By boosting efficiency of processes using productivity-enhancing tools, less effort, money, labour, time and materials can go into producing higher output yields and increasing operational profits.

Here are several aspects of productivity that can benefit food manufacturers:

1. Process optimisation plays a crucial role in minimising resource consumption, reducing food and packaging waste and lowering the environment impact of business operations. This is achieved by identifying and eliminating unnecessary steps and streamlining operations. For example, utilising automated food inspection technology, integrating equipment into a smaller-footprint single system, and introducing automatic testing.
2. A connected, streamlined factory plays a huge role in increasing traceability and recall responsiveness. Additionally, process integration and networked communications provide seamless connectivity, which can help to immediately highlight inefficiencies and potential bottlenecks in processes upstream, as well as minimising production line downtime. Here reliability more often than not requires simplicity.
3. Implementing lean manufacturing principles has a significant impact on food safety, quality and competitiveness. By reducing complexity, there is less chance of errors or contaminants entering the production line; an important consideration given that production and energy costs are still rising, while the prices paid by retailers and wholesalers for food are generally the same or falling. As there is no value in downtime, automating processes like product learning and machine re-calibrations can save significant time, energy and product waste.
4. Most people prefer to be productive with their time. However, more often than not it can be inefficient processes that compromise productivity. Research indicates that the average company loses more than 20% of its productive capacity – more than a day each week – to organisational drag. However, employees report feeling more empowered and less overwhelmed when companies invest in well-considered tools and technologies that support processes that remove repetition and stress. The added benefit is a productive workplace fosters a positive work culture, innovation and continuous learning.
5. Increased productivity encourages an innovative environment, with potential ideas transforming food safety and supporting the pursuit of food security. Productive employees have more time and mental capacity to explore new ideas and solutions, cultivating creativity when faced with challenges and inefficiencies.

“Ultimately, the future of our food systems will be dependent on food companies finding innovative ways to tackle sustainability, while simultaneously generating greater output. Choosing reliable, productivity-enhancing equipment and systems is the first step,” concludes Phil.