Staying current with new technologies helps food manufacturers remain competitive and meet consumer demands. Rapid technological advancements offer exciting opportunities for the food industry to improve their lines and increase efficiency. Believe it or not, we don’t just mean artificial intelligence.
In our experience, progress happens in two key aspects of manufacturing: Product Innovation and Process Innovation.
Product Innovation involves advances that make manufacturing equipment more efficient, reliable, or safe. Manufacturers constantly look for ways to upgrade their equipment to streamline their production process and minimize downtime. Innovative features such as improved sensors, automated cleaning systems, and predictive maintenance tools help ensure the equipment runs smoothly and consistently.
On the other hand, Process Innovations focus on technology that enhances installation, planning, or operations. These innovations help manufacturers optimize resources, reduce waste, and maximize productivity. For example, advanced planning software can help streamline production schedules. At the same time, smart sensors can monitor the production line in real-time, identifying bottlenecks or potential issues before they become costly problems.
Food manufacturers can realize significant benefits by investing in both Product and Process Innovations. They can achieve higher production rates, reduce costs by minimizing downtime and waste, and ultimately deliver high-quality products to their customers.
TECHNOLOGIES TRANSFORMING FOOD MANUFACTURING AUTOMATION
As an equipment manufacturer, we’re constantly keeping an eye on emerging technologies that will not only improve our machines but also the service we provide to the food processing industry. Our team thrives on innovation, and we’re always excited to see something new that we can integrate into our business. A couple of recent examples of this constant innovation are below:
Saddlepack Taper Innovations
We’ve recently begun using new drive systems in some of our builds. These allow us to create more precision speed control, reduced maintenance, and a simpler design. Let’s break it down:
Enhanced control over speed: This means we can adjust part speeds to meet the demands of the equipment without sacrificing efficacy. So, there is a greater ability to start and stop specific parts without putting undue stress on the motor or connected parts.
Reduced maintenance: Say goodbye to operating wear and tear. By reducing the shock and strain put on parts, we can extend the life of each element and reduce wear out and replacement.
Simpler design: By integrating these new drives, we can remove shock absorbers, air cylinders, and other parts designed to regulate less precise motor operation. By embracing new technology, our equipment becomes simpler, with fewer opportunities for something to “go wrong.”
The adoption of this new part has allowed us to update our Saddlepack Taper, which needs less ongoing maintenance. This is a perfect example of how technology provides product innovation and long-term cost savings for manufacturers.
Delmia by Dassault Systèmes
We recently had a perfect example of Process Innovation as well. We put together a cool experience powered with Delmia by Dassault Systèmes. This software has many incredible capabilities that can help make your manufacturing line more reliable and efficient than ever before.
One of the unique features of Delmia is its ability to create 3D models of manufacturing systems. While this data is good to have, the industry has often struggled to find solid use cases for it. While working on a recent proposal, our team put together an innovative approach to help our client visualize their situation.
For this proposal, we connected Delmia’s 3D scans with VR goggles to create plant visualizations the customer could use for layout planning. We were able to show how new equipment would integrate with existing machines, helping the customer “see” the updated processing line.
But the benefits didn’t stop there. By using this software, we brought all the important stakeholders to the table to evaluate the proposal at the outset of the process. Safety personnel could identify potential hazards, and operators could recognize issues the layout might pose. We could even jumpstart installation planning, giving electricians and other skilled personnel a chance to see the proposed layout and anticipate the needs for a swift transition.
Our team recognized an innovative opportunity to improve an experience and put the pieces in place to give our customers confidence in the outcome.
ITERATION AND INNOVATION: A PROACTIVE APPROACH
How can the food industry avoid stagnation and inefficiency? It all starts with an iterative process of innovation. Iteration is repeating a process while making improvements along the way based on feedback and analysis. In the food manufacturing world, it means identifying the challenges that hinder reliability and efficiency and developing strategies and technologies to overcome them.
One of the major benefits of our approach to building equipment is we can iterate with each order. Since we aren’t mass-producing our automation machines, we have the ability to make improvements with each fabrication and installation. This helps us make sure our customers are getting modern, efficient equipment every time.
At a plant level, you can take an iterative approach to improving the operation of your production processes. Look for ways to automate repetitive tasks and improve worker safety. Logistics are often a place where incremental improvements can be made. How are you moving raw materials around the facility? Small tweaks can go a long way toward boosting the efficiency of the entire operation.
Additionally, sustainability is a growing concern in the food industry. With innovation and iteration, engineers can develop eco-friendly solutions that minimize waste and energy consumption. This can involve optimizing packaging materials, improving water and energy efficiency, and implementing recycling programs.
By adopting a proactive approach to iteration and innovation, plant engineers can tackle the challenges of reliability, efficiency, and cost control in food processing. By embracing constant improvement and the role of automation, they can pave the way for a successful and sustainable future in the industry.
Addressing Common Challenges
Challenges are catalysts for innovation. Often, taking a look at some of the most common obstacles faced by food processors, you can find areas to innovate and improve performance. Challenges are simply opportunities in disguise.
Spare Parts Management
Spare parts management is a crucial aspect of ensuring a reliable and efficient food processing line. It is important to have a well-organized inventory management system in place. This includes properly cataloging and labeling all spare parts and implementing a clear tracking system. The plant engineer can avoid unnecessary delays and downtime by knowing exactly what spare parts are available and their quantities.
Procurement is also a key factor in efficient spare parts management. By partnering with reliable suppliers and negotiating favorable contracts, you can ensure timely delivery of spare parts at the best possible prices. Establishing strong relationships with suppliers is also important to gain access to their expertise and support when needed.
To help our customers with this daily challenge, we’re developing an in-house ERP system that will track and catalog all the parts a plant might need to maintain and service our equipment. Our goal is to help customers avoid downtime or delays by keeping them well-stocked with spare and replacement parts.
Proactive Maintenance
Proactive maintenance is the key to keeping your food processing line running smoothly and efficiently. By taking a proactive approach to maintenance, you can prevent breakdowns and reduce downtime, keeping costs down and production up.
To support plant engineers, we’ve begun to look at some unique materials that are proving to be more durable with reduced wear and tear in normal operation. Specialty plastic provides longevity and reliability for bearings and conveyors in your food processing line. We’ve started to incorporate plastic bearings and conveyors for a few reasons:
- Longevity: Specialty plastic is designed to last. It can withstand the demanding conditions of a food processing plant, including high temperatures, corrosive chemicals, and heavy loads. By using specialty plastic bearings and conveyors, you can avoid frequent replacements and extend the lifespan of your equipment.
- Reliability: Traditional materials like metal can be prone to rust, wear, and tear, leading to frequent breakdowns and costly repairs. Specialty plastic, on the other hand, is resistant to corrosion and requires less maintenance. It keeps your food processing line running smoothly and reduces the risk of unexpected downtime.
This is a great example of new technology that not only improves the equipment but also provides relief for a plant engineer on the maintenance cost front.
Enhancing Automation with Curiosity
Curiosity is a key component in enhancing automation. When humans are involved, they bring a natural sense of curiosity that can explore new possibilities and identify areas for improvement. This curiosity drives us to ask questions like “Why is this happening?” and “How can we make it better?” We can uncover innovative solutions and optimize the food processing line by seeking answers to these questions.
By combining the power of automation with the curiosity and expertise of our engineers, we create reliable solutions for the food processing industry. Collaboration with plant engineers allows us to continuously refine and improve our automated systems, ensuring that they meet the ever-evolving needs of our customers.
THE ROI OF INNOVATION: SAVE COSTS, BOOST PRODUCTION
One of the most important places you’ll see the impact of new technology is in the lifetime cost savings of new investments. While there’s no question the cost of new equipment can be high, production efficiency, labor savings, and reduced maintenance can all combine to rapidly increase ROI.
For example, when we incorporated new motor drives into our Saddlepack Taper design, it allowed us to remove shock absorbers and air cylinders. These are two high-maintenance elements. The reduced stress on the equipment as a whole also created part and maintenance savings. With these updates, our customer was able to realize full equipment payback in less than one year of operation.
INNOVATION IN FOOD MANUFACTURING
A successful food processing line depends on reliability and efficiency. New technologies can support both of those outcomes. We understand the challenges you face and the need to stay ahead in a competitive market.
So, like you, we embrace innovative technologies whenever we find them. They not only improve efficiency but also help you meet the rising demands for quality and safety.
If you’re ready to explore some innovative automation options for your food processing line, contact Fremont Automation. Our team is here to provide personalized consultations and tailor-made solutions that will transform your operations. Don’t wait; embrace our unique brand of homegrown innovation today.