Our guide to the ultimate modern food factory

Ambrey Baker prides itself on its eagle-eyed attention to detail from new builds to refurbishments. This attention is key when optimising food factories for productivity and efficiency.

In our 30 years of business, what defines the ultimate modern food factory has changed dramatically. Technological advances, net-zero targets, Covid-disruption, energy challenges, inflation and the shifting landscape of the manual workforce have all played their part in altering the playing field.

Here, executive director Paul Waldeck identifies the key focus points to optimise a food factory in 2022.

Factory Optimisation & Hygiene

Factories are living, breathing entities. That means they require consistent maintenance, just like any other piece of machinery. Over time, factories can suffer from reduced energy efficiency and productivity as the wear and tear of time grinds away. Even the smallest of details can all reduce the efficiency of a factory and also compromise hygiene security. From hinges rusting, seals becoming compromised through intensive day-to-day usage, leaking roofs, and thermal movement disrupting wall and ceiling joints, this impacts your factory.

Food factory MOTs put every nook and cranny of a property under the “microscope” to identify problems and provide quick, affordable fixes before they grow into more costly issues.

During this process, our team’s knowledge of food safety, hygiene standards and cold storage will be at your disposal. We can identify where occupational health & safety and food safety could be at risk. The most common issues can then be quickly fixed to get your factory as safer and as efficient as it can be, for the benefit of both your products and staff.

Automation

It wasn’t so long ago that machines fulfilling the roles of the labour force were only seen in fiction. Today, automation is very much a part of our reality. Automation can boast higher accuracy, longer operating hours and improved waste management. Covid disruption and the need to be more resilient in business operations has accelerated the transition coupled with tax breaks from the HMRCs “Super-Deductions Scheme”. As a result of all these factors, many factories are now overwhelmingly in favour of automation.

Improved accuracy also means less waste – offering financial and environmental benefits – whilst the data helps automation managers continue to improve and maintain the equipment. Given so many drivers now, automation is essential in the modern factory.

Contrary to belief, integration can be a simple process. Our experience allows us to assess factory layouts and processes and how a reshuffling of the pack can make better use of the space, incorporating new automation in the processes.

It comes in many shapes and sizes, working a myriad of roles. Our in-depth industry knowledge will help you discover the right automation for your needs, factory space and budget. It can easily be integrated into existing factories, invaluably saving the time and money it costs for new builds.

Biodiversity & Sustainability

There have been plenty of reports relating to how food production is driving biodiversity loss to the extent that some reports warn that by 2050 it could be possible to have reversed biodiversity loss – if the industry continues at its current rate.

It’s clear that the UK’s food factories need to be equipped with the technology and processes to tackle the issues. Luckily, there are increased options available to produce positive results.

Biomethane trucks have been reported to reduce tailpipe emissions by up to 80-90%. Yet, it is estimated that only 1.5% of the UK’s long-haul HGVs run on biomethane – which derives from food waste and manure – even though HGVs account for 4.2% of UK carbon emissions. It feels the potential for improvement here is extraordinary.

Further into the supply chain

Minimising the use of plastic packaging – and increasing the use of recycled raw materials–helps food factories massively towards de-carbonisation.

From Lidl pledging to remove two billion pieces of plastic packaging by the end of 2022 to the rise of seaweed and other recyclable or biodegradable packaging solutions, there is a renewed effort from the industry to make a difference. Those striving for a modern food factory should be taking note.

For factory managers, it’s imperative that regular maintenance checks are carried out. Even the most minor of defects can amplify into huge productivity loss or hygiene risks. In 2022, the ultimate modern food factory may be equipped with the latest in technology and be running as close to carbon neutrality as possible. However, that doesn’t make them immune to wear and tear. Often, the desire is to fit out existing buildings with new automated lines can present its own risk to success. It’s worth doing the due diligence on the environment that the new line will operate within.

For more information about Ambrey Baker, head over to the company page or follow us on LinkedIn.