How Flexible Engineering is Revolutionising the Industry

The food and beverage industry is constantly evolving, facing new challenges like increased consumer demand, shorter production runs, and sustainability concerns. While automation and digitalization are key trends, simply placing machines in factories isn’t enough. This article explores the rise of “flexible engineering,” a collaborative approach between equipment builders and food manufacturers that prioritizes adaptability, data-driven optimization, and a human-machine partnership for a future-proof food production environment.

The Need for Agility: Adapting to a Changing Food Landscape

The food and beverage industry is a dynamic landscape, constantly adapting to meet consumer demands and navigate market shifts. Rising demand for fresh, high-quality products year-round, coupled with a focus on sustainable practices, puts pressure on manufacturers to optimize production while minimizing environmental impact. Adding to this complexity is the ever-present need to control costs and maximize productivity.

Traditional approaches to factory design, with a focus on standardized equipment and inflexible layouts, are no longer sufficient. This is where “flexible engineering” emerges as a critical solution. Flexible engineering moves beyond simply installing new machines. It’s a collaborative approach where engineers work closely with food manufacturers to design and build equipment and facilities that are specifically tailored to their unique needs. This could involve customizing mixing equipment to meet specific production requirements or designing modular processing lines that can be easily reconfigured for different products.

The Rise of Automation: A Partner, Not a Replacement

Automation has been a major topic of discussion in the food and beverage industry for years, and the COVID-19 pandemic has only amplified this conversation. With labor shortages impacting production and increased hygiene requirements, many manufacturers are turning to automation as a labor-saving solution. Robots, for example, offer several advantages: they can perform repetitive tasks consistently, don’t require sick leave, and are increasingly equipped with advanced vision systems that allow for safe collaboration with human workers.

However, it’s important to recognize that automation is not a one-size-fits-all solution. A complete end-to-end automated system is often cost-prohibitive for many manufacturers. The most effective approach often involves a hybrid system where humans and robots work together, leveraging each other’s strengths. Determining which aspects of a production line should be automated depends on the specific product being manufactured and the manufacturer’s current level of automation. For those with limited automation, focusing on solutions that offer quick implementation and high returns can be a good starting point.

The Power of Data: Optimizing Processes with Sensors and IoT

Flexible engineering is not just about physical equipment. It also involves harnessing the power of data to optimize processes. The increasing adoption of cloud-connected sensors and IoT-enabled machinery is a game-changer for food production. By integrating real-time data from sensors and analytics platforms, manufacturers can gain a deeper understanding of their machinery and production processes. This data can be used to identify inefficiencies, predict equipment failures, and optimize production parameters for improved yield, reduced waste, and higher productivity.

For example, sensors can be used to monitor equipment health, allowing for predictive maintenance and preventing costly downtime. Machine learning algorithms can analyze data and identify trends that might indicate a potential problem, allowing for early intervention. Additionally, software tools can help plant engineers analyze process data, identify areas for improvement, and gain valuable insights to optimize production.

Engineering a Remote Future: Adapting to Changing Collaboration Models

The COVID-19 pandemic has not only impacted food production itself, but it has also fundamentally changed the way engineers interact with food companies. With travel restrictions and social distancing guidelines in place, remote design, engineering, and testing have become essential for keeping production lines running smoothly. Food manufacturers and engineers have embraced virtual technologies such as remote factory acceptance tests, video demonstrations, and augmented reality tools that allow for collaboration even when physical presence is not possible.

While remote collaboration offers significant benefits, the importance of traditional on-site expertise should not be discounted. The most successful projects often involve a combination of local engineers who understand the specific needs of the facility and digitally-present engineers who can provide expertise and support remotely.

Investing in the Future: Considerations for Flexible Engineering Solutions

When considering flexible engineering solutions, it’s crucial to carefully evaluate the total cost of ownership (TCO). This goes beyond simply looking at the initial equipment cost and encompasses a wider range of factors that impact the long-term financial viability of the investment. Here are some key considerations:

• Initial Equipment Cost: While not the only factor, the upfront cost of the equipment is an important consideration. However, it’s crucial to avoid solely focusing on the lowest price tag. Higher quality equipment may command a premium upfront, but it can offer significant cost savings in the long run through factors like:
  • Durability: Well-built equipment lasts longer, reducing the need for frequent replacements.
  • Reliability: Reliable equipment minimizes downtime and lost production, which translates to revenue protection.
  • Lower Maintenance Costs: Durable and efficient equipment typically requires less frequent and less expensive maintenance.
• Ongoing Maintenance and Sanitation: Flexible solutions often require specialized cleaning procedures to maintain hygiene standards. Factor in the cost of cleaning supplies, labor for cleaning, and any additional equipment needed for proper sanitation.
• Service and Spare Parts Costs: Evaluate the availability and cost of service technicians and spare parts. Easy access to reliable service and readily available spare parts minimizes downtime in case of equipment failures.
• Equipment Performance and Impact on Labor Needs: Analyze how the equipment will impact production efficiency and labor requirements. Will it increase output and reduce labor needs? Conversely, might it require additional training for staff to operate effectively? Quantify the potential cost savings or increased labor costs associated with the solution.
• Scalability and Flexibility: Consider the future growth plans of the company. Can the chosen solution be easily scaled up or down to accommodate changing production demands? The ability to adapt the equipment or layout to accommodate new products or production lines is a key benefit of flexible engineering solutions.
• Return on Investment (ROI): Evaluate the projected ROI for the chosen solution. Consider factors like increased productivity, reduced waste, and improved product quality when calculating the potential return on investment.

By carefully evaluating these factors, food manufacturers can make informed decisions about flexible engineering solutions that not only meet their current needs but also offer long-term value and contribute to a sustainable and efficient food production operation.