Designing and building a food processing plant may seem like a herculean challenge for many due to the technicalities involved but it is vital for any food manufacturing company.
The construction of the plant for whatever food that goes through a manufacturing process is vital to ensure the safe and effective usage of all the equipment and raw materials to produce the finished food product.
When companies seek to build and design their food plant, they are faced with several problems that may hinder the process.
Knowing what to consider when constructing a food plant will save you a lot of trouble especially as this is a capital intensive project. mistakes are expensive so avoiding it should be at the top of your mind.
In this guide you’ll see the major considerations for a food plant construction. Including those to that are vital before, during, and after the construction.
Regulatory Compliance and Food Safety Standards
The first thing to consider when building a food plant is the regulatory compliance and safety standards set by the bodies in charge. Every location has both local and international food safety laws guiding it.
Adhering to these laws are vital to get and maintain the license to produce food. Regulations like FDA, HACCP, GMP, and USDA are popular compliance standards for plants in the US with many more local standards depending on specific locations.
You need to include food safety in the design face for these plants with certifications like SQF and BRC helps you design your food plant with food safety in mind.
Site Selection and Layout
The location of the plant is one of the most important steps and should be considered early enough. Some regulatory processes cannot be completed before the location is determined to show you how important this is to food production.
You want to choose a strategic location for your plant that is close to suppliers and has good access to a good transport network and utilities required for the successful running of that plant.
Apart from the location, the layout is also quite important as it ensures an effective workflow around the facility. You want a location that also presents opportunities for future expansion which is vital to scale your plant.
Material Selection and Construction Standards
Since this is a food plant, the materials you use should correspond to the standards including using only food-grade processing materials for your plant. Materials like stainless steel, aluminum, titanium, high density polyethylene, and food-grade paper and cardboard are vital for a food plant.
The construction standards make it easier to clean these materials, ensuring the production of safe and healthy food. Aside from the ease of clearing these equipment, the durability of these materials is also among the considerations to prevent easy breakdown and additional costs replacing damaged ones.
Food plant design and construction companies like DeJong know the importance of these materials in their planning stage so only recommend and utilize them when making a plant for a food manufacturer.
When selecting materials, you want to avoid those that can harbor bacteria and contaminants which can affect the quality of the food produced.
Environmental Considerations
Food plants often leave a lot of waste which may lead to contamination of the environment. Whether it is wastes from the raw materials, noise pollution from the machinery, and the heavy power needs required to run and maintain a facility.
You need to consider what this means for your plant and make arrangements for sustainable practices.
Consider using energy efficient systems from your HVAC to your lighting to reduce energy bills while other improvements like proper waste disposal and noise cancellation headsets and padded walls.
Using more eco-friendly materials during construction, minimizing waste through recycling, conserving water, and employing energy saving methods can help your food plant stay on the side of environmental sustainability.
Technology and Automation
Modern plants use a lot of technology and are highly automated to improve its efficiency and you must put this into consideration during the design and building phase of the plant.
There are lots of these technologies that are particularly helpful for food processing and packaging that you should be considering including robotics for sorting and packaging, AI and machine vision for spotting defects, and smart packaging with QR codes.
The importance of automation and technology in your food plant cannot be overstated for safety, efficiency, and consistency. You should also consider the maintenance and running of these systems.
Budget and Project Management
All plants including food plants require a budget and proper project management to be completed successfully especially as construction is capital intensive. Which is why budgeting and project management cannot be overlooked in food plant construction.
This is where you have to balance the cost with the quality of the plant and compliance with the standards.
You do not want to cut corners to save cost but also want to make use of more efficient materials and processes that lets you save cost without a drop in quality.
Detailed planning with attached timelines makes it easier to complete a huge project like a food plant. Same with working with experienced professionals especially those who have food plant construction experience like DeJong Consulting.
Conclusion
Building a food processing plant involves a lot more than just constructing its walls. It involves a lot of planning design and consideration for not only the physical components of the plant but also its workflow.
With factors like compliance and regulation, location, environmental considerations, and budget vital while planning any food plant construction.
Neglect can be damning considering the financial implication and regulations you may be breaking. Which is why manufacturing companies looking to build a food plant seek professionals who understand the industries and processes like DeJong Consulting.
DeJong specializes in designing and building facilities to process and manufacture food products. This experience in the food industry makes them the perfect solution for companies looking to build a food plant.
It is always easier to have an expert do the designing and planning for you especially in an industry like plant construction where novel innovations can completely transform your processes in food production. DeJong Consulting is the team you need.
