Steps for Reducing Waste in Food Manufacturing Today
April 17, 2024
Preventive maintenance, shortening conveyance distance can reduce food waste.
Food Engineering recently spoke to Dave Hicks, vice president, and maintenance excellence practice leader at TBM Consulting, about strategies for reducing food waste in manufacturing, including collaborating with employees, shortening conveyance distances, and preventive maintenance.
In this interview, David Hicks talks about :
How half of all food waste is caused by mismanagement in the supply chain.
Production line spoilage, contamination, and product variation contribute to almost 1.3 billion tons of annual food waste.
The importance of manufacturers working to get the equipment running back up to its standard and then implementing a preventive maintenance strategy.
As often as possible, take advantage of scheduled plant shutdowns for cleaning. Having the opportunity to touch the equipment will ensure issues are noticed quickly.
Why is waste such a persistent problem in food processing operations?
Waste is persistent in food processing because variability is often built into daily operations. The article explains that yield loss, overproduction, rework, downtime, and spoilage are frequently treated as unavoidable costs of doing business. When processes are unstable and problems are managed reactively, waste becomes normalized and hidden within routine operations rather than addressed systematically.
What are the most common sources of waste in food processing plants?
The article highlights common sources of waste such as overfill, scrap, quality defects, unplanned downtime, and inefficient changeovers. These losses are often spread across multiple steps in the process, making them difficult to see in isolation. Without clear visibility and disciplined management, small losses accumulate into significant margin erosion over time.
How can food processors reduce waste without increasing risk to quality or safety?
Food processors can reduce waste by improving execution discipline rather than cutting corners. The article emphasizes stabilizing processes, reinforcing standard work, and using daily management to surface problems early. When waste reduction is driven by better control and faster problem‑solving, organizations improve yield and productivity while protecting food safety, quality, and compliance.
