Strategies for Increasing Yield in Food and Beverage Manufacturing. In food and beverage production, yields can make or break the profitability of manufacturers.

The drive to increase yield in the industry demands targeted actions. These include fine-tuning process control for smoother operations, enhancing quality assurance for consistent product standards, implementing lean manufacturing to eliminate unnecessary steps, optimising supply chain management for greater efficiency, and proactively reducing energy and resource waste to meet environmental standards. These key strategies are essential for increasing yield, as they directly influence the efficiency of production processes.

Optimise Process Control

A central aspect of increasing yield lies in optimising process control. Process control encompasses every element of your production flow, from initial ingredient sourcing to the final packaging stage. Implementing effective control strategies can significantly reduce waste, improve consistency, and consequently, boost overall yield.

Consider the case of a leading dairy company: Challenged by inefficiencies and waste, the dairy company sought TBM Consulting Group's expertise to transform its processes. Identifying key areas for improvement, they adopted a lean transformation strategy, which included retooling equipment and refining workflows. This decisive action cut waste in half, increased efficiency by up to 5 points, and ultimately led to a sustainable boost in profitability, showcasing the power of strategic process control and continuous improvement in achieving operational excellence.

Investing in process control optimisation extends beyond just acquiring advanced equipment or technology. It also involves focusing on the people and procedures that enable effective process management. This requires a comprehensive approach, including staff training, regular equipment cheques, and cultivating a continuous improvement mindset.

Enhance Quality Assurance

Enhancing quality assurance mechanisms can significantly contribute to yield improvement. Quality assurance ensures that the final product consistently meets established quality standards. This involves the implementation of several methodologies. The application of Good Manufacturing Practises (GMP) is essential, focusing on the consistent production and control of quality. GMP encompasses comprehensive documentation of all processes, thorough training of staff, and routine internal audits.

Additionally, the integration of lean manufacturing practises significantly contributes to eliminating waste and boosting efficiency. Techniques such as Just-In-Time (JIT) production, Kaizen, and 5S are instrumental in reducing process variation and waste, which in turn enhances yield. The adoption of Hazard Analysis and Critical Control Points (HACCP) is another element, targeting the prevention of food safety hazards. By identifying and managing potential hazards at specific stages in the manufacturing process, HACCP effectively reduces product recalls, thereby improving overall yield.

Frozen Food Giant's Lean Achievements

A global frozen food manufacturer implemented a Continuous Improvement programme in 48 plants, reducing labour turnover by 10% and employee absences by 4%. They maintained 85% of process improvements, increased productivity by 8%, and cut downtime and defects by 5%. Energy kaizen events also resulted in $300k average savings per event, marking a notable success in their lean transformation efforts. Here's how you can start:

  1. Value Stream Mapping: This technique allows you to identify all the actions required to deliver a final product, from raw materials to customer delivery. By mapping out these processes, you can easily identify areas of waste and inefficiency.
  2. Kaizen: This continuous improvement approach encourages all employees to propose small, incremental improvements to their processes. Over time, these minor changes can lead to major enhancements in yield and efficiency.
  3. Just-In-Time Production: This strategy focuses on producing only what is needed when it's needed, reducing waste from overproduction and minimising inventory costs.
  4. Standardised Work: By establishing uniform procedures for all tasks, you can ensure consistency in performance and product quality, leading to improved yields.
  5. 5S Methodology: This method (Sort, Set in order, Shine, Standardise, Sustain) is designed to organise the workplace, promote efficiency, and reduce waste.

Improve Supply Chain Management (SCM)

Managing and optimising supply chains is an important aspect of achieving yield improvement in the food and beverage manufacturing industry. An efficient supply chain means that raw materials are sourced sustainably, transported safely, and processed efficiently, ensuring that the final products meet the highest quality standards. Additionally, streamlined supply chains can significantly reduce waste, promoting more sustainable practises and increasing profitability.

An essential strategy for optimising supply chains involves implementing robust inventory management systems. By accurately forecasting demand, manufacturers can avoid both underproduction and overproduction, thereby reducing waste and ensuring maximum yield from their resources. In addition, adopting just-in-time (JIT) production strategies can greatly improve yield by reducing the time that raw materials spend in storage before being processed, which is particularly important in the food and beverage industry where products often have a short shelf life.

Reduce Energy and Resource Waste

The food and beverage manufacturing industry has a substantial opportunity in reducing energy and resource waste to improve yield. In the production process, inefficiencies often result in significant waste of raw materials and energy. For instance, in a beverage production line, the overfilling of bottles leads to unnecessary wastage and higher production costs. By closely monitoring and controlling the filling process, manufacturers can significantly reduce waste, improve yield, and increase profitability.

Power consumption is another area where significant efficiency gains can be made. Equipment such as chillers, boilers, and refrigeration units consume a significant portion of the energy in a manufacturing plant. By implementing energy-saving practises, such as regular maintenance to ensure machines operate at their maximum efficiency, and the strategic scheduling of energy-intensive operations during off-peak times, manufacturers can substantially reduce energy costs. More importantly, these practises contribute to a more sustainable and environmentally friendly operation, aligning with global efforts to reduce carbon emissions. If your company is tracking against ESG metrics, these operations and maintenance efforts will contribute to that initiative.

Your Turn

Optimising process control, enhancing quality assurance, implementing lean manufacturing principles, improving supply chain management, and reducing energy and resource waste are key strategies for elevating the yields in the food and beverage industry. By integrating these strategies, manufacturers can expect enhanced efficiency, cost-effectiveness, and sustainability. Optimised processes and quality assurance methods ensure that resources are used effectively, product quality is consistently high, and waste is minimised. Lean manufacturing and efficient supply chain management can considerably reduce the time and resources needed for the production process. Ultimately, these strategies align with the pressing global movement towards sustainability, making them not only profitable but also responsible choices for any forward-thinking enterprise in the food and beverage manufacturing industry. TBM Consulting Group is committed to helping food companies in the successful adoption and implementation of these strategies to transform operations, reduce costs, and increase profitability.