FIT- Optimization of storage & production

Food Ingredients Technologies is a company that makes flavor and spice blends for a wide range of customers. They start from a wide range of individual ingredients and blend them in the right proportions to create a finished end product.

This end product can be intended for making marinades, sauces, broths, flavor enhancers,... but can also be intended as an ingredient for fish, meat and vegetarian preparations.

This end product can be intended for making marinades, sauces, broths, flavor enhancers,... but can also be intended as an ingredient for fish, meat and vegetarian preparations.

Project Notes

FIT has experienced tremendous growth in recent years. This rapid growth brings many practical challenges at the existing location. The warehouse is completely bursting at the seams, the movement of raw materials and personnel is time-consuming and inefficient.

Objective

For FIT, the objective was therefore clear: adapt the current processes and flows so that the existing production space would be used optimally. The goal of this assignment was first to identify all areas for improvement and then to translate these into concrete and realistic solutions. 

• Optimization of the warehouse for ingredients (pallet racks)
• Refurbish and revise the preparation and mixing zone
• Optimize general flows on site (raw material, packaging and personnel flows)
• Setting up a new "dedicated" cleaning zone (away from powders, herbs, mixtures,...)
• Increase comfort and ergonomics in production

The above points were analyzed and resolved one by one.

Approach to optimizations

STEP 1: WAREHOUSE OPTIMIZATION 

A quick analysis of the existing raw materials warehouse, immediately revealed that the available area could be used much more efficiently. By making adjustments to the layout and using a narrow aisle reach truck, more than 45% of additional storage capacity could be created.   

David Landau, owner and business manager at Food Ingredient Technologies, confirms the added value of DDE:  That 45% additional storage capacity results in me being able to stay at my current production location a little longer anyway.

STEP 2: GENERAL LAYOUT AND FLOWS 

The layout of production and related movements of raw materials and personnel were a direct result of the rapid growth that FIT experienced. It followed that this layout and flows were no longer optimal. Together with FIT's project team, our engineers mapped the processes and determined a new layout that resulted in higher efficiency. The new layout not only brought more efficient movements, but also resulted in increased safety and ergonomics for the employees. We also created a lot of additional space by moving the flow of pallets with the weighed ingredients through the existing floor.

STEP 3: CONVERSION OF EXISTING PRODUCTION 

After the layout was determined, a plan of action was drawn up for the further optimization and conversion of production. All requirements and needs were identified, prioritized and budgeted. In order to optimize production, adjustments were needed in several areas. These included electricity, fire detection, civil needs, HVAC, utilities, etc.

Within these different domains DDE the lead in contacting and selecting the right partners to implement the modifications. Below is a brief overview of some of the modifications:

• The drainage of the existing floors was inadequate. The floors were therefore replaced with new concrete floors with an epoxy coating. Dir resulted in increased cleanliness and cleanability of production.
• In the weighing zone, the capacity was significantly increased by an additional weighing zone. This zone was also adapted and laid out in accordance with the regulations and also taking into account the handling of powders. To minimize dust formation, a new ventilation system was installed and, where necessary, shielding and adjustments were made in accordance with food safety legislation.
• The mixing plant was also taken in hand. Through a number of smart adjustments, we increased capacity, quality, safety and ergonomics. The mixing area was divided into dedicated areas equipped with a well-dimensioned extraction system, resulting in increased quality and cleanability. It was also taken into account that empty containers can be quickly removed and disposed of.
• In the context of food safety, a dedicated cleaning area was built in the cleared space where all equipment and mobile devices can be wet cleaned. Proper ventilation was also provided in this area so that drying of the equipment is done quickly and efficiently.

Result

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