CHAIRMAN OF THE BOARD, TREASURER Al Diggings • adiggins@emccanada.org
VICE PRESIDENT, COMMUNITY PARTNERSHIPS AND STAKEHOLDER RELATIONSHIPS Bren de Leeuw • bdeleeuw@emccanada.org EDITOR
(519) 376-0470 (866) 323-4362
VICE PRESIDENT, MANUFACTURING SECTOR PERFORMANCE Scott McNeil-Smith • smcneilsmith@emccanada.org
COVID-19 and the Food and Beverage Industry
In normal times, there are only a few industries that we think of as being absolutely essential. Those include first responders, health care, utilities (water and electricity), and for many education, postal services, and others. However, at a personal level, food is the most essential, as everyone needs it to survive, and of course some beverages as well.
This reality has been shown around the country, as physical distancing is now the norm, and a trip to the grocery store (which has been deemed essential by governments) is for many the only reason to leave their house. As only a select number of people are allowed into stores at a time, line-ups around the store are common. In this picture you would expect to see empty shelves; however, apart from a few items, such as toilet paper (don’t get me started on that), hand sanitizer, disinfectant wipes, and in some cases flour; shelves are fully stocked for people to be able to buy what they need.
The reason for this is that Canada has a robust food and beverage industry with a great supply chain. Therefore, any shortages caused by “panic buying” are temporary, and in most cases a short-term issue. Therefore, most people who have the means, will be able to get the food they need to feed their families.
On the other end of the spectrum is the restaurant and bar industry. While they are still able to get any supplies they need to prepare food and drinks. The problem for many is the loss of business. As a result of essential business rules being put in place, many are only open to provide takeout and/ or delivery. While this allows many restaurants to remain operational, business has dropped. Many people are now preparing food at home instead of
“going out for dinner” or ordering from a restaurant. Therefore, some businesses have had to close all together, as the loss of revenue was too great.
Montreal-based MTY Food Group Inc (which operates 80 different brands in Canada, US, and elsewhere, including Thai Express) earlier this month laid off half its workforce, said that 2,100 of its restaurants are now closed, with other operating at reduced capacity.
Another issue with the COVID-19 pandemic is food companies need to make sure employees, and customers are safe. Many have been taking extra precautions to try and minimize the threat. In the majority of cases, additional measures are working. However, the extra vigilance has caused some business to close if a case is reported at their facility.
Maple Leaf Food closed a poultry plant in Brampton, Ontario, when three employees tested positive for the virus, the plant than received a deep clean.
Finally, according to Statistics Canada, one of the hardest hit industries in terms of employment was the accommodation and food services industry, which saw an employment loss of 23.9 per cent. It is an industry that depends on the public for revenue, and does not lend itself to working from home, as many people are currently doing.
From everyone at Food & Beverage magazine, stay healthy and safe.
Mario Cywinski, Editor Food & Beverage
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A UNIQUE TWIST FOR THE OLD TASTE BUDS
Germans love big salty, soft-breaded pretzels. In the south of Germany, a freshly baked pretzel with butter and the aroma of freshly brewed coffee is a must on any breakfast table. Achieving the perfect shape, a symmetrically twisted pretzel, usually involves a lot of painstaking manual labour.
The Schill bakery in Denkendorf, near Stuttgart, opted to automate the process, including the trickiest of stages, the dough twisting, in turn boosting production over four-fold.
As automated dough-shaping goes, large German-style pretzels present an interesting challenge. Croissants, by comparisons, are just a simple roll-up of a triangular slice of dough, but large pretzels require dual gripper synchronization, and consistency is a must.
Before the pretzel enters the oven at Schill, the dough is first kneaded and portioned automatically into lengths of consistent thickness. Then, these strips are transported on a conveyor belt to the next stage: rolling out. Here, the classical shaping of the dough length begins: fattening the belly and thinning the ends for twisting. The dough exits this process in an U-shape.
The U-shaped strand is aligned on the conveyor with a positioning
unit employing Festo pneumatics, so the grippers can grasp the ends in exactly the right places. This is followed by the twisting process, a dual grip-and-twist motion performed by actuators including DFM guided drives.
Guided drives and guided slides provide stability and resistance against torquing and twisting that simple ISO cylinders do not, ensuring consistency and accuracy in a wide range of applications.
Thanks to the sensitive end-of-arm tooling, the dough strand is gently picked up at the ends. In less than a second, the strand becomes a precisely twisted pretzel.
Automated production turns out 2,300 pretzels per hour; a crew could twist 500 to 600 in that time by hand. It used to take hours of boring work for the staff to make the equivalent daily output. “The advantage is that the employee can use the time gained to use their expertise for other tasks in the bakery, we have lots of delicate and individual tasks for which we can use any free pair of hands,” said Martin Schill, Owner and Master Baker.
Schill says the pneumatic systems have performed consistently well despite high levels of flour dust, thanks to seals that protect the drives from dry particle ingress.
The twisting apparatus also can be rapidly adapted to forming other shapes, like braiding twisted buns. For this purpose, a different gripper set is substituted, specifically adapted for that end product.
If an error should occur during retooling, sensor technology on the machine detects incoming dough and stops the process automatically.
FROM THEFT PREVENTION TO QUALITY CONTROL: HOW IOT-BASED SURVEILLANCE CAN HELP
BY GAVIN DALY
It was a food and beverage manufacturer’s worst nightmare; $187,000 worth of product stolen in plain sight. It happened at a Tavistock dairy plant in 2019, when a man presented what appeared to be legitimate paperwork for a large quantity of cheese to be loaded onto a truck, and delivered to New Brunswick. It wasn’t until the delivery failed to arrive at the location that they realized the cheese was stolen. It goes without saying that any F&B
manufacturing facility, factory, or warehouse needs a good security system. Besides the materials and goods that need to be monitored and protected 24/7, there are also plenty of quality control, health, and safety procedures to follow.
From a site’s perimeter and car park, to entrances and exits, office areas, delivery and dispatch, and
the manufacturing and assembly areas, a security system using Internet Protocol (IP) network cameras and Internet of Things (IoT) technology can be very valuable. For example, the big cheese theft could have been prevented, through innovations like facial and license plate recognition, and stricter access controls at the doors.
THE TECHNOLOGY EXPLAINED IN PLAIN TERMS
Many are familiar with what IoT is; the ‘thing’ in IoT is an object (such as a camera) that can be given an IP address so it can send data over a network. An IP camera or ‘smart camera’ has sensors connected to an IoT platform, which reads and organizes the collective data through analytics. This enables protection of a facility beyond what’s possible with standard analog cameras, as data can be collected anywhere that can be measured by sensors, so potential issues can be addressed before they escalate, and make smarter, evidence-based business decisions. Through IoT analytics, artificial intelligence (AI), and machine learning (ML), are what make specialized security applications possible, such as facial recognition, licence plate identification, virtual fences, unauthorized person and
vehicle tracking, loitering, and “object left behind” flagging. A robust network surveillance system can consist of IP-based thermal and visual cameras, radar, door stations and audio equipment, all connected to converge a network that talks to each other in real time. This cost-effective technology is easily scalable and updatable and can also integrate with other IP-based systems, making it future-proof. It is end-to-end protection for a site, employees, and improves operational efficienc since it allows users to manage multiple sites from a central location.
SECURITY STARTS WITH PROTECTING THE PERIMETER
‘Smart’ IP cameras can easily monitor gated and fenced areas, while recording all vehicle license plates. Access control for visitors is vital at all points of entry, and even employees need access control,
as some will be authorized to enter specific areas of the facility and some not. Door stations with integrated video and audio can enable remote confirmation verification and decline any unauthorized personnel. Being able to halt breaches before they escalate is another big network surveillance gamechanger. For instance, if an intruder attempts to enter the facility, a camera can send an e-mail to security, illuminate the area with a floodlight, and activate an audio alarm or a message through a loudspeaker, telling the intruder to leave immediately. Audio can also be an effective deterrent while security staff observe the scene remotely on their phone or laptop and decide next steps.
In the shipping and receiving area, single cameras can cover vast areas, with a 180 by 90 degree field of view. A pan, tilt, zoom camera can be useful in busy bays where you need to monitor several rolling doors. Each time a door opens, the camera can automatically tilt and zoom to record that area. An alternative is a multi-sensor, fixed
field wide angle camera that oversees the entire area and can zoom in as necessary.
KEEPING THE PRODUCT SAFE AND ADHERING TO REGULATIONS
Anyone who works in the F&B industry knows that food safety is of upmost importance, to supply quality products to the end consumer, but also to comply with increasingly strict food regulation laws. This is where IoT-based sensors in cameras can be particularly beneficial. IoT
sensors can track the product in transit and storage, while also monitoring the temperature to ensure conditions do not impact food safety or quality. They can even supply data for detailed and accurate records for each stage of production, from manufacturing to transport to storage, and trigger when staff need to do food safety inspections when the sensors’ data finds potential issues or violations.
At the SugarCreek packing plant in Indiana, USA, IoT sensors are placed on every piece of machinery on the factory floor, which can detect biochemical and chemical reactions during harvesting, manufacturing and transportation. This enables them to identify certain pathogens and remove them before they reach further in the supply chain. Even a micro-brewery can benefit from (and afford) such smart technology, as demonstrated by The Caveman Brewery in Swanscombe, Kent, England. During their brewing process, the beer is pumped from a hot boiling kettle through a heat exchanger, cooling it to 20°C. Up to the heat exchanger, sanitation isn’t a problem because
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of the high temperature, however, as soon as the temperature falls below 20°C, the beer is vulnerable to contamination and spoiling. The brewery does not have the resources for continuous onsite monitoring of the brewing process, so by installing an IP surveillance system, it has allowed them remote access to view from any number of locations, where they can zoom-in and read the heat exchanger temperature and react quickly to any problems.
KEEPING THE PEOPLE SAFE AND ACCOUNTABLE
Workplace accidents can be serious, and costly, for manufacturing businesses. Video surveillance can help to reduce the cost of accidents, as the footage can be used in post-incident investigation, and identify whether responsibility lies with the employer, or the employee. The video reference can help in taking action to ensure that it doesn’t happen again, through more visible signage, protective barriers, or new machinery. Surveillance footage can also be used for employee safety education. In addition to deterring theft, visible cameras can help to ensure employee compliance with health and safety practices.
Other ways smart cameras can increase employee safety are: they can trigger alarms,
turn off equipment, and even lock doors preventing access when a dangerous substance or circumstance is detected (gas leak or equipment overheating). The ability to monitor network surveillance remotely is a safety feature as well, as cameras can be used to examine dangerous and/ or malfunctioning machinery in real time, versus having a worker go out in person.
LIKE A SILVER BULLET FOR EFFICIENCY
Maximizing production and minimizing downtime is a goal for any manufacturing facility. Machine malfunctions and breakdowns can be particularly costly, and IoT can help to take proactive action to avoid them, through technologies like thermal imaging, which can highlight potential issues, and sending alerts when sensors detect that a machine needs maintenance or repair.
Video surveillance can help to monitor the overall production process, smart cameras with IoT sensors can push that productivity further, video analytics can be used to study the flow of people and product throughout the manufacturing plant, highlighting areas where small changes can result in big improvements in efficiency.
IoT camera sensors can also help with inventory and delivery, as they can retrieve real-time data that tracks inventory, indicating when replenishment is needed, triggering automatic shipments, monitoring and tracking the shipments, and even planning alternative routes to ensure that products are delivered on time.
Gavin Daly manages the Professional Service Group at Axis Communications, Inc., providing technical expertise and personalized advice for internal and external customers.
We are in the throes of a brand-new decade full of potential opportunities. Unfortunately, the sudden and unexpected growth and development of the COVID-19 global pandemic presents significant challenges to manufacturers in Canada and around the world. Hopefully, from this current trial other opportunities will surface enabling businesses to build and grow.
In January when we turned over to 2020, I asked, what will industry look like in five, 10 or 20 years? Then what new products will be developed, how will automation impact our capabilities, what skills will be required in maintenance, and how will a company’s initiatives towards food safety, corporate sustainability, and global competitiveness effect today’s businesses and entrepreneurial start-ups to come?
Now, as the world endeavours to navigate the current crisis, other questions come to mind, with each there could possibly be interesting solutions, and exciting possibilities. Such as working with other companies to problem solve product development, for example, what is currently being done to produce equipment and protective apparel for frontline workers during the COVID-19 pandemic.
As we roll out our 2020 Food, Beverage, Bio and Ag Sector program, there is lots to discuss and a great deal to learn through peer discussion, and best practice sharing with manufacturers from across the country.
The world is currently a complicated place for manufacturers throughout Canada. The impact of the Coronavirus has caused reactions that are
unexpected and immediate, in line with preventative measures, and compliance, according to government orders. Companies have retooled to provide emergency apparel and equipment for front line workers, others have closed and laid off personnel.
Supply chains have been disrupted, first because of rail blockades, and now as a result of COVID-19. Our ability to compete is going to be more complex. Add the ongoing challenge facing manufacturers across Canada before the pandemic; sourcing and retaining talent, good, qualified, and skilled labour.
Through these challenges, opportunities surface, and when people start discussions, brainstorming solutions, preventative actions, and alternative thoughts, amazing things happen.
During the rail blockade, companies looked at sourcing products via different means of transportation and alternative routing, preventative measures and updated policies; and now procedures are being developed and implemented across all aspects of business steadying us, as we rally against the COVID-19 outbreak. From a building talent perspective, many organizations, including universities and colleges, partners, and EMC, continue to explore, discuss, and map-out ways to upskill, re-skill, and train the existing workforce, and encourage interest in young students to follow a career path in industry.
Engagement in Excellence In Manufacturing Consortium (EMC) networking events, services, and programs provide manufacturers with the perfect opportunity to connect with others who are experiencing similar challenges. There is a general appreciation that whatever may lie in front of us, such as the current COVID-19 crisis, there are others who are on the very same path interested in uncovering solutions. Various programs and
services are available to aid in business growth, B2B possibilities, better procurement, knowledge enhancement, and training and development,.
A recognition that we produce different products, but face challenges that are similar, and learning from peer experiences, and best practices, is where EMC began 30 years ago. Knowing that others are working on similar projects, and solving like challenges, can result in new and creative ideas, quicker solutions, and lend to a culture of improvement, which brings all facets of a business together.
EMC’s team of Field Service Advisors do their best to keep things relevant, and timely.. A quick peak from a reliability and maintenance perspective, demonstrates a number of interesting sessions relating to this field that have surfaced over the years. Interest in developing or continuing dialogue relating to program implementation, or potential opportunities to explore include:
• Currently - the impact of COVID-19 in maintenance;
• Predictive maintenance vs preventative maintenance;
• Computerized maintenance management systems;
• Use of digital tools;
• Internet of Things;
• Data and machine monitoring;
• Asset management (equipment reliability);
• Scheduling PM vs production;
• Stores inventories of spare parts;
• Implementing lean management and tools (5S, TPM);
• Skilled trades, coaching, mentoring;
• Integration of maintenance into self-directed work teams;
• Maintenance training; and
• External service companies.
Looking ahead, when our Food and Beverage Sector program rolls out again, each of the subject areas has broader impact for maintenance and reliability, whether discussing food safety, culture development, environmental monitoring, or future in the food industry.
WHAT’S IN EMC’S TOOLBOX FOR DISCUSSION IN 2020?
Brad McKay, Former CEO of HFS – Healthcare Food Services, will share his perspectives on the Future of Manufacturing in the Food Industry. Today’s population is growing at the rate of one billion people every 12 years, as a result more efficient means of producing, and manufacturing food are needed. By 2050, another two billion people will need to be fed, and technology will be required to help. This presentation reflects back on the beginning of manufacturing and casts a glance toward the future. NSF International is also taking part by sharing their EyeSucceed technology and capabilities.
Later in the year, we will be exploring the concept of developing and
motivating an engaging workforce. How are companies building, and fostering a positive culture reflecting a company’s vision and goals? What are some best practices for generating ongoing continuous improvement projects throughout all areas of the business? How might we become an employer of choice?
Due to COVID-19, EMC’s first peer networking event was postponed, the special Food, Beverage, Bio and Ag Sector program was to look at world class food safety best practices with Maple Lodge Farms and SkjodtBarrett Foods (a new date has not yet been set). Staying abreast of changes in legislation, adhering to proper food handling, sanitation and pest control, and nurturing a culture that understands, engages, and continually seeks improvement on current practices is all part of the broader picture of developing an enduring world class food safety program. This event will provide participants with an opportunity to garner insight from peers on how they may build programs, and engage people when it comes to dealing with food safety.
The Strategy Institute’s National Food Safety Summit has set a new date (August 19 and 20, 2020) for their conference, and EMC will be partnering once again. For 16 years in a row, this conference has brought people from across North America and Europe to learn the latest in government regulations and legislation, hone in on best practices adopted around the world, and take stock of where their next steps should be in developing, enhancing, and maintaining successful food safety programs.
Finally, we will be finishing the year with a presentation looking at environmental monitoring best practices. 3M Canada - Food Safety, in partnership with Cornell University, recently completed an Environmental Monitoring Handbook for the food and beverage industry. At this event, we will explore the concepts of environmental monitoring, including controls, risk assessments, and recalls. We are in the throws of a new decade and there are challenges; such as the global pandemic, but looking beyond this, the possibilities for the future in manufacturing new products, in companies working together, discovering new methods of production, engaging and building a dedicated team-oriented workforce, of strengthening and enhancing programs to ensure safe production and quality goods, and of course remaining competitive; are exciting opportunities.
Moving forward, if you are interested in learning more about involvement in EMC’s Strategic Interest Groups or our special Food and Beverage Sector Networking Sessions, feel free to reach out and we would be happy to share information on what is coming up in your region.
How do you get involved? If you are interested in learning more about EMC (Excellence in Manufacturing Consortium) and the Food Sector Initiative, please feel free to touch base with Bren de Leeuw, Vice President, Community Partnerships and Stakeholder Relations (bdeleeuw@emccanada.org) anytime!
