10 ways food manufacturers can reach zero waste
Food loss and waste is not just a societal and environmental problem: it’s also a bottom-line problem for the food industry. Manufacturers in particular contribute to some 5% of global food waste, which hurts profit margins at the same time as it increases global food insecurity and greenhouse gas emissions.
But there are a number of strategies and techniques that food manufacturers can employ to reduce or even completely eliminate waste at their facilities.
1. Improve production lines by investigating production quality issues.
Much food loss during manufacturing occurs as a result of quality issues or food spoilage. Significant reductions in food loss can be created by simply auditing production lines and identifying areas for optimization, such as food being overcooked or improperly thawed. Monitor production quality regularly to ensure you are continually cutting down on quality-related food waste.
2. Evaluate machinery performance and keep on top of equipment maintenance.
Product jams and mechanical mishandling are key contributors to food loss during manufacturing. It’s important to evaluate the effectiveness of your machinery to identify potential waste sources and schedule regular maintenance checks to ensure these mechanical assets don’t become a liability.
3. Track produce and monitor your data.
Upgrading your system monitoring and control can provide real-time insights to help cut down on unnecessary food loss. For many manufacturers, digital sensors can replace manual data collection along production lines to cut down on production errors and help teams make more informed decisions.
4. Improve forecasting.
Investing in better forecasting and analytics means you’ll be less likely to experience the common food manufacturer’s dilemma: over-anticipating demand. Inaccurate demand forecasting is a key driver of food loss and waste — but it’s also one that is easily improved with new, data-driven technologies that offer highly accurate predictions based on past data.
5. Optimize stock rotation.
Natural products have varying shelf lives, so it’s important to optimize production processes and stock rotations to ensure that more perishable goods are processed ahead of longer-lasting foods.
6. Improve packaging and storage.
Whether food becomes waste has a lot to do with how and where it is stored. And just as different types of foods have different shelf lives, they also have different needs when it comes to storage conditions. Assess your current food storage arrangements to determine whether some goods might fare better in a different setup.
7. Educate employees on safety practices.
Employee education is a crucial tool in combatting food loss and waste. Train staff on appropriate food management and food safety practices. These practices, such as routine checks and sanitization, can go a long way toward minimizing waste.
8. Divert what you can.
Some amount of food loss is inevitable, but there are many opportunities for these byproducts to take on a second life rather than being sent to landfills. In some cases, it may be possible to donate unused food items to food banks and charities. If that’s not a possibility, it may be possible to upcycle your organic byproducts into new products such as animal feed, biofuels, textiles, plastics, pharmaceutical drugs, and more. What’s more, upcycling allows your company to earn money by diverting food byproducts.
9. Compost what you can’t divert.
The next best option for food waste that can’t be donated or upcycled is composting. Composting allows organic materials to decompose naturally, releasing critical nutrients back into soils and ecosystems without any of the methane emissions associated with landfill decomposition.
10. Recycle non-food waste.
Not all waste generated by food manufacturers is food waste. These facilities also deal with significant amounts of packaging waste. Look for ways to recycle this waste either with suppliers or through third-party partners, which can create additional revenue streams. If the packaging poses recyclability challenges, talk to your suppliers (or shop around) to solve the root of the problem.
11. Bonus tip: Work with a waste management partner like PRI Environmental
PRI Environmental helps food manufacturers in Ontario and Quebec upcycle bakery goods into high-quality animal feed. In addition, we conduct process audits to determine how your company operates and where waste is created, as well as opportunity assessments, which offer a detailed look at how you can bring your business into the circular economy and capitalize on overlooked revenue streams.
When we work with clients to minimize food loss, we’re not just diverting waste from landfill and lower harmful emissions; we’re creating something new from the waste that will help provide food for animals across the country.
Interested in learning more about PRI Environmental’s waste recovery options? Contact us today.