MANUFACTURING

1
MANUFACTURING

• OBECTIVES
• To understand what is required to manufacture a
  new product

2
What?

• What are the characteristics of the new or
  modified product to be manufactured?
• What raw materials, ingredients, equipment and
  packaging are required?
• What product and safety requirements will be
  needed based on pilot plant work?

3
How Much?

• How much to make will depend on
• Projects sales volume?
• Seasonal factors
• Raw material availability
• Seasonal markets
• Projected costs of manufacture (capitol and
  operating
• Marketing and distribution
• Return on investment

4
Where?

• Existing plant?
• Additional energy, water and waste treatment
  requirements and cost?
• New Plant
• Locations factors, taxes, and possible abatement
  incentives municipal services (availability of
  utilities) transportation networks available
  labor having required skills proximity to
  sources of raw materials and important markets
  energy (fuel sources, electricity) costs water
  and waste treatment and environmental control
  systems requirements and costs requirements for
  additional steam boilers
• Co-Packers Contract Packers?
• Costs of manufacture taking in the options listed
  about

5
When?

• How long will it take to modify an existing
  plant design and construct and new plant
  develop contractual agreements with suppliers of
  raw materials, ingredients, packaging or contract
  packers, and obtain delivery install and test run
  new equipment?
• How long will it take for the manufactured
  products to pass through the distribution chain?

6
Who?

• Will do design and construction for modify an
  existing plant or new plant at a new location?
• In house engineering or Architect/Engineering
  (A/E) firm?
• Federal and state or local regulatory
  regulations? x
• What kind of quality control/assurance laboratory
  and staff will be required?

7
How?

• Will you meet any changes needed in the
  organization for managing the modified or new
  facility?

8
Manufacturing Plant Design and Costs

• Most organizations will use an A E firm along
  with in-house engineering staff in design and
  construction phases. An A E firm should be
  selected on the basis of the firms experience
  gained from previous projects in the particular
  food product area
• Quality and safety must be designed into the
  manufacturing process, taking into account the
  results of prior consumer studies, product
  quality analysis, Federal, state and local
  regulatory requirements for product safety
  (cGMPs_ environmental and occupational safety.

9
Manufacturing Plant Design and Costs (cont.)

• A detailed review of plant design and
  construction costs is essential for compliance
  with plans and contract provisions to prevent
  cost-overruns

10
Manufacturing Plant Start-Up

• The final plant must be given a final inspection
  to determine that all terms of the contracts have
  been met.
• All plant operating, sanitation and maintenance
  personal must be available and trained for
  start-up and continuing operations
• All electrical services, water, wastes and steam
  lines and cleaned-in-place (CIP) sanitation
  systems must be tested
• A total preliminary plant sanitation inspection
  should be made before the initial plant run. The
  HACCP plan must be in place

11
Manufacturing Plant Start-Up (cont.)

• All equipment (processing, materials handling and
  packaging) must be installed and test-operated
  individually and as a part of the total process
  in a trial manufacturing run. Any corrective
  actions must be taken before full scale
  production is started
• If treatment is needed for process water if
  waste pretreatment is required before discharge
  to a municipal treatment system or if an
  individual waste treatment system is installed
  the operation of these units must be included in
  the plant start-up

12
Manufacturing Plant Start-Up (cont.)

• Warehousing must be evaluated for proper
  sanitation and environmental controls including
  insect, rodent, bird and other animal control
  measures
• Product quality and safety sampling and
  analytical systems must be in place
• All ingredients, packaging supplies and
  sanitation supplies must be available for start-up

13
Case ExampleYeast Production

• SEE SEPARATE FILE