MANUFACTURING

OBECTIVES To understand what is required to manufacture a new product

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?

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

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

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?

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?

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

Manufacturing Plant Design and Costs

Most organizations will use an A & E firm along with inhouse 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.

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

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

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

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

Case Example Yeast Production

SEE SEPARATE FILE