the food and beverage industry - royal haskoningdhv
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increasing profitability and productivity through high performance operations
UK edition
The food and beverage industry:
the food and beverage industry the food and beverage industry
The stronger voice of the consumers has become a driving force for food
and beverage manufacturers to produce in a smarter way.
To differentiate themselves, manufacturers need to place consumers at the
centre of operations and respond effectively to their changing demands.
They can do this through a combination of high performance operations
and a consumer-driven supply chain. High performance multipurpose
sites are being developed out of a holistic approach to operations which
integrates automation, connectivity, lean tools and more. At the same
time, the supply chain is being transformed in line with the pull of
consumers, allowing manufacturers to respond more quickly and more
cost effectively.
The combination of Royal HaskoningDHV experience and innovative
approaches is guiding companies in the adoption of new technologies
and how to get the most value from them to build competitive advantage.
Introducing the new reality for manufacturers
Integrated solution cuts time and cost
A new 35m-high cold store in
Cambridgeshire is Britain’s largest freezer
with capacity for around 77,000 pallets.
Cold store infrastructure presents a range
of complex issues across disciplines.
Royal HaskoningDHV’s multidisciplinary
design services provided an integrated
engineering solution, passing on time
and cost benefits to the client. Alongside
deep freeze functions, the facility is a
highly efficient distribution centre for
the nearby food factory.
the food and beverage industry
The challenges facing our clients in the F&B sector today are both complex and
multifaceted. Whether it be reducing energy costs, meeting changing consumer demand or creating
smarter manufacturing facilities, our clients rely on us to deliver innovative and multidisciplinary
solutions that turn these challenges into a real competitive advantage.
The macroeconomic prospects for the global
food and beverage industry are good. Growing
populations and rising wealth feed into strong
growth projections.
Customisation and faster product life cycles are forcing changeGlobal trends such as mass customisation,
automation, faster product introduction and
life cycles are forcing change and adaptation
within the industry. Environmental challenges
including the circular economy are also relevant.
Harnessed effectively, these trends can be
the drivers of competitive advantage that will
underpin the long-term success of food and
beverage manufacturers.
In response, food and beverage manufacturers,
like most organisations, are exploring how to
reinvent themselves.
Craig HuntbatchResident Director
Royal HaskoningDHV UK
Opportunities abound for
manufacturers who can adapt
the food and beverage industry
Productivity and competitiveness are crucialA recent survey by EEF The Manufacturers’
Organisation indicated that more than 50% of
manufacturers planned to increase investment
in technology and innovation in 2017.
Investment is being driven by the need to increase
productivity which is holding back development
and constrains international competitiveness.
The challenge is made more urgent by the
general political and economic uncertainty
which followed the country’s decision to
withdraw from the European Union.
This is allied to an increased pressure on prices
resulting from a weaker currency. The government
has pledged to support the manufacturing sector
to increase its global competitive position and
this support is likely to increase as a consequence
of Brexit.
In pursuit of 100% reliability
Operational efficiency is vital for
companies producing high-volume,
low-margin products in a highly
competitive market. A major UK sugar
manufacturer is constantly exploring
ways to optimise its production process
and achieve 100% reliability. In these
activities, Royal HaskoningDHV is a
trusted partner, operating alongside
in-house engineering teams to bring
specialist technical knowledge as and
when required.
The manufacturing sector in the United Kingdom
is committed to adopt this smarter production.
The sector has the largest share of innovative
firms in the UK and accounts for more than
two-thirds of total business R&D expenditure.
Manufacturers in the United Kingdom are investing in technology and innovation
the food and beverage industry
Consumer demand
requires moreagility from
manufacturers
Consumers are placing increasing
demands on producers, particularly in
mature markets like the UK. Powered
by social media conversations, a taste
trend can sweep through the industry
at considerable speed. Consumers expect
products to be available when and where
they want them.
Consumers want products here and nowManufacturers require speed and agility
to respond. They need to transform their
activities so they can react to the pull of
the customer instead of pushing products
out to the market.
Smarter production is therefore required
which encompasses efficiencies and
economies of scale. At the same time,
there is a need to prepare for distributed
manufacturing operations, automation,
digitalisation, flexible production and
cost reductions.
the food and beverage industry
Industry 4.0
Tim FryDirector Engineering UK
Royal HaskoningDHV
Robot
Instrument
HMI
Sensor
Monitoringtool
Smartfactory
Control system
“To be at the winning end, manufacturers need a vision
and roadmap, while at the same time improve value and grow profitability on
a daily basis.”
Tight budgets and day-to-day pressures remain. These include the need to
improve value and grow profitability while dealing with challenges such as
material supplies, production efficiency, energy consumption, hygiene,
working conditions and more.
UK manufacturers require a
long-term vision and road map to
ensure they stay ahead in a rapidly
changing market. The fitter the
operations are, the better they will
be prepared for what is to come.
Adopting a Lean 4.0 approach
can provide the ideal platform for
transitioning from the current
“Lean” programme to a more
effective journey.
Incorporating digital technology and
live data capture allows for forward
thinking decision making, enabling
transparency and predictability in
delivering value in the complete
supply chain.
Keep the big picture in mindSustainability, efficiency and flexibility
are high on this agenda and there is
recognition that a holistic data-driven
approach will underpin transformational
change. Manufacturers are also
exploring new technologies to
increase productivity and respond
more quickly to consumer demand.
R&D and innovation remain as
important as ever.
UK Manufacturers need a vision and
roadmap for the future
the food and beverage industry
Wastewater issues solved
Royal HaskoningDHV has solved
wastewater treatment issues at
a global beverage company’s
production plant in the West
Midlands. The introduction of its ABR®
(Anti-Bulking Reactor) considerably
improved performance, and ongoing
support continues to deliver enhanced
operations. By teaming up with Royal
HaskoningDHV, the organisation has sa-
feguarded business continuity and saved
money on short-term fixes.
Operations and supply
chain are key to achieving
objectivesOperations and the supply chain have a big impact on a company’s ability to achieve these objectives. Whether integrating a newly acquired company, ensuring consistent product quality, looking at how to use vacant facilities, or reorganising the R&D function, it is the operations and supply chain which can either boost or delay efforts.
Whilst the market implications of Brexit remain uncertain, the regulatory position is that “until exit negotiations are concluded, the UK remains a full member of the European Union and all the rights and obligations of EU membership remain in force. During this period the government will continue to negotiate, implement and apply EU legislation”.
The Environmental Permitting regime which regulates emissions can be expected to remain, and the Environmental Audit Commission has called for a new environmental protection act. However the environmental lobby fears that laws affecting greenhouse gas emissions will test the UK’s international commitments, and complex Directives on pesticides and chemicals will need to be unravelled.
• A focus on winning or maintaining market share: Most players need to be first in their business. Time to market can make the difference.• Ensuring profitable growth and competitiveness: How to do this in a volatile environment where consumer demands are constantly changing.• Flexibility in production facilities: How can changes in production be achieved without requiring major new investment?• Ensuring consistent quality: In particular across locations and countries, whether producing in Africa, Asia, Europe, etc.• Staying compliant in the ever-changing legislative environment• Working sustainably and responsibly while saving costs
Working with clients on a global and local level, we are finding that key items for the management team are:
the food and beverage industry
Towards high performance operations
A game changer for industry
A new state-of-the-art processing factory
for a major meat-processing company uses
Nereda® technology to treat wastewater.
The company, which is a sustainability
pioneer, chose Nereda® because it delivers
high quality effluent at a low cost with a
small footprint. To deliver high quality
products and remain competitive,
manufacturers need cutting edge,
cost effective technologies like Nereda® -
a game changer for the food industry.
To be ready to compete, organisations need to differentiate themselves from the competition. The requirements of manufacturing companies have been evolving, driven by changes in consumer demands and the general macroeconomic situation. As digital technologies advance, we see manufacturing sites becoming elements of cyber-physical systems.
Change delivers the flexibility needed to meet market trendsWhat will differentiate manufacturers in this highly competitive and rapidly changing market is a combination of high performance operations and a consumer-driven supply chain. Both are drivers within the company to place consumers in the centre of operations and respond effectively to changing demands. These differentiators will have a profound effect on the design of manufacturing facilities and warehousing, which are becoming more flexible and reconfigurable. Facilities will be more sustainable, more automated and will engage workers in improving the production process and saving costs, empowering them to innovate. Creation of these high performance multi-purpose sites requires a holistic approach, integrating automation, connectivity, lean thinking and more.
the food and beverage industry
Expect competition for skilled peopleIndustry 4.0 creates huge challenges for management. Already there is a shortage of highly skilled operations and supply chain specialists. As the fourth industrial revolution proceeds, demand will only increase.
Overall, the changes foreseen will require upskilling in the workforce. Complex problem solving and critical thinking are typical of the general competences that will help organisations adapt quickly to the changes ahead. Specific skills in, for example, big data analytics will be vital for faster digital business adaptation.
Collaboration is vital to realise the opportunitiesFor practical reasons businesses will need to collaborate and share information to take full advantage of the possibilities of Industry 4.0. This is partly a function of the shortage of people with the necessary skills but also because it will be too expensive and time consuming to manage all adaptations in-house.We have been working with leading food and beverage companies in the UK and elsewhere for over 60 years, improving their bottom line business results by helping them adapt successfully to new trends and technologies. In the UK today our multi-disciplinary teams are working with our clients to build connected digital operations of Industry 4.0.
Working alongside our consultants on a project basis and through ongoing collaboration, businesses adapt more quickly and learn from the market. In this way our clients are developing, executing and managing their operations in a flexible fashion nationally and internationally. Collaboration is vital to successfully build competitive advantage and realise the opportunities from Industry 4.0. Our experience and expertise is guiding companies in the adoption of new technologies and how to get the most value from them.
The new collaboration:
partnering with consultants…
and competitors
The fourth industrial revolution, Industry 4.0, will provide opportunities
to improve production and increaserevenues. We saw this in the three
previous revolutions. We also saw there are winners and losers depending on
companies’ ability to adapt.
the food and beverage industry
Master plan for jammanufacturing site
Activities at a thriving and long-
established jam manufacturer in Essex
had resulted in ad hoc development on
the company’s site over a hundred years.
To successfully meet the demands of
expanding operations over future
decades, Royal HaskoningDHV prepared
a design for a new sustainable and lean
factory which allows for growth.
Integrated multi-disciplinary
solutions bring added value
It is clear the challenges facing manufacturers are
complex and originate from many different areas
of operations. For example, buildings need to be
flexible and adaptable; long-term energy costs need
to sustainable; resources, especially water, must be
managed; and new technologies implemented.
With activities and expertise in all these areas and
more, Royal HaskongingDHV can put together
multi-disciplinary teams which draw on experience
from a range of industry sectors. These teams have
the breadth of expertise to develop the integrated
solutions companies need to add value for
clients and partners.
“With our wealth of experience in the
Food & Beverage industry, our teams help
accelerate transformationof businesses.”
Katherine MoorePrincipal Project ManagerRoyal HaskoningDHV UK
the food and beverage industry
Smart Solutions is a new structural
approach within Royal
HaskoningDHV to help clients solve
complex challenges. It addresses
the societal trends affecting our
clients and draws on our own
expertise in areas such as high-
performance sites, smart energy
solutions and healthy and inspiring
work environments.
Our projects are embedding digital
solutions, pioneering technologies,
resilience, flexibility and future
functionality for businesses and
communities across the world.
Specific services we offer to the
food and beverage industry include:
• Multi-disciplinary engineering: all RIBA stages, Level 2 BIM Delivery
• On-site and off-site renewable energy solutions from the business
case up to implementation
• Innovations in waste management and water treatment
• Technical due diligence for mergers and acquisitions
• Productivity and efficiency programmes including operational support
• Accelerate productivity and efficiency programmes with a Lean 4.0 approach
• Principal Designer (CDM Regulations 2015) & Lead Consultant functions
• Value engineering and design optimisation
• Digital tooling such as 3D Scanning of the existing plant and virtual
prototyping and simulation
• Design and engineering of standardised buildings supporting fast
organic expansion in developing markets
• Parametric design allowing for flexibility and last minute changes
with minimum impact on the project programme
• Re-masterplanning and repurposing sites and buildings
Smart solutions to increase efficiency, improve sustainability and create flexibility
Contact us and meet the team
www.royalhaskoningdhv.com/ukfoodandbeverage
Principal Manufacturing ConsultantNeil Wallburton
neil.wallburton@rhdhv.commobile: +44 (0)7552 262817
Principal Project ManagerKatherine Moore
katherine.moore@rhdhv.com mobile: +44 (0)7795 565047
Projects DirectorChristopher Mortlock
christopher.mortlock@rhdhv.com mobile: +44 (0)7500 960406
Business Development ManagerAntonina Firsova
antonina.firsova@rhdhv.com mobile: +44 (0)7920 727895
Royal HaskoningDHV is an independent, international engineering
and project management consultancy with 135 years of experience.
Backed by the expertise and experience of 6,000 colleagues all over
the world, our professionals combine global expertise with local
knowledge to deliver a multidisciplinary range of consultancy
services for the entire living environment in some 150 countries.
By showing leadership in sustainable development and innovation,
together with our clients, we are working to become part of the
solution to a more sustainable society now and into the future.
Please visit royalhaskoningdhv.com/ukfoodandbeverage for more information
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