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FOOD PROCESSING & PACKAGING TOLL PROCESSING OFFERS A LIFELINE
Ben Beattie, manager at Forbeats
These networks can also be relied upon to deliver other services, helping to solve problems in areas such as distribution and import/exports.
In the midst of ongoing disruptions, Ben Beattie, Manager at Forbeats, explores how toll processing can be a vital lifeline for food manufacturers, offering additional capacity, expertise, agility and problem-solving benefits
he food industry currently finds itself impacted by a range of challenges. With no end to the Russian-Ukrainian war in sight and with ongoing attacks on shipping lines in the Red Sea, current shortages are set to continue. At the same time, the aftermath of Brexit means companies face delays while being saddled with higher costs, more paperwork and increased regulation, such as UK REACH.
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The consequence is that ingredients and raw materials vital to the food manufacturing process are often hard to source, have inflated prices and arrive late. This creates a situation that is highly disruptive for the industry given that many ingredients have a limited lifespan and where manufacturers operate with Just-in-Time strategies. Toll processing offers food processors an effective means to overcome these hurdles. An experienced provider with fully equipped facilities will have the flexibility, capacity and know-how to deliver the full suite of processing services. This includes carrying out blending operations, with experienced providers having the expertise and capabilities to blend multi-ingredient formulas and create accurate custom formulations for each job. In this respect, they can offer true end-to-end solutions, with the agility to deliver both continual and one-time operations. Moreover, the solutions provided are not limited to manufacturing. Additional services can include custom packing, repacking and labelling, warehousing and logistics, import and export clearance, administration services
28 OCTOBER 2024 | PROCESS & CONTROL
as well as batch traceability. With repacking, for example, toll processors will have the connections to secure custom packaging options specific to each client’s individual requirements, together with the expertise to efficiently and safely re-package materials into the size and type of container specified. Partnering with a subcontractor that offers this extensive suite of services not only enables manufacturers to resolve bottlenecks quickly and complete orders within deadlines but to do so without convoluted outsourcing setups, improving cost-effectiveness and efficiency. Importantly, a toll processor will also have a highly skilled workforce, often with decades of expertise. This significant experience ensures the contractor will have the capability to deliver solutions with autonomy. Furthermore, it means it can provide streamlined, efficient and safe operations, with robust quality assurance, to deliver high-quality, low-waste processing every time.
Learning from previous challenges, toll processors will have the foresight to predict potential disruptions and issues, and will have established relationships with other firms to forge large-scale supply networks that hold the highest BRC Accreditation. This ensures safety and quality, both of which are vital for the food processing industry.
Furthermore, through maintaining an up-to- date surplus goods database, an experienced toll processor will have developed a setup that is focused on mitigating shortages and delays, enabling them to obtain ingredients and products swiftly from surplus network supplies.
A toll processor’s focus on stock control, order forecasting and process and cost optimisation also enables them to overcome disruption-related problems. With these in place and having the flexibility to react swiftly to demand, production schedules can still be planned and end-to-end solutions delivered, despite disruption, ongoing or unexpected. Companies within the food processing and packaging industry need assurance that any subcontractor will handle ingredients and materials safely and comply with all applicable regulations. The know-how and capacity to deliver this is critical, as they ensure that risk to life, fines, damaged reputation, waste and poor-quality processing are all reduced. Indeed, a trustworthy toll processor will not accept a contract if they lack the experience or facilities to fulfil it safely. As such, experienced toll processors will be fully up to date with the current regulations for handling foodstuffs and will operate in strict compliance with them. To ensure this, they will have ISO9001 accreditation and the experience to process and pack a huge range of foodstuffs safely. This setup also enables them to alleviate operational bottlenecks. To ensure ingredients, materials and finished products are stored, processed and transported in line with regulations and best practice, competent toll processors will complete food processing operations to the highest possible standard, with sample analysis, batch traceability and paperwork provided if required. They will also ensure that all necessary equipment, including specialist plant and apparatus, is available. This is vital, not just for ensuring product quality and safety, but for scaling up operations and providing manufacturers with the benefit of at-scale savings without ever impacting quality. For manufacturers within the food processing and wider chemical industry, partnering with an experienced toll processor offers a smooth supply chain in which delays, bottlenecks and shortages can be alleviated. Offering flexible, end-to-end, full-service solutions, such partnerships can mitigate disruption, ensuring orders can be completed within deadlines and that subcontracted services are delivered with quality, cost- efficiency and safety.
Forbeats
forbeats.co.uk
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