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    Manufacturing Line Optimization

    Diversion Potential:
    20K Tons

    Economic Value Per Ton:
    $1,770

    GHGs Reduced:
    61K Tons

    Water Saved:
    7B Gallons

    Definition

    Target systemic and sporadic waste generation by optimizing equipment operating conditions (e.g. determining the most efficient run settings), addressing production line design flaws, modifying production schedules to minimize changeovers, and identifying novel ways to repurpose discarded food for sale

    Challenges

    • Each plant and product line is unique with different opportunities for waste reduction, leading to difficulties identifying widespread solutions.
    • Many of the most obvious waste prevention opportunities have already been implemented as cost-savings initiatives.

    Stakeholder Actions

    • Manufacturers’ internal action teams can identify waste reduction opportunities, including holding competitions among facilities that incentivize workers to reduce waste.
    • Manufacturers can enhance existing worker training programs to include a food waste identification component and develop programs to reward proactive employee behavior

    Examples & Resources

    • ConAgra changed the way it transitioned between pudding flavors to create blended flavors that could be sold at a lower value.

    Related Solutions

    Top Rated Solution:
    Most Cost Effective

    Packaging Adjustments

    Modifying packaging sizes and designs to optimize consumer consumption and avoid residual container waste

    $3,443 /ton
    in financial benefit

    208 K tons/yr
    in diversion potential

    0 M meals/yr
    meals recovered

    830 K tons/yr
    in GHG reduction

    100 B gal/yr
    in water conservation

    0
    jobs created

    Learn How >

    Secondary Resellers

    Opening retail stores and creating dedicated market environments to sell discounted groceries sourced from food manufacturers and distributors

    $218 /ton
    in financial benefit

    167 K tons/yr
    in diversion potential

    0 M meals/yr
    meals recovered

    510 K tons/yr
    in GHG reduction

    58 B gal/yr
    in water conservation

    0
    jobs created

    Learn How >
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