Food innovation in Virginia isn’t a new phenomenon. Dating back to the 17th century, the Commonwealth’s farming of cash crops, notably tobacco, helped establish it as the richest of the initial 13 colonies in agriculture. Fast forward four centuries and Virginia is once again at the forefront, this time in the controlled environment agriculture (CEA).
These advanced techniques involve hydroponic, aeroponic, vertical, and indoor farming systems, attracting investments aimed at producing fresh, sustainable, and locally grown foods.
In Hampton Roads specifically, 1 in 8 manufacturing jobs are in food & beverage processing.
Food manufacturing is a critical industry that employs millions globally, beginning with harvesting and processing these crops into daily necessities like bread, cereal, pasta, meat products, and dairy goods.
Despite misconceptions, factory-produced food often undergoes more rigorous regulation and inspection than smaller farms due to its industrialized nature. This rigorous quality control ensures safety and consistency at every stage of production—from growing to packaging.
So, who makes sure all these safety protocols are spot-on? Consultants are absolutely vital in maintaining high standards of quality control in food manufacturing. They bring knowledge from endless sectors, enacting best practices at every stage of food production.
In today’s guide, we’ll learn about quality control in food manufacturing and its related concepts:
- Sustainability
- Safety
- Transparency
- Productivity
- Visibility
- Quality
6 Things A Food Manufacturing Consultant Can Help You With
Sustainability
Consultants help manufacturers develop sustainability strategies that resonate with today’s eco-conscious consumers. They begin with thorough sustainability audits to pinpoint areas for improvement.
From there, they suggest water-saving techniques like drip irrigation and advocate for natural pest control solutions over chemical pesticides. They also aid in sourcing eco-friendly packaging to cut down on waste. Consultants also guide manufacturers in optimizing energy use, often by shifting to renewable energy sources.
Notably, in 2021, 44 percent of consumers preferred to buy from sustainable brands like Smithfield Foods, a global food company based in Smithfield, Virginia, and the world’s largest pork processor.
Smithfield Foods pledges to sustainability initiatives like lowering greenhouse gas emissions, conserving water, and investing in renewable energy.
Safety
Just as a pinch of salt can transform a dish, introducing strong food safety programs can dramatically improve product quality.
Consultants guide businesses through complex state regulations, such as the FDA Food Safety Modernization Act (FSMA) and the Hazard Analysis and Critical Control Points (HACCP) system.
They help design and execute comprehensive workforce training plans that address everything from basic food safety training to specialized lean manufacturing techniques that make your operations smarter (and, by correlation, safer).
Transparency
Today’s consumers want to know the ingredients of their meal down to the last crumb. Consultants assist manufacturers in crafting transparent and accurate labels, avoiding the pitfalls of misleading claims like “natural” or “GMO-free.” They help Virginia businesses adopt digital technologies such as blockchain to track and share the entire lifecycle of a product—from sourcing to shelf—enhancing traceability and consumer trust.
Consultants also make it a huge priority to ensure manufacturing processes meet the highest standards by guiding companies through certifications in quality systems like ISO 22000 and BRC, providing a verifiable commitment to quality and safety. With 56% of Americans feeling they can’t trust state health departments to ensure nutrition labeling is accurate, providing clear and honest information can earn a brand a five-star rating of trust.
Productivity
Imagine a kitchen where every chef knows exactly what to do and when to do it. That’s what consultants bring to food manufacturing with systems like Automated Statistical Process Control (SPC). By monitoring key performance indicators in real-time and quickly addressing any issues, consultants help maintain steady quality and productivity.
Boosting productivity in food manufacturing benefits more than a single business; it can have big implications for the entire economy. The food processing and beverage industry makes up about 33% of Virginia’s manufacturing sector’s activity, playing a major role in the state’s economic growth.
Visibility
By utilizing advanced supply chain services like CONNEX™ Virginia, consultants stimulate supply chain visibility and break down silos to create a transparent journey from farm to fork.
This visibility helps detect bottlenecks and quality issues early.
Quality
Ultimately, consultants add that final finishing touch that transforms a good product into a great one. They create an organizational understanding of quality costs and emphasize the importance of addressing defects at the source. By doing so, they help food manufacturers whip up products that are not only delicious but also trusted and loved by consumers.
For example, Smithfield Foods also employs advanced data analytics to monitor food safety indicators and collaborate with relevant regulatory bodies like the USDA and FDA to increase consumer protection. Their commitment includes maintaining Global Food Safety Initiative (GFSI) certification at all applicable facilities and running a strong food safety employee training program.
