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White Papers

Food processors are constantly adapting business processes to meet new challenges in food safety, increased competition and cost containment. In this white paper, we look at some of the trends moving the industry forward and improving operational efficiencies within plants. From sustainability to food safety to wireless automation, we examine these new programs and techniques that, we predict, will be more widely adapted in 2014.
While they represent a significant capital investment, automation components, software and systems are critical to the success of any food processing or cold storage facility. But no technology—no matter how innovative—can last forever. In this white paper, we review the signs that it’s time to replace your refrigeration controls system, the benefits of newer systems, what remote monitoring can do for you, and how to get the most out of your HMIs.
The design and construction of a distribution warehouse is more complex than meets the eye. In this white paper, we discuss the benefits of an integrated, team approach to designing a cold storage facility and address important budget considerations. We also highlight the advantages of two best-in-class features for warehouses, the Quell™ fire protection system and shrinkage-compensating flooring.
Natural disasters can wreak havoc on a food processing facility, not only causing physical damage to the building, but also resulting in a huge economic loss in product and production downtime. In this white paper, we look at proactive steps food plants can take to prepare for a natural disaster and the two types of OSHA-mandated emergency response plans. We also provide steps your plant should take in preparing a plan, and discuss federal regulations targeting food plants with hazardous materials.
Food manufacturers today face a host of new opportunities and challenges. Not only must they keep up with ever-changing consumer trends, but they must remain vigilant in their sanitary practices and procedures to ensure the highest levels of food safety. In this paper, we review just a few of the current trends, opportunities and challenges facing food processors today.
Materials used in a food processing plant’s building envelope will have an impact on energy efficiency, durability, safety and sanitation. In this white paper, we discuss the essential components that make up the building envelope, from the walls and ductwork to the roof and interior doors and how the selection of materials will impact the facility.
As design-build experts in the food processing industry, we’re committed to implementing the industry’s best practices in our projects. We also understand the importance of working closely with a plant’s owners to fully understand their current and future needs and goals. This allows us to better control the budget and ensure the project moves along smoothly without any unexpected consequences. Here, we discuss many of the issues necessary to address in the planning stages of a new greenfield plant, expansion or renovation.
More and more food companies are expanding into emerging markets such as China, capitalizing on growing middle classes and increasing popularity of westernized diets. Yet setting up a food processing facility in China – from financing and permitting to quality control and food safety – is a vastly different process than in the U.S. In this white paper, we explore these issues and offer our tips and insights based on our own experience operating in China.
The design of your food processing plant can be a lengthy and tedious process, but is where the most critical decisions will be made. Your architects and engineers will assess your plant’s physical requirements, but will also want to look at your product’s manufacturing and sanitation needs, in addition to anticipated production volume and optimal workflow. In this white paper, we’ll take a look at how these factors influence design and why a utility matrix is an important tool in your plant’s design. We’ll also look at how plant owners are using Building Information Modeling (BIM) to make better business decisions.
The food processing industry continues to look at ways to improve and enhance food safety requirements and compliance. In this white paper, we look at proposed changes for the Food Safety Modernization Act (FSMA) and how Enterprise Resource Planning (ERP) systems can assist facilities in adherence to these new standards. We also explore trends in sanitary equipment design and important considerations when hiring an installation subcontractor.
The Food Safety Modernization Act (FSMA), enacted in 2011, aims to ensure the U.S. food supply is safe by shifting the focus from responding to contamination to preventing it. Food plant architects, plant managers and employees are playing a more active role in food safety from the initial plant design to equipment to on-site inspections. In this paper, we address the proactive steps plants can take to ensure they’re in compliance with all regulations and actively preventing food safety issues.
Improvements to efficiency on the factory floor can lead to lower costs that are reflected in the bottom line. This paper summarizes the basics steps towards efficiency reform for companies needing a common sense approach or road map to evaluate their production output on the factory floor.

In this white paper, we address the pros and cons of the most popular industrial refrigerants and take a look at the myths surrounding CO2 and its use in cascade systems. As more food processing facilities explore the use of alternative refrigerants, we also examine Europe’s stringent F-gas regulations and share successful implementation strategies of natural refrigerants within the European Union.

Food processors are facing new challenges with their industrial refrigeration systems as regulatory requirements are calling for the reduction or elimination of dangerous components. Ozone-depleting R-22 refrigerants are being phased out requiring facilities to find a more environmentally friendly alternative. Plants are also looking for ways to maintain regulatory compliance and increase safety by reducing their system’s ammonia charge. In this white paper, we discuss these topics and answer the many questions surrounding relief valves and compliance requirements.
In this white paper, we address innovative solutions for solving processing challenges. As food processors increase product offerings to meet consumer demands, we provide tips for managing multiple SKUs and look at best practices in preventing cross-contamination when introducing gluten-free products. We also offer insight on how automation can increase throughput and share a case study on one plant’s solution to eliminate noxious odors.
Your food processing plant’s mechanical system is the single most important function necessary to keep your facility operating efficiently. In this white paper, we’ll look at special considerations in budgeting for your mechanical requirements and ways to conserve your facility’s precious energy resources. We’ll also address the importance of having a reliable and redundant mechanical system to keep your plant operating at maximum efficiency.
As of January 2015, The EU F-Gas Regulation will be applicable throughout the European Union. This regulation intends to reduce quantities of fluorinated hydrocarbons (F-Gases) to 21% of current quantities by the year 2030. Such regulation may be on its way to the US very soon, with California leading the way with its own regulation already in place.

In this Digital PSM Buyer’s Guide you’ll learn exactly what you should look for when evaluating compliance software solutions.

The building blocks of a successful Process Safety Management (PSM) program are detailed piping and instrumentation diagrams (P&IDs) and standard operating procedures (SOPs). In this white paper, we offer the key elements to include in these documents, along with the benefits of implementing a digital PSM program. The end game is having a successful PSM compliance audit so we’ll share some of the top violations and how to avoid them.
As food processors face stronger regulation and fierce competition, the need for a long-range strategic plan is more important than ever. A strategic plan provides a roadmap for growth by addressing operational, budgetary and visionary goals. Here, we discuss the attributes and process for developing a business plan, master plan, manufacturing plan and feasibility studies.
More and more companies are turning to high-rise storage solutions and the automated storage and retrieval systems (AS/RS) utilized within them, to increase distribution efficiency and control, decrease energy use, reduce labor costs and maximize use of available land. With numerous advantages, high-rise warehousing can provide a valuable alternative to conventional warehousing.
From cold storage warehouses to meat processing plants, all ammonia refrigeration systems run the risk of dangerous ammonia leaks, particularly older systems with piping that is aged and outdated. While these refrigeration systems are widespread, companies that own older systems or are updating existing systems need to be aware of the safety issues and requirements related to the systems’ relief components.
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Stellar has upheld our brand promise of Taking Solutions Further® for three decades. With unmatched self-performing capabilities, we offer clients a single point of accountability while maintaining the highest level of quality. Our team has experience across a wide range of industries, backed by a company-wide commitment to exceeding our customers’ expectations. We build relationships to last, and have enjoyed successful partnerships with Fortune 100 and industry-leading companies.

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