reconfiguring food facilities in response to covid-19
TRANSCRIPT
Reconfiguring Food Facilities in Response to Covid-19
August 5, 2020
Guest Speaker Brian King, President | A M King
2THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Learning ObjectivesFood facilities will find it necessary to develop long-term solutions to combat the spread of the virus throughout their facilities to ensure employee safety and work-force retention.
The reconfiguration of Food Facilities is a viable and necessary solution.
There are four specific solutions to be considered, each providing varying degrees of defense while incurring different levels of facility and cost impacts.
Since the start of the Coronavirus pandemic in the US, more than 70 food facilities have been forced to shut down for a period of time.
635
BY THE NUMBERS
Source: FERN, as of July 31, 2020The Food and Environment Reporting Network (www.thefern.org)
Meatpacking and food processing plants
Farms and production facilities
FACILITIES
89WORKERS
Confirmed cases | Covid-19
51,453 221
The Food Industry and Covid-19
Tested positive | Covid-19 Died | Covid-19
3THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
38,641 meatpacking workers 7,314 food processing workers5,498 farmworkers
174 meatpacking workers34 food processing workers 13 farmworkers
Source: www.fooddive.com
What Industry Leaders are Saying
The closure of this facility, combined with a growing list of other protein plants that have temporarily ceased operations across our industry, is pushing our country perilously close to the edge in terms of our meat supply. It is impossible to keep our grocery stores stocked if our plants are not running.
Everyone is most worried about factory workers. We can find different packaging-materials or raw-materials suppliers, but we need those plants to keep operating.
If you’re a business you want to make money, and the only way to do that is by continuing to operate the plants with healthy employees. So what is good for employees is also good for business.
KEN SULLIVANCEO Smithfield FoodsAnnouncing the initial closing of Smithfield’s Sioux Falls facility
PATRICK CRITESERChief Executive Tillamook County Creamery Association
STEWART GLENDINNINGExecutive Vice President & Chief Financial Officer Tyson Foods
4THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
1 2
Food Safety
Keeping the product safe from pathogens or harmful materials
Employee Physical Safety
Protecting the worker from physical harm
5THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
The Two Layers of Food Facility Safety
Infectious Disease Protection
Keeping employees safe from the spread of virus
36
THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
The NewThird Layerof Safety
Unique aspects of food processing and food distribution facilities
Essential businesses for our society
Workers cannot work remotely
7THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Facility designs involved close proximity between workers
8THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Protecting workers from
contracting harmful virus during normal
work activities
Maintaining operational productivity
and efficiency amid facility changes
Retaining workforce
New Challenges Covid-19 Presents to Food Facility Operators
9THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Reconfiguration of Food Facilities is a long-term solution to address the challenges presented by Virus Pandemics as related to the unique aspects of food processing and distribution.
UP
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DNDNDN
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A2012
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x1 x2 x3 x4 x5 x6
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xA.7
xB
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xC.5
xD
xD.5
xE
xE.5
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3
SECURITYOFFICE
116
JAN. CLOSET113
MEN'SLOCKER
111
USDA OFFICE106
OFFICE107
OPENOFFICES
105
MAINCORRIDOR
104STAIR 3
112SECURITY
115
FISHGOWNING
149
MEATOFFICES
142
MEATGOWNING
141
STAIR 2102
ELEVATOR103
RECEPTION101
EXPRESS121
MEN'S ROOM123
WOMEN'SROOM
122
35° CHEESEROOM
144
34° DRY AGEROOM
145
-20° BLASTFREEZER
146
STAIR 1124
-10° FREEZER154
32° COOLER155
MAINTENANCE127
DRY DOCK126
DRYSTORAGE
125
32° COOLERDOCK
156
RECEIVING /INVENTORY
133
OTR DRIVERS135
OFFICE134
32° COLDCORRIDOR
148
MAINTENANCEOFFICE
128
RESTROOM136
2A301
4A301
1A301
61' - 11" 54' - 0" 54' - 0" 54' - 0" 54' - 0" 2' - 6"
277' - 11"
258'
- 8"
20' -
0"18
' - 8"
29' -
8"
49' -
4"50
' - 0"
50' -
0"50
' - 0"
59' -
4"
A1031
A1093
35° FISHDOCK
152
A1081 A107
1
A1092
A1061
RF ROOM132
4A304
EMPLOYEEENTRY
117
ELECTRICALROOM
157
A1041
A1051
WOMEN'SROOM
108MEN'S ROOM
110
WOMEN'SLOCKER
109
STORAGE129
SCRUBBERPIT
35° SCRAPCOOLER
153D.7
E.3
E.4
E.9
1.1
1.1
1.5 2.2 2.7 3.4
8" 34' - 11" 26' - 4" 7' - 8" 34' - 0" 12' - 4" 21' - 8" 32' - 4"
1.3
C.7
5A303
1A303
P&P OFFICES137
ICE PIT
6.1
6.3 6.7
A.8
A.4
B.2
1.48" 26' - 0"
1A302
2A302
3A302
4A302
4A303
1A304
2A304
3A304
5A304
6A305
4A305
1A306
1A306
SIM
2A306
1A308
2A308
3A308
4A308
5A306
3A3064
A306
3A305
1A307
SIM
6A307
2A307
4A307
19' - 2" 25' - 7"
99' - 2" 22' - 4" 65' - 4" 8' - 2" 29' - 4" 19' - 0" 35' - 1"
48' -
6"12
3' - 1
0"73
' - 8"
12' -
8"
166' - 10" 20' - 0" 91' - 7"
24' - 0" 146' - 4" 16' - 6" 51' - 8" 39' - 11" 47' - 3"
70' -
3"20
' - 3"
79' -
9"16
' - 2 7
/8"42
' - 4 1
/8"
49' - 8" 29' - 8" 56' - 6"
5A308
5A308
SIM
NORTH
70' -
10 1/
2"10
1' - 5
1/2"
86' -
4"
26' -
7"
24' -
4"25
' - 0"
25' -
0"25
' - 0"
25' -
0"25
' - 0"
25' -
0"25
' - 0"
20' -
0"20
' - 0"
19' -
4"
44' - 9"
29' -
1"
21' -
4"8'
- 2"
BREAKROOM114
UTILITYROOM
131
FIRE PUMPROOM
158
EQUIPMENTSTORAGE
130
GLYCOL PIT
45° FISHPROCESSING
150
35° FISHSTORAGE
151
35° MEATPROCESSING
143
9' - 0
"11
' - 0"
9' - 0
"9'
- 8"
10' -
4"19
' - 4"
7"29
' - 7"
4' - 5
"14
' - 9"
15' -
5"34
' - 7"
16' -
8"33
' - 4"
8' - 4
"25
' - 0"
9' - 7
"25
' - 0"
5' - 1
0"23
' - 9"
22' - 10" 12' - 1"
2A306
SIM
MEAT SCRAP147
SCRAPCOOLER PAD
159
ELECTRICALCLOSET
160
6' - 0
"
FISH OFFICE161
A1083
54' - 10"
1A305
2A303
2A305
4A302
SIM
3A303
25' -
0"25
' - 0"
25' -
0"25
' - 0"
5A305
6A306
1A305
1
0" T.O.S.
5" RIGID INSULATION (30PSI) & 4" MUD SLAB
1
2
2A303
SIM
6' - 8
1/8"
3
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REVISIONS:FOR PERMIT AND CONSTRUCTION
10/11/19
OVERALL FIRSTFLOOR PLAN
A101
407 W
ESTC
LIFF R
OAD,
GRE
ENSB
ORO,
NC
2740
9
ISSUED: 3/22/2019
CBI -
SOU
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ODS
UPFI
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PHASE 2: INTERIOR COMPLETION
3/32" = 1'-0"1 OVERALL FIRST FLOOR PLAN
NO. DATE DESCRIPTION1 5/10/19 Revision 12 7/03/19 Revision 23 10/11/19 Revision 3
Space Planning
Barriers of Separation
Process Modification
THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Automation
Four solution considerations
with varying degrees of facility and
cost impacts
10
Barriers of Separation
11THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Methods and materials providing barriers
Consider areas of separation (production, welfare, entrances and exits)
Employee efficiency and productivity negatively impacted
Low to Medium
Equipment relocation additional doors or walls / traffic lanes / finishes
Low to High
ProcessModification
THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
Evaluating existing processes to allow distancing and separation
Employee access / work functions and locations / shift changes
Movement within a facility of equipment and product
12
UP
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x1 x2 x3 x4 x5 x6
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xA.7
xB
xB.5
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xC.5
xD
xD.5
xE
xE.5
xF
3
SECURITYOFFICE
116
JAN. CLOSET113
MEN'SLOCKER
111
USDA OFFICE106
OFFICE107
OPENOFFICES
105
MAINCORRIDOR
104STAIR 3
112SECURITY
115
FISHGOWNING
149
MEATOFFICES
142
MEATGOWNING
141
STAIR 2102
ELEVATOR103
RECEPTION101
EXPRESS121
MEN'S ROOM123
WOMEN'SROOM
122
35° CHEESEROOM
144
34° DRY AGEROOM
145
-20° BLASTFREEZER
146
STAIR 1124
-10° FREEZER154
32° COOLER155
MAINTENANCE127
DRY DOCK126
DRYSTORAGE
125
32° COOLERDOCK
156
RECEIVING /INVENTORY
133
OTR DRIVERS135
OFFICE134
32° COLDCORRIDOR
148
MAINTENANCEOFFICE
128
RESTROOM136
2A301
4A301
1A301
61' - 11" 54' - 0" 54' - 0" 54' - 0" 54' - 0" 2' - 6"
277' - 11"
258'
- 8"
20' -
0"18
' - 8"
29' -
8"
49' -
4"50
' - 0"
50' -
0"50
' - 0"
59' -
4"
A1031
A1093
35° FISHDOCK
152
A1081 A107
1
A1092
A1061
RF ROOM132
4A304
EMPLOYEEENTRY
117
ELECTRICALROOM
157
A1041
A1051
WOMEN'SROOM
108MEN'S ROOM
110
WOMEN'SLOCKER
109
STORAGE129
SCRUBBERPIT
35° SCRAPCOOLER
153D.7
E.3
E.4
E.9
1.1
1.1
1.5 2.2 2.7 3.4
8" 34' - 11" 26' - 4" 7' - 8" 34' - 0" 12' - 4" 21' - 8" 32' - 4"
1.3
C.7
5A303
1A303
P&P OFFICES137
ICE PIT
6.1
6.3 6.7
A.8
A.4
B.2
1.48" 26' - 0"
1A302
2A302
3A302
4A302
4A303
1A304
2A304
3A304
5A304
6A305
4A305
1A306
1A306
SIM
2A306
1A308
2A308
3A308
4A308
5A306
3A3064
A306
3A305
1A307
SIM
6A307
2A307
4A307
19' - 2" 25' - 7"
99' - 2" 22' - 4" 65' - 4" 8' - 2" 29' - 4" 19' - 0" 35' - 1"
48' -
6"12
3' - 1
0"73
' - 8"
12' -
8"
166' - 10" 20' - 0" 91' - 7"
24' - 0" 146' - 4" 16' - 6" 51' - 8" 39' - 11" 47' - 3"
70' -
3"20
' - 3"
79' -
9"16
' - 2 7
/8"42
' - 4 1
/8"
49' - 8" 29' - 8" 56' - 6"
5A308
5A308
SIM
NORTH
70' -
10 1/
2"10
1' - 5
1/2"
86' -
4"
26' -
7"
24' -
4"25
' - 0"
25' -
0"25
' - 0"
25' -
0"25
' - 0"
25' -
0"25
' - 0"
20' -
0"20
' - 0"
19' -
4"
44' - 9"
29' -
1"
21' -
4"8'
- 2"
BREAKROOM114
UTILITYROOM
131
FIRE PUMPROOM
158
EQUIPMENTSTORAGE
130
GLYCOL PIT
45° FISHPROCESSING
150
35° FISHSTORAGE
151
35° MEATPROCESSING
143
9' - 0
"11
' - 0"
9' - 0
"9'
- 8"
10' -
4"19
' - 4"
7"29
' - 7"
4' - 5
"14
' - 9"
15' -
5"34
' - 7"
16' -
8"33
' - 4"
8' - 4
"25
' - 0"
9' - 7
"25
' - 0"
5' - 1
0"23
' - 9"
22' - 10" 12' - 1"
2A306
SIM
MEAT SCRAP147
SCRAPCOOLER PAD
159
ELECTRICALCLOSET
160
6' - 0
"
FISH OFFICE161
A1083
54' - 10"
1A305
2A303
2A305
4A302
SIM
3A303
25' -
0"25
' - 0"
25' -
0"25
' - 0"
5A305
6A306
1A305
1
0" T.O.S.
5" RIGID INSULATION (30PSI) & 4" MUD SLAB
1
2
2A303
SIM
6' - 8
1/8"
3
© C
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r i g
h t 2
0 1 9
J
o h n
N .
K o
u r y
, A
r c h
i t e c
t a
l l r
i g h
t s r
e s e
r v e
d
REVISIONS:FOR PERMIT AND CONSTRUCTION
10/11/19
OVERALL FIRSTFLOOR PLAN
A101
407 W
ESTC
LIFF R
OAD,
GRE
ENSB
ORO,
NC
2740
9
ISSUED: 3/22/2019
CBI -
SOU
THER
N FO
ODS
UPFI
T
PHASE 2: INTERIOR COMPLETION
3/32" = 1'-0"1 OVERALL FIRST FLOOR PLAN
NO. DATE DESCRIPTION1 5/10/19 Revision 12 7/03/19 Revision 23 10/11/19 Revision 3
THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 202013
Modifications involve design and construction
Medium to High
UP
UPUP
UP
UP
DNDNDN
DN
DN DN
A2012
A201
A201
A201
1
4
x1 x2 x3 x4 x5 x6
xA
xA.3
xA.7
xB
xB.5
xC
xC.5
xD
xD.5
xE
xE.5
xF
3
SECURITYOFFICE
116
JAN. CLOSET113
MEN'SLOCKER
111
USDA OFFICE106
OFFICE107
OPENOFFICES
105
MAINCORRIDOR
104STAIR 3
112SECURITY
115
FISHGOWNING
149
MEATOFFICES
142
MEATGOWNING
141
STAIR 2102
ELEVATOR103
RECEPTION101
EXPRESS121
MEN'S ROOM123
WOMEN'SROOM
122
35° CHEESEROOM
144
34° DRY AGEROOM
145
-20° BLASTFREEZER
146
STAIR 1124
-10° FREEZER154
32° COOLER155
MAINTENANCE127
DRY DOCK126
DRYSTORAGE
125
32° COOLERDOCK
156
RECEIVING /INVENTORY
133
OTR DRIVERS135
OFFICE134
32° COLDCORRIDOR
148
MAINTENANCEOFFICE
128
RESTROOM136
2A301
4A301
1A301
61' - 11" 54' - 0" 54' - 0" 54' - 0" 54' - 0" 2' - 6"
277' - 11"
258'
- 8"
20' -
0"18
' - 8"
29' -
8"
49' -
4"50
' - 0"
50' -
0"50
' - 0"
59' -
4"
A1031
A1093
35° FISHDOCK
152
A1081 A107
1
A1092
A1061
RF ROOM132
4A304
EMPLOYEEENTRY
117
ELECTRICALROOM
157
A1041
A1051
WOMEN'SROOM
108MEN'S ROOM
110
WOMEN'SLOCKER
109
STORAGE129
SCRUBBERPIT
35° SCRAPCOOLER
153D.7
E.3
E.4
E.9
1.1
1.1
1.5 2.2 2.7 3.4
8" 34' - 11" 26' - 4" 7' - 8" 34' - 0" 12' - 4" 21' - 8" 32' - 4"
1.3
C.7
5A303
1A303
P&P OFFICES137
ICE PIT
6.1
6.3 6.7
A.8
A.4
B.2
1.48" 26' - 0"
1A302
2A302
3A302
4A302
4A303
1A304
2A304
3A304
5A304
6A305
4A305
1A306
1A306
SIM
2A306
1A308
2A308
3A308
4A308
5A306
3A3064
A306
3A305
1A307
SIM
6A307
2A307
4A307
19' - 2" 25' - 7"
99' - 2" 22' - 4" 65' - 4" 8' - 2" 29' - 4" 19' - 0" 35' - 1"
48' -
6"12
3' - 1
0"73
' - 8"
12' -
8"
166' - 10" 20' - 0" 91' - 7"
24' - 0" 146' - 4" 16' - 6" 51' - 8" 39' - 11" 47' - 3"
70' -
3"20
' - 3"
79' -
9"16
' - 2 7
/8"42
' - 4 1
/8"
49' - 8" 29' - 8" 56' - 6"
5A308
5A308
SIM
NORTH
70' -
10 1/
2"10
1' - 5
1/2"
86' -
4"
26' -
7"
24' -
4"25
' - 0"
25' -
0"25
' - 0"
25' -
0"25
' - 0"
25' -
0"25
' - 0"
20' -
0"20
' - 0"
19' -
4"
44' - 9"
29' -
1"
21' -
4"8'
- 2"
BREAKROOM114
UTILITYROOM
131
FIRE PUMPROOM
158
EQUIPMENTSTORAGE
130
GLYCOL PIT
45° FISHPROCESSING
150
35° FISHSTORAGE
151
35° MEATPROCESSING
143
9' - 0
"11
' - 0"
9' - 0
"9'
- 8"
10' -
4"19
' - 4"
7"29
' - 7"
4' - 5
"14
' - 9"
15' -
5"34
' - 7"
16' -
8"33
' - 4"
8' - 4
"25
' - 0"
9' - 7
"25
' - 0"
5' - 1
0"23
' - 9"
22' - 10" 12' - 1"
2A306
SIM
MEAT SCRAP147
SCRAPCOOLER PAD
159
ELECTRICALCLOSET
160
6' - 0
"
FISH OFFICE161
A1083
54' - 10"
1A305
2A303
2A305
4A302
SIM
3A303
25' -
0"25
' - 0"
25' -
0"25
' - 0"
5A305
6A306
1A305
1
0" T.O.S.
5" RIGID INSULATION (30PSI) & 4" MUD SLAB
1
2
2A303
SIM
6' - 8
1/8"
3
© C
o p y
r i g
h t 2
0 1 9
J
o h n
N .
K o
u r y
, A
r c h
i t e c
t a
l l r
i g h
t s r
e s e
r v e
d
REVISIONS:FOR PERMIT AND CONSTRUCTION
10/11/19
OVERALL FIRSTFLOOR PLAN
A101
407 W
ESTC
LIFF R
OAD,
GRE
ENSB
ORO,
NC
2740
9
ISSUED: 3/22/2019
CBI -
SOU
THER
N FO
ODS
UPFI
T
PHASE 2: INTERIOR COMPLETION
3/32" = 1'-0"1 OVERALL FIRST FLOOR PLAN
NO. DATE DESCRIPTION1 5/10/19 Revision 12 7/03/19 Revision 23 10/11/19 Revision 3
Space Planning
Provide opportunity for employee distancing
Allocation opportunities of existing space
Conversion of under-utilized space
Expanding a facility footprint
THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 202014
AutomationAvailable automation solutions vs solutions under development
Collaboration with equipment vendors / manufacturers
Consideration of long-term goals
Conduct an ROI exercise
HighFootprint, processes and operations may all be impacted
Further Considerations
FACILITY IMPACTNo solution will be without some level of impact, both to the facility and from a cost perspective.
EXPANSION & GROWTH When determining re-configuration to protect workers from virus spread, consider future expansion and growth needs and goals.
NECESSARY ADJUSTMENTS Safety requirements addressing Virus Pandemics will alter the design and operations of food facilities. Successful companies of the future will be those who adapt and adjust to operate the most productively in this new environment.
15THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 2020
COLLABORATION A collaborative team will always develop the best solutions – designers, construction professionals, equipment manufacturers, facility management and facility workers.
Resources
THE RECONFIGURATION OF FOOD FACILITIES IN RESPONSE TO COVID-19 | AUGUST 5, 202016
