Red Meat Processor Client – New Zealand

During our site audit and meetings with site management, BioGiene identified a range of areas where significant value could be added to our New Zealand client’s meat processing operation.

In consultation with Plant Management, we focused on:

• Water Savings
• Chemical Savings / Chemical Management
• Labour Management

Water Savings

BioGiene proposed installation of an Open Plant Cleaning System to the facility.

Installing an Open Plant Cleaning System (OPCS) would offer significant reductions in water and chemical usage, which in turn would add significant financial benefit to the site’s bottom line.

***BioGiene have unique and direct access to these systems direct from Europe, without the need to source through distributor or retail equipment resellers, which ensures our clients a more competitive buying price than otherwise achievable.

The advantages of using these systems are many, with our clients receiving the benefits such as:

• Higher Cleaning Standards
• Improved Cleaning Efficiency
• Reduced Use of Chemicals
• Less Down Time
• Reduced Surface Damage
• Lower Equipment Maintenance Costs
• Less Water Wastage
• Safer Cleaning Environment
• More Productive Cleaning Staff

Chemical Savings

Through implementation of the Open Plant Cleaning System (OPCS), BioGiene saw an opportunity to reduce the current consumption of the primary main foam cleaning product on site by over 10%.

• Expert cleaning industry management processes, driven by BioGiene management and the developed IMS (fully Integrated Management System for site hygiene) implemented by BioGiene.
• Mechanical aid – from the OPCS system, which offers enhanced technology, to produce a foam application that is superior to the traditional single point injection blocks that were being utilised.
• The new ability to allocate volumes to each user, in a controlled format through de-centralising the application units – rather than providing unlimited access to cleaning staff via a Central Foam system which was currently being used.

Health, Safety and Labour Improvements

Following the plant audit, and coupled with the proposed installation of a specialised cleaning system, BioGiene proposed significant improvements in Health and Safety, as well as other associated areas of labour retention, attendance, and cost of service.

• Existing mains pressure cleaning equipment required very heavy tools (hoses and equipment). Our proposed Open Plant Cleaning System (OPCS) equipment was considerably more ergonomic, and designed to operate on controlled and consistent water pressure, temperature, and with fixed chemical application technology. This offered significant improvement to operator safety, as well as fatigue and manual handling injuries.
• Hot water supply was set to 65 degree maximum temperature, providing optimum cleaning, whilst mitigating the risks associated with some staff using >82 degree water for cleaning.
• Implementation of a site specific IMS, complete with intensive training programs that comply with latest ISO 45001:2018 Safety standards, as well as ISO 9001:2015 Quality Systems
• Staffing levels – BioGiene assuming responsibility for cleaning operations, enabled our client to improve utilisation of its own staff for production related functions.

BioGiene’s recruitment team sourced staff from additional external avenues, supported by recognised Pacific Quota arrangements, developed systems with MSD, and other external recruitment programs.

• Fatigue Management – Production staff were at risk of fatigue through “Overtime cleaning programs” (where production staff remained after processing to “double” as cleaners). Solving this recruitment issue improved performance and quality outcomes, as well as attendance and general wellbeing of Production staff.
• Costs – Production staff typically attract inflated “Skilled” labour rates, as well as penalty rates associated with working Overtime for cleaning duties. Procurement of cleaning consumable tools, and PPE for cleaning staff was also taken on by BioGiene.
• Contingent external support – BioGiene provided an established management team, including qualified senior support teams covering labour/recruitment, Human Resources, Health & Safety, Quality/Compliance, Training and Improvement opportunities. This effectively removed costly and time consuming processes from Alliances HR, Payroll and training departments.

Meet the BioGiene Person

Human Resources are integral to our effectiveness, so we take care of our people, and ensure they are well trained, and well cared for.  This has reduced our staff turnover rate significantly, and our team enjoys a long working relationship with us.

Our unique investment in our HR is significant.

Learn a little more about the ‘BioGiene person’ to better understand how this can save you time and money.