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Are Old Chilled Food Sites Becoming a Food Safety Time Bomb? Global Perspective Wanted

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GMO

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Posted 26 March 2025 - 06:47 PM

In the 1990s there was a huge explosion in the food industry in the UK and many of the sites with us now were built between the early 90s and 2000.

 

Sometimes the designs didn't meet best practice at the time.  Sometimes there wasn't better knowledge.  While high care / high risk standards were normally in place, some of those drains are now failing.  Roofs designed for rainfall much less intense than we get leading to troughs being overwhelmed...

 

Food manufacturing is the biggest manufacturing industry in the UK.  

 

So where is the investment?  Where are the new buildings going up future proofing us for the next 30 years?

 

We have businesses sweating assets and only one or two businesses are actually investing and only then if it's for the return, not to replace tired buildings which are going to be (for Brits out there) like Trigger's broom.  In one recent site, every time we refurbished a room, I insisted we put in money to fix the drain issues we'd inevitably find.  But it's sticking plaster upon sticking plaster....  I could see and tried to push for a long term plan for something more robust, even a new site.  Because there comes a point where, especially if repairs have been haphazard, repair probably won't fix all the problems, if they're even fixable.  

 

The problem is the old food sites in the UK aren't the chilled ones and in some ambient sites, to an extent you can get away with it (albeit look to the likes of cadbury's when you really can't.)  Apart from cheese, which, for the most part is not quite the same, I cannot think of a major company with a chilled site in place since before the 80s.  And even that old is rare.  It's a ticking time bomb in my view of food safety risk that no site directors want to face up to knowing they'll be in role for 3 years max and moved on before it becomes critical.

 

How are your establishments bearing up around the world?  Are they of a similar age?  Is there any strategy to replace?  


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kfromNE

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Posted 26 March 2025 - 07:57 PM

Continuous improvement of the building. Now some of these projects were on the budget for multiple of years before approved - especially the floors. The building has been around since the 80s with additions including the blast freezer in the 2000s. 

Ceilings fixed within the last few years to help reduce condensation - has helped a lot. Floors patched up and some replaced. 

Cooling units - replaced as needing. 


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GMO

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Posted 27 March 2025 - 06:45 AM

Continuous improvement of the building. Now some of these projects were on the budget for multiple of years before approved - especially the floors. The building has been around since the 80s with additions including the blast freezer in the 2000s. 

Ceilings fixed within the last few years to help reduce condensation - has helped a lot. Floors patched up and some replaced. 

Cooling units - replaced as needing. 

 

Do the patched up floors hold out?  The reason I ask is so many are patched and then not given the time to cure properly or just creating a weak spot elsewhere.  Have you put cameras down your drains to know the condition?  So many places haven't and find some alarming results when they do.  One site I worked at had drains which were essentially domestic, terracotta type.  Not stainless as you'd build now.  Surprisingly enough(!) they'd cracked in places and were getting soil ingress.  It is only a matter of time before either a void is created (and the environmental pollution risk) due to waste water eating away at the surrounding foundations and soil and a potential collapse of that part of the floor or the drains back up. 

 

Did the leadership want to know?  I'll leave you to guess that one.  Imagine how long you have to shut down a high risk area to dig up and replace all drains...


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kfromNE

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Posted 27 March 2025 - 11:56 AM

The patch is the short term fix for a longer term fix eventually. The issue is with our floors that have a covering over the concrete. Those patches seem to not last as long in certain areas. I forget the material. Some areas - we keep people off the area for a week when able. This does work then. 

 

As for drains/pipes - not my area of expertise. Though knowing by boss and our Directory of Maintenance - they probably know and do care. 


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GMO

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Posted 27 March 2025 - 02:35 PM

Sounds good.  Sadly in the UK we are getting into a habit now of short term senior leaders which I don't think is helping.  Why fix something that won't be a problem in your tenure?  Not when you can save money and get a bigger bonus...


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kfromNE

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Posted 27 March 2025 - 05:27 PM

Sounds good.  Sadly in the UK we are getting into a habit now of short term senior leaders which I don't think is helping.  Why fix something that won't be a problem in your tenure?  Not when you can save money and get a bigger bonus...

 

Our corporate was in the habit of changing out the presidents of our location - supposed to change. So I've been through 3 presidents in 6 years but my boss is the VP of Operations. For some the SQF/QC manager under the VP of Operations would be a conflict of interest. For us, it works because of by boss's priorities.


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