Reliability Simplified Food and beverage plants
Reliability support for mid-size food and beverage processors, grain and corn millers and co-packers: the methods refineries use, sized for a plant where maintenance also owns sanitation changeovers and the line has to run tomorrow.
Plants where downtime shows up as missed orders.
Mid-size food and beverage plants are the least served market in reliability. The large consultancies chase refineries and chemicals. Equipment vendors sell service contracts on their own lines. The plant is left with a maintenance manager, a parts room, and a CMMS nobody trusts.
Food adds its own problems: washdown on everything, frequent changeovers, allergen runs, seasonal peaks, and audits where a failed seal is a food safety event, not just a repair. A PM program that ignores sanitation gets ignored by the crew.
The work concentrates on conveyors and packaging lines, pumps and heat exchangers, refrigeration and compressed air, boilers, dryers and ovens, mills and mixers. We build the register, rank what matters, find the repeat failures, and set PMs the crew can do between runs.
Register, criticality, bad actors, PMs, spares.
Every item is done hands-on with your team and scoped to your plant. Nothing here is a software license.
- ✓ Asset register and CMMS data build
- ✓ Criticality ranking, RS 7-factor model
- ✓ Bad actor analysis from your work order history
- ✓ PM strategy with sanitation and changeovers built in
- ✓ Critical spares and packaging change parts
- ✓ Refrigeration, compressed air and boiler reliability
- ✓ CMMS implementation and cleanup
- ✓ Operator rounds and basic care
Two ways to start.
Site assessment
Fixed price · $5,600 · travel includedWe come to the plant, walk it, review your CMMS and failure history, and talk to the people doing the work. You get a scored report on where your program sits, the gaps that matter, and what to fix first.
Book the assessment →Reliability Support Plan
One flat monthly rate for a block of reliability hours, sized like a part-time engineer. The hours go where the need is that month: a criticality ranking, a bad actor review, a PM rewrite, a spares call, a problem on the floor. Run out, and you add hours at your tier rate or step up a tier for a lower rate. Month to month, or 3, 6 and 12 month terms. Ask us about it today.
Ask us about the planStraight answers.
We are not a refinery. Does this really apply to a food plant?
Yes. Criticality, failure modes, PM strategy and spares logic are the same on a filler as on a pump. What changes is the consequence side: food safety, sanitation time and missed orders. We score for those.
Our maintenance team also runs sanitation changeovers. How does a PM program fit?
By being built around the changeover window. We set PM tasks that fit the time the line is already down and move the rest to the planned shutdowns, so the program adds no new downtime.
Vendors already maintain our packaging lines. What is left for you?
The decisions the vendor will not make for you: which lines and components are critical, which spares to hold, whether the vendor PMs match your failure history, and what the vendor contract should cover.
Our CMMS data is thin. Can you still find the bad actors?
Yes. We start from the work orders you do have, parts purchases and what the crew remembers, one line at a time. The register gets built as we go.
Will this help with SQF or BRCGS audits?
It helps with the maintenance evidence auditors ask for: a maintained asset register, a PM program with records, and a calibration list. We do not do the food safety audit itself.
What does it cost?
The site assessment is $5,600, fixed price, travel included. The monthly program is one flat rate for a block of hours that goes wherever the need is that month. Run out, add hours at your tier rate or step up a tier for a lower rate. Month to month, or 3, 6 and 12 month terms. Stand-alone jobs are scoped and quoted before we start.
Start with an assessment.
Tell us about your plant and what is failing. We will tell you where to start, and the assessment is one fixed price, travel included.