Insight
Ensuring smart transformation success

Insight
Smart transformation projects in food factories can unlock efficiency, reduce costs and improve quality, but only if they are managed with clear objectives and strong collaboration. Having supported smart factory programmes for more than 20 years, Ed Keenan, Head of Food Process Consulting at NIRAS, reflects on the lessons that matter most today.
Before any technology decisions are made, it’s vital to be clear on what you want to achieve. Is the aim to cut downtime, improve traceability, reduce waste, or lower energy costs? A proper audit of current processes and digital maturity is the best place to start. Operators and maintenance teams are key voices here, they deal with the day-to-day challenges and often know exactly where improvements will have the biggest impact.
Once the priorities are agreed, they should be translated into clear and measurable goals. Whether that’s boosting Overall Equipment Effectiveness (OEE), cutting waste, or tracking energy use more closely, these measures keep everyone aligned. When it comes to budgeting, think beyond the upfront price of new technology. Factor in integration, training, and ongoing support. Showing early wins, tangible savings or efficiency gains, helps to build momentum and strengthen the case for continued investment.
Technology should always respond to genuine needs. The most effective solutions are often the ones that feel the most practical, predictive maintenance that prevents costly breakdowns, real-time monitoring that improves quality, or automated controls that reduce errors. Choosing modular, scalable systems makes it easier to adapt as your factory evolves. And because food factories have specific demands, compliance and resilience matter. Equipment must meet industry standards and stand up to harsh operating environments, from regular washdowns to round-the-clock production.
Smart transformation is as much about people as it is about systems. Success comes when silos are broken down and teams, from IT and production to quality and safety, work together. Having a project champion to lead, align stakeholders, and keep things moving can be a game-changer. But no technology works without buy-in. Clear communication, early training, and reassurance about how new tools will support rather than replace people are all vital. Change is easier to embrace when everyone understands the benefits to their own role.
The best results often come from starting small. Trialling a solution on a single line or machine allows teams to gather data, prove the concept, and build confidence before scaling up. Small wins create momentum and make the bigger changes feel less daunting.
Smart manufacturing isn’t a one-off project. It’s an ongoing journey that will continue to evolve as technologies like AI forecasting and robotics become more mainstream. The companies that thrive will be the ones that keep their goals clear, stay open to new ideas, and bring their people along every step of the way.
Smart transformation doesn’t succeed because of technology alone, it succeeds because of people working with purpose. By focusing on solving the right problems, setting clear goals, and building a culture of collaboration and trust, food manufacturers can turn digital ambition into real, lasting results.
Chris Bullock
Director of Engineering (UK)
Burton upon Trent, United Kingdom