The Hidden Cost of Unstable Utilities in Manufacturing — And How to Combat It

In the fast-paced world of food manufacturing, from processing fresh meat to crafting artisanal baked goods, the reliability of power, water, and compressed air utilities can make or break your operations. For industries like meat, dairy, bakery, and produce, downtime doesn’t just mean delays—it means spoiled products, missed deliveries, and a direct hit to your bottom line.

At MULTIVAC Group, we specialize in manufacturing solutions, but we recognize how critical power, water, and compressed air stability are to your production success. While we don’t control utilities, we have seen firsthand how disruptions impact operations, and we work closely with customers to help mitigate those risks.

Did you know that downtime costs in manufacturing can range from thousands to tens of thousands of dollars per hour? Exact figures vary by industry, but the reality is clear: power, water, and compressed air instability can lead to lost revenue, wasted product, recovery time, and supply chain disruptions. Even a brief disturbance can result in costly downtime and damaged equipment, creating long-term financial strain.

The worst part? 80% of power quality problems originate within the facility itself—often due to improper installations, inadequate surge protection, or aging infrastructure. Additionally, water and compressed air quality issues such as fluctuating pressure, moisture contamination, and leaks can cause significant damage to equipment and lead to compliance concerns. For dairy processors maintaining temperature control, produce packagers relying on consistent water flow for cleaning systems, or bakeries depending on compressed air for precision mixing and forming, utility instability can be a major operational threat.

The shift to renewable energy sources like wind and solar has introduced variability to the power grid, creating additional risks for food manufacturers. Similarly, water and compressed air infrastructure challenges, including aging pipelines, inconsistent municipal supply, and air compressor inefficiencies, pose risks to production stability. However, manufacturers can take proactive steps to reduce these risks:

• Proactive Power, Water, and Compressed Air Monitoring: Using high-speed power recorders, water quality sensors, and air pressure monitoring systems to detect and address disturbances before they escalate.
• Proper Surge, Filtration, and Pressure Regulation: Installing surge suppressors and line reactors at key service entrances for power stability, industrial water filtration systems to prevent contamination or scaling, and air dryers and filters to ensure clean, dry compressed air.
• Smart Equipment Design: Ensuring that transformers, impedance ratios, water treatment systems, and air compressor capacity are properly sized to prevent inrush currents, pressure fluctuations, or quality inconsistencies that can damage equipment.
• Evaluate Legacy Systems: Conducting a week-long power, water, and compressed air quality assessment to pinpoint vulnerabilities, such as poor grounding, oversized systems, mineral deposits in water lines, or compressed air leaks, to inform improvements.
• Invest in Conditioning and Backup Systems: Implementing constant voltage power conditioners, uninterruptible power supplies (UPS), backup water reserves, and compressed air storage systems to maintain consistent performance even during disturbances.

By implementing these strategies, food manufacturers can significantly reduce the risk of downtime and equipment failures caused by unstable utilities.

Resilient operations are built on preparation, not reaction. Food manufacturers can strengthen their production lines by:

• Performing regular power, water, and compressed air utility assessments to understand unique facility risks.
• Working with trusted third-party experts to implement best practices in surge protection, grounding, water treatment, and compressed air management.
• Equipping teams with the knowledge to identify early warning signs of utility instability.

By taking these steps, manufacturers can reduce costly shutdowns, maintain compliance, and protect product integrity.

While mitigation strategies form the foundation of a resilient operation, MULTIVAC’s Smart Services provide a tailored approach to take your performance to the next level. Designed with our customers in mind, Smart Services enable you to:

• Monitor Equipment and Utilities in Real-Time: Detect and address power, water, and compressed air quality disturbances before they lead to failures or interruptions.
• Analyze Historical Data: Understand trends in downtime, enabling smarter decisions about equipment maintenance and upgrades.
• Maximize Equipment Performance: Ensure MULTIVAC’s packaging, slicing, and portioning equipment operates at peak efficiency—even in challenging environments.

At MULTIVAC Group, we’re more than a solutions provider—we’re a partner in your success. Contact us today to learn how our Smart Services can help safeguard your operations, protect your bottom line, and keep your products moving from line to shelf without interruption.

Schedule a demo today! Call 1-800-877-5200 to talk to a digital professional.