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Supply chain disruption, tight deadlines and post-Brexit red tape are pushing food and beverage manufacturers to their limits. Ben Beattie, director at Forbeats, explains how partnering with an experienced toll processor can offer the flexible capacity, technical know-how and end-to-end support needed to meet demand, maintain quality and stay ahead in an unpredictable landscape.

When partnering with a toll processor, safety is non-negotiable for the food and beverage industry. Manufacturers need complete confidence that contractors are compliant with up-to-the-minute regulations and standards, have the expertise and capacity to safely handle ingredients and materials and can deliver products that are safe and of the highest quality.

An experienced toll processor will provide this assurance. ISO9001 accredited, they will be proficient at handling a broad range of materials across hazard classes and viscosities, and to high safety standards, while also having access to multi-discipline expertise from within their vast, trusted partner network. Moreover, they will have a thorough understanding of the spectrum of food handling regulations, which is essential in the evolving, post-Brexit landscape.

Toll processors will also have the correct plant and equipment for high-quality processing and transport, and will provide sample analysis, batch traceability and paperwork. Together, these also deliver the ability to scale operations, providing manufacturers with the associated savings.

Tackling operational challenges

While the government seeks to reset the UK’s relationship with the EU, food and beverage manufacturers continue to be affected by the legacy of Brexit. Understaffed border controls and import and export regulations, including UK REACH, Export Health Certificates and Sanitary and Phytosanitary checks, have driven up costs, increased paperwork and led to delays. For manufacturers, these disruptions make it more challenging to meet order deadlines, especially when late deliveries create bottlenecks.

These problems are exacerbated by extreme events, the Russia-Ukraine war and Red Sea shipping attacks, which have led to further shortages, delays and higher prices. The consequences are not just problematic for manufacturers but also have the real potential to leave end users with fewer choices, rising costs and consumers with empty supermarket shelves.

With a highly skilled workforce and in-house expertise honed over decades, toll processors are an effective way for food and beverage manufacturers to address these challenges. Having the know-how, facilities and capacity to undertake the gamut of processing requirements, together with the agility to begin operations promptly and manage reoccurring projects, means they are ideally suited for dealing with impediments and tight deadlines. This includes the ability to produce custom formulations and conduct multi-ingredient formula blending, kibbling, powder blending and liquid blending.

Furthermore, toll processors can operate autonomously, delivering high-quality, low-waste processing where safety, efficiency and stringent quality control are assured.

Beyond processing, experts can undertake a wider range of vital services that enable manufacturers to tailor their solutions. Services can include custom packing options, the safe repacking of goods into prescribed container sizes, labelling, warehousing and logistics, import and export clearance, administration, paperwork and batch traceability.

With the flexibility to offer these for both one-time as well as repeat projects, and at an international scale, an experienced toll processor, provides manufacturers with a true end-to-end solution that can go a significant way towards mitigating bottlenecks and achieving order deadlines, while remaining focused on important in-house matters, like sales, marketing also research and development.

In addition, partnerships of this nature allow manufacturers to rationalise and streamline outsourcing. Rather than managing a string of different contractors, working with a single, dedicated supplier results in reduced costs, greater efficiencies and time savings.

Network capacity and expertise

Long-established toll processors have considerable experience in dealing with a wide range of challenges, acquiring the problem-solving acumen over many years to overcome issues facing many companies today. A cornerstone of this approach has been the forging of trusted, long-term relationships with third-party suppliers, including those with BRC accreditation.

The approach means long-standing toll processors have been able to build extensive and frequently exclusive supply networks through which they can obtain ingredients and goods with ease from suppliers. With an up-to-date surplus goods database enabling procurement to happen swiftly, it is possible to overcome the problems caused by delays and shortages in a timely and cost-effective manner.

Equally of value is that toll processors can also access a plethora of vital services, such as logistics and import/exports, from their network partners, providing significantly enhanced capacity and agility. With stock control, order forecasting and process and cost optimisation also key foci, an experienced toll processor can swiftly react to demand, formulate effective production schedules and deliver end-to-end solutions, even when facing disruption.

In today’s volatile environment, a smooth supply chain is essential for food and beverage manufacturers. An experienced toll-processing partner is a proven and effective way to address delays, shortages and bottlenecks. Delivering agile, full-service, end-to-end solutions, toll processors enable manufacturers to mitigate disruption and fulfil orders comfortably within deadlines, while providing services that are safe, high-quality and cost-effective.

Furthermore, partners of this stature will also provide their expertise as a consultancy service, assisting clients with the latest information, connections and regulatory support.