Food Manufacturers Implement a Rainbow of Hues in their Color-Coding Programs

“We’re seeing them really ramp that up and adding colors,” she said, qualifying that “color coding is as complex as you make it.” Freis said that some manufacturers simply need existing types of products in different colors while others are applying new rigor in how tightly they control work areas and want a bigger catalog of products. For instance, in the past a customer may have used standard white mops throughout the plant, but today the manufacturer may want different colors to ensure cleaning equipment don’t stray into the wrong areas. At the same time, customers are looking for color uniformity in items such as squeegees, which in the past might have had a blade that was a different hue than the handle. Color coding, she added, can reach into every aspects of an operation, from hair nets to lab coats to even gaskets.

“It comes back to the questions of ‘Is that product you are using going to pose any risk of cross contamination, is it cleanable, and does it meet the end user application requirements,” she pointed out.

Regulatory pressures

What’s driving the greater rigor around color coding? Jay Cherwin, senior manager of segment strategy for Grainger, a Chicago-based supplier of color-coded products, believes regulations such as FSMA is in partly responsible. Although the act doesn’t specifically require color coding to improve products safety, it is having an effect in how manufacturers respond to the legislation.

“Food safety standards will be more demanding,” Cherwin said, adding that companies will increasingly turn to visual management as a way to protect food integrity. “It has a proven utility and it will be expanded in its current form.”

Some of that expansion is driven by large manufacturers broadening their programs, companies introducing color schemes to facilities they’ve acquired, and smaller producers who need certification to stay within the supply chain of some customers. Whatever the reason, food companies are turning to suppliers such as Grainger and others for tools that will enhance their color-coded programs. Additionally, they are seeking advice on what works best, Cherwin noted. For instance, a Grainger representative may walk a customer’s plant floor to identify deficiencies or make suggestions.

While food manufacturers ultimately make key decisions on how they implement color coding in their facilities, consultants and suppliers do provide valuable input that help strengthen their programs. Bob Serfas, the founder of R.S. Quality Products, a manufacturer and distributor of cleaning products and utensils based in Allentown, Pa., advises companies to simplify their approach and conduct extensive training to gain employee buy-in. Adhering to these two principles will increase the effectiveness of any color-coding program.

“I think it’s best to make the plan as simple as possible but still get the color coding you need,” he said. “A plan that is too complicated makes it almost impossible for the employees to learn. Training is key.”

A color-coded shadow board with cleaning tools supplied by Grainger.

He advises manufacturers to conduct a thorough walk-through of their facility to determine zones and the colors that will be used in each one. Color should be chosen based on the food processed in that area. For instance, a white brush would be a poor choice for an area that processes coconuts since a bristle that breaks off may be difficult to spot in the end product. Therefore a contrasting color such as green or red is more appropriate.

As food companies ratchet up their coding efforts, their needs for novel colors products are growing as well. That’s why R.S. Quality and other suppliers say they are constantly working with vendors as well as developing their own unique offerings to meet new demands. For instance, Serfas said his company has seen a surge of requests for products that are more durable. As a result, the company began making sanitary aluminum and stainless steel handles to replace weaker fiberglass versions. These may be attached to standard-thread mop heads. Additionally, he said food companies are requesting unusual hues such as orange, pink, and purple to expand their palette.