Cut Costs and Reduce Delays: Shadow Boards for Change-Out Parts

A common question we hear is: How can I organize my equipment's change-out parts to streamline startup times? OR to eliminate lost items, reduce costs, or increase production efficiency?

This challenge often results in different approaches to solutions. Some facilities place change-out parts—such as gaskets, clamps, pipes, tubes, fittings, blades, and plates—on carts stationed near the equipment. These carts are typically cleaned by the sanitation crew, which is also responsible for disassembling and cleaning the equipment. Once the equipment dries and is deemed process-ready, your Environmental Monitoring Program (EMP) swabbing takes place to ensure cleanliness.

Here’s where delays occur: If recleaning is needed or reassembly takes longer than expected, production startups can be significantly delayed. That not only means wasted time, it’s also wasted money.

A Better Solution: Shadow Boards for Change-Out Parts

A more efficient strategy is using a shadow board with dedicated spots for every change-out part. Each part—whether it's a gasket, clamp, or pipe—is removed from the shadow board for use and placed back in its designated location after cleaning. This method keeps everything accounted for during the breakdown and cleaning process.

What’s more, the cleaning process itself can happen directly on the shadow board. Using hooks and stainless steel carabiners, parts are secured so that high-pressure sprays or foam cleaners won’t knock them onto the floor. This saves time and ensures cleanliness while keeping parts organized for reassembly.

The Benefits of Shadow Boards for Change-Out Parts

1. Labor Savings and Increased Efficiency

Using a shadow board can reduce equipment setup times by 30% to 55%. That extra 15–50 minutes gained per shift can lead to significant increases in production throughput and profits. When you produce more without increasing overhead, your plant becomes more profitable—a strategy that directly impacts your bottom line.

2. Reduced Costs from Lost Items

Lost change-out parts can be expensive. Stainless steel components and complex machined parts often have high price tags. If a missing part contaminates a product or damages processing equipment, the costs escalate further due to wasted product and energy. Shadow boards ensure every part is accounted for, reducing these risks.

3. Water and Cleaning Efficiency

Efficient cleaning with less water is a big win for any plant. By cleaning parts directly on the shadow board, you minimize water use and wastewater treatment costs while ensuring proper sanitation. Reducing how much water your plant uses is also a plus in making your operation greener.

4. Lower Risk of Product Recalls

Shadow boards add another preventive control to your food safety program. While they can’t guarantee you’ll avoid all recalls, they help reduce risks. For example, lost gaskets or parts that escape detection by metal or X-ray detectors could lead to contamination issues. Shadow boards help prevent these situations by keeping parts organized and accounted for.

Conclusion

Shadow boards for change-out parts are an essential tool for improving accountability, efficiency, and safety in food processing facilities. They save time, reduce costs, and add an extra layer of risk mitigation. Think of them as a small investment that delivers big returns for your plant’s profitability and safety.

If you’re ready to take your plant’s organization and efficiency to the next level, consider implementing shadow boards. They’ll not only streamline your processes but also give your team confidence in knowing that everything is in its place.

Making the Case for Shadow Boards in Your Plant

If you’re considering shadow boards for your facility, you can start making a case with the benefits we’ve laid out here. The next step is to get advice tailored to your operations. That’s where we come in.

We’re here to discuss your unique requirements and offer options to help you make a sound investment that enhances productivity and food safety.

Reach out today to get a quote on a 5S shadow board, and let’s talk about the best approach for your facility.

About the Author

 I'm Kevin Boyt, COO of Amerisan, and I’ve written this blog because I’m passionate about 5S shadow boards and their impact on food processing facilities. Having consulted with hundreds of food processors, I understand the challenges you face when implementing 5S systems, and I’m here to help. My team and I have refined our shadow boards over the years based on your feedback, creating solutions that stand the test of time. If you have any questions or need assistance, feel free to reach out—we’d love to help you build a safer, more organized facility.