If you’re considering introducing shadow boards as part of a 5S program in your food plant, you’re probably wondering about the cost and potential return on investment. While there’s no one-size-fits-all answer, the cost is shaped by several factors—some straightforward, others more nuanced. Here’s what you need to know to estimate a budget for shadow boards and see how they can add value to your facility.
Hard Costs: The Direct Expenses
First, let’s break down the tangible, or “hard,” costs associated with shadow boards. These include:
- Materials: The type of board material greatly affects the cost. Options range from high-end laser-annealed stainless steel, which is highly durable, to more affordable choices like Storlam or StorShield. Consider the environment and longevity requirements, as cheaper materials may need to be replaced sooner.
- Design and Components: Custom design fees, along with selecting hooks, holders, and mounts, can impact the price. We recommend using stainless steel, hygienic components over cheaper materials to ensure long-term durability and sanitation.
- Shipping and Installation: If your team won’t be installing the boards, you’ll need to factor in subcontractor costs. Magnet-mounted boards can often save time and installation costs, as they can be easily repositioned without drilling, making them a cost-effective option that also meets high sanitation standards.
Soft Costs: Time and Efficiency
Unlike hard costs, soft costs are less tangible but can add up significantly. These include:
- Labor and Planning: Your time and that of your team are valuable resources. Time spent planning, coordinating, and installing these boards—especially if you choose to handle it in-house—can quickly accumulate. If you need to halt production for installation, this downtime could also impact your bottom line.
- Opportunity Costs: The real question is whether the time and effort spent installing shadow boards could be better used elsewhere. For instance, consider the cost of a maintenance technician’s time. Are there more critical issues, like structural repairs, that might be bigger priorities?
- Learning Curve: If this is your first time implementing shadow boards, there may be a trial-and-error period. Working with an experienced partner can help mitigate some of these initial missteps, saving you time, frustration, and expense.
Weighing Cost Options: Quality Matters
When choosing your materials and setup, it’s tempting to go with lower-cost options, like basic plywood boards and spray paint. But remember: lower initial costs can sometimes lead to higher long-term expenses. Cheap materials can result in a lack of durability, giving employees the impression that the boards are disposable and low-priority. In contrast, a high-quality, professionally produced shadow board instills a sense of pride and care, making it more likely to be respected and maintained.
Innovative Solutions for Food Safety and Hygiene
We’ve seen an evolution in shadow board designs specifically for the food industry. For instance, our latest hygienic mobile frame is the first of its kind: it’s easy to assemble, completely tubeless for better sanitation, and built from stainless steel with no bacterial harborage points. These design details, crafted in collaboration with food industry experts, make it possible to move our shadow boards safely and clean them efficiently, ensuring food safety standards are met.
Getting the Right Shadow Board for Your Needs
Ultimately, shadow board costs vary widely based on material, design, size, and installation method. If you’re considering shadow boards for your facility, it’s helpful to explore different strategies and get advice tailored to your operations. 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.
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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 faced 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.