In the fast-paced world of food manufacturing, small operational adjustments can have a big impact. For operations managers tasked with driving efficiency while upholding strict hygiene and safety standards, knowing where — and how — to integrate hygiene protocols is critical.
We spoke with Mike Kapalko, Industrial Segment Manager – North America, at Essity, maker of the Tork brand, to discuss the often-overlooked connection between hygiene strategy and production efficiency. In this Q&A, he shares practical advice on how the strategic placement of hygiene products, training integration, and KPI tracking can help food manufacturing facilities boost uptime, improve compliance, and maintain consistent standards across shifts.
Q: How does strategic placement of hygiene supplies directly impact production uptime and efficiency in food manufacturing?
Mike Kapalko: When hygiene supplies, such as wipers and sanitizing agents, are easily accessible at workstations, employees can quickly address cleaning needs without disrupting their workflow. Where you place these products can seriously boost productivity. It’s a small detail that makes a big difference in keeping food processing operations running efficiently. For example, the average manufacturing worker is interrupted over 20 times per shift to acquire and dispose of cleaning products. Further, if workers need to travel long distances to retrieve cleaning products, it can lead to significant lost time over the course of a shift.
Placing hygiene products in high-traffic areas isn’t just convenient — it’s smart. Strategic placement of these supplies keeps cleaning tasks quick and easy during the busiest times on the factory floor. Plus, when supplies are within reach, employees are more likely to follow hygiene protocols, helping to build a culture of cleanliness.
Q: What hygiene-related metrics should operations leaders track alongside their production KPIs?
MK: If you’re interested in seeing how hygiene impacts your production goals, start by tracking cleaning-related metrics. They offer valuable insights into how your facility is really performing.
Here are a few key metrics to watch:
- Employee absenteeism rates due to illness, which can severely impact productivity
- Hand hygiene compliance rates, which demonstrate adherence to sanitation protocols
- Stock levels of hygiene supplies, particularly during peak times like shift changes
By monitoring these indicators, leaders can better assess what’s working, and which areas need attention or improvement. This goal-driven strategy ensures that both hygiene and production processes are aligned with the real needs of the facility. That means better efficiency, safer operations, and fewer surprises. A KPI-driven approach helps industrial leaders create a healthier workplace, cut down on absenteeism, and remain compliant — all while driving better productivity and business success.
Q: How can plant managers effectively integrate hygiene training into existing workforce development programs?
MK: Weaving hygiene training into existing workforce development programs is key to reinforcing food safety practices. Plant managers should not only embed hygiene education into onboarding, but also offer regular refresher sessions throughout an employee’s entire career. Accessible training materials — such as instructional posters, quick-reference guides, and visual aids — should be readily available near workstations and in break areas to remind staff of proper hygiene practices, and made available in multiple languages to ensure accessibility and retention. This approach helps build a culture focused on health, safety, and consistent hygiene standards.
Q: What practical approaches help maintain consistent hygiene standards across multiple shifts and production lines?
MK: Maintaining consistent compliance with hygiene standards across shifts and production lines comes down to clear communication and smart systems. Standardized checklists and clear hygiene protocols help ensure every team picks up right where the last one left off. Regular audits are also key — they help leadership make sure the right supplies are available and identify any areas for improvement.
Sometimes it’s as simple as choosing the right soap. If a product is too harsh, employees might avoid using it, especially if they have skin sensitivities. Choosing soap options that are certified gentle on skin encourages better hand hygiene, which is critical in food production. When hygiene tools and training are aligned with real employee needs, it helps prevent illness, boosts productivity, and keeps operations running smoothly.
Q: How can operations teams streamline hygiene compliance procedures without compromising food safety standards?
MK: In addition to providing ongoing trainings and auditing hygiene supplies, incorporating visual reminders of cleaning protocols throughout the plant floor can reinforce the role hygiene plays in safety. Simple signage showing where key products can be found in the facility, as well as easily accessible handwashing stations, encourage consistent hygiene-centric behavior and help employees embed protocols into their daily workflow. Ultimately, it’s all about facilities being able to foster an environment where everyone prioritizes workplace safety, and therefore food safety.
Mike Kapalko is Industrial Segment Manager, North America, at Essity, maker of the Tork brand. With 25+ years in away-from-home and B2B markets, he’s held leadership roles in product management, service solutions, sustainability, and strategic marketing. He helps manufacturing and food processing organizations improve operational efficiency and hygiene standards.
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