FILE – In this May 22, 2017, photo, cans of Campbell’s soup are displayed at a supermarket in Englewood, N.J. (AP Photo/Seth Wenig)

Plants ‘operating 24/7’ to meet consumer demand for food amid COVID-19

Kraft Heinz Canada reported an 80% increase in demand for its Kraft Dinner product last month compared to March 2019

Campbell Soup Company’s production goes into overdrive during what executives dub “soup season.” Starting in October and ending with the close of winter, Campbell’s manufacturing centres run non-stop, staffed by extra employees.

Since the arrival of the COVID-19 pandemic, consumer demand has soared, eclipsing that of the company’s busiest time. In March, there were more orders during one week than are typically seen in the entire month.

“Our plants are operating 24/7 right now, which is fairly unusual for April, to be honest,” said Beth Jolly, vice-president of communications at the company’s meal and beverages division, which includes Campbell Canada. “It’s really just been a dramatic shift to a full-out production increase.”

Demand for food, particularly non-perishable products, has surged as physical distancing measures keep Canadians close to home. Grocers are ordering more from manufactures, who like Campbell have hired more workers, increased operating hours and enacted other measures to increase production.

At Campbell’s, weekly case orders for that one week in March jumped about 366 per cent at the company’s meal and beverage division, Jolly said.

Kraft Heinz Canada, meanwhile, reported an 80 per cent increase in demand for its signature Kraft Dinner product last month compared to March 2019, the company says.

To meet that demand, both manufacturers had to make several changes to ramp up production.

Kraft’s Montreal-area production facility — where more than 90 per cent of its food for the Canadian market is produced — now operates 24 hours a day, seven days a week, said Av Maharaj, chief administrative officer for Kraft Heinz Canada.

The company is considering new ways to increase efficiency. It may prove simpler to produce only one type of packaging for Kraft Dinner rather than a variety of box designs, Maharaj said.

“From an efficiency perspective — you don’t want to stop your line, change packaging, build out the other one for a smaller packaging line,” he said. “But rather, produce the most popular brand, popular size and that gets more product to the market.”

More difficult is changing production lines. Demand is down from food service clients, such as restaurants and hotels. But transforming a food service production line to one making grocery products is not so simple.

“In many ways, it’s like, you know, a giant Lego system where every piece is connected,” said Maharaj.

It can be very expensive to switch a production line and take months to do, he said.

“You can’t sort of switch overnight from one product to the next.”

The company has been in talks to see if any of its food service products, such as single-serve peanut butter packets, can be sold at grocery stores.

Campbell’s, meanwhile, is trying to focus more on its most popular varieties of soup.

“It’s a bit of a balance,” said Jolly, since the company has to ensure it has enough ingredients to match the increased production.

“It’s not as if we can just put out chicken noodle and tomato.”

Campbell’s also dipped into its existing stockpiles. The company had about 1.5 million cans with limited-edition Andy Warhol labels ready to release in May, but decided to forgo the promotional activity and release the product in April to address demand.

These changes allowed the companies to make more of their products quicker.

Kraft typically makes about seven million Kraft Dinner boxes a month, according to the company. Last month, it made roughly 15 million.

Once the product is made another challenge is getting the extra goods to distribution centres and eventually grocery stores.

“Most food manufacturers don’t own their own trucks,” said Maharaj, and Kraft hires local trucking firms to transport its goods from production facilities to distribution centres.

“Very often, that can be a bottleneck because everyone needs trucks right now to get food out the door,” he said, noting the company’s logistics team has been working hard and “for the most part, we’ve been able to find the trucks that we need.”

In some cases, Kraft is bypassing distribution centres entirely and instead shipping straight to grocers.

“That’s one of the ways we’re speeding up getting product to customers.”

Aleksandra Sagan, The Canadian Press

CoronavirusFood

Get local stories you won't find anywhere else right to your inbox.
Sign up here

Just Posted

Langley City’s Community Day will go virtual

Details are being worked out next week as to what efforts will replace the June 20 festival

ON COOKING: Chef goes a little over the top integrating bacon

His unexpected jam recipe is garnering attention in kitchens and at fair alike

Playgrounds, parkour site, and Langley City hall will partially reopen

City amenities are slowly reopening with physical distancing rules in place

Twilight Drive-In reopens with concession sales approved by Fraser Health, owner says

100 cars of people will now watch films, planning to adhere to new provincial health 50-car capacity

Cloverdale businessman funds wells in Cambodia

Revive Washing in Clayton Heights donates three per cent of profits to charity

Mission prison COVID-19 outbreak ends, 9 new cases in B.C.

New positive test at Port Coquitlam care home

Facing changes together: Your community, your journalists

Thanks for helping the Langley Advance Times to continue its mission to provide trusted local news

Getting hitched at historic B.C. gold rush town still on table during COVID-19 pandemic

Micro-weddings, online visits, offered at Barkerville Historic Town and Park

VIDEO: Police look for suspect seen tripping elderly woman in Burnaby

The elderly woman was walking near the SkyTrain station when she was randomly tripped

Chilliwack teachers, assistants concerned with lack of PPE guidelines ahead of school reopening

As schools get ready to open, many worry measures won’t be enough to protect students from COVID-19

Revelstoke woman finds welcoming letter on her Alberta-registered truck

There have been multiple reports online of vandalism to vehicles with Alberta licence plates

Spirit bear possibly spotted in West Kootenay

A local resident spotted the white-coloured bear while on an evening trail run near Castlegar on May 27

B.C. businesses ‘can’t shoulder burden’ of COVID-19 sick pay

Trudeau’s plan should be tied to federal emergency aid

B.C. teacher reprimanded for sharing homophobic and sexist memes, making racist comments

Klaus Hardy Breslauer was accused of making a laundry list of concerning decisions as a science teacher

Most Read