Weetabix Case Study: Shadow Board Storage Solutions

Weetabix

Standardised Storage Solutions& Colour-Coded Equipment

With a focus on raising hygiene standards and improving operational efficiency,
Ed Campion, Hygiene Transformation Project Manager at Weetabix, asked the Klipspringer team to address three key challenges:

Challenge 1: Lost and Damaged Equipment

The Weetabix site lacked a standardised storage solution for cleaning equipment, resulting in tools being regularly misplaced or lost. Inconsistent storage practices also led to frequent equipment damage.

Challenge 2: Inconsistent Colour-Coding

Hygiene tools were not reliably colour coded, further contributing to equipment loss. The absence of clear colour-coding standards made it difficult to ensure tools were used in the correct factory areas, negatively impacting both operational efficiency and employee engagement.

Challenge 3: Avoidable Replacement Costs

Improper use and inconsistent storage meant cleaning equipment was often damaged or worn prematurely, despite being otherwise fit for purpose. This led to unnecessary replacement costs across the Weetabix site.

Weetabix is a well‑established and trusted food brand with a heritage dating back to 1932, recognised for producing tasty, nutritious cereals.

Built on a legacy of quality and integrity, the business continues to innovate while staying true to its vision: to ready the nation with products made the right way.

This commitment underpins everything Weetabix does, from crafting its iconic wholegrain biscuit to continually enhancing standards across operations, sustainability, and product excellence.

The Solution – Shadow Boards and Colour-Coded Hygiene Equipment

To strengthen consistency, efficiency, and hygiene control on site, Weetabix introduced a system of shadow board storage supported by colour‑coded hygiene tools. This structured approach provided a practical, reliable solution to previously identified operational challenges.

Clearly defined storage locations reduced equipment loss and damage, while intuitive colour‑coding ensured that the correct tools were consistently used in the designated factory areas.

The solution was shaped through on‑site visits and close collaboration with key stakeholders. Existing processes, pressure points, and improvement opportunities were reviewed in detail, enabling a clear understanding of site requirements and ensuring the final approach aligned with hygiene, safety, and operational excellence standards.

Before and After Shadow Boards

“Our team has reported greater operational efficiency, as tools are where they need them, when they need them. There is also reduced spend on hygiene equipment per storage location, as tools now have a defined place and are kept in better condition.”

Ed Campion, Hygiene Transformation Project Manager at Weetabix

The Results – What was the impact?

Since introducing the shadow board system and colour‑coded hygiene tools, site audits at Weetabix have shown more consistent use of the correct equipment across key factory areas. Teams have reported noticeably improved operational efficiency, with tools now readily accessible and stored in clearly defined locations.

This increased accessibility is also expected to support stronger employee engagement, contributing to heightened morale and a more proactive approach to hygiene practices across production areas.

Additionally, spend on hygiene equipment per storage location has reduced. Improved organisation has minimised damage and loss, extending equipment lifespan and reducing the need for unnecessary replacements. This is a clear win for cost efficiency and sustainability.

Partnering with Klipspringer

Ed Campion, Hygiene Transformation Project Manager at Weetabix, highlighted the value of partnering closely with Klipspringer throughout the project.

He described the Klipspringer team as friendly, helpful, and highly informative, noting their willingness to engage across a wide range of issues and provide consistent support.

“They add real value by genuinely engaging with us and committing to deliver a high level of service while putting our needs first,” Ed said. “I would recommend Klipspringer as a core partner in hygiene tool service delivery. They are always responsive and provide excellent service every time.”