MICRO · 01Microbiology troubleshooting
Make sense of recurring spoilage, gas and short shelf life.
Off-flavors, late gas, yeast and mold, recurring positives in environmental monitoring.
What we review
- Root-cause trees from lab and EMP data
- Starter and culture performance review
- Sampling plans and challenge-study design
LINE · 02Process & line improvement
Steadier make times and fewer stops on the line.
Bottlenecks, unstable make times, changeover losses, CIP and sanitation time.
What we review
- Remote line walk on video
- OEE and downtime analysis
- Parameter windows and SOP rewrites
COST · 03Cost reduction
Find the costs that crept up over time.
Ingredients, cultures, energy, water and rework that quietly eat margin.
What we review
- Formulation and ingredient substitution
- Rework and give-away control
- CIP chemistry, water and energy use
YIELD · 04Yield improvement
Keep more fat and protein in the product.
Losses to whey, moisture control, fines, trim and packaging give-away.
What we review
- Mass balance and Van Slyke yield checks
- Whey fat and fines loss tracking
- Moisture and composition targeting
R&D · 05R&D and new products
Take new products from bench to plant.
Line extensions, reformulation, clean-label, high-protein and plant-based projects.
What we review
- Bench-to-plant scale-up plans
- Shelf-life and stability studies
- Spec sheets for co-packers and customers