When a top 10 dairy producer discovered a missing thermometer in a freezer unit during the cheese curd-making process, it sent shockwaves through their operations. With 1.6 million pounds of Monterey Jack cheese on hold, the stakes were high—scrapping the product meant losing millions.
Faced with the potential for a major financial setback, the producer knew they needed a fast and reliable solution to assess the situation and salvage as much product as possible. Fortunately, they had a trusted partner in FlexXray, having worked with us on previous projects.
A Swift Response with Trusted Expertise
Our team stepped in immediately, offering an efficient, cost-effective plan for inspection and recovery. With the product already on hold, the dairy producer’s QA team needed an expert who could quickly assess the contamination risk and maximize the recovery of their inventory. FlexXray’s X-ray technology was up to the task, allowing for precise detection and removal of any potential foreign materials.
The plan was to inspect each truckload, which averaged 42,000 pounds of cheese, and salvage as much product as possible—all while ensuring food safety standards were met.
The Impact of X-Ray Inspection
In just 11 days, FlexXray completed the round-robin inspection process, and the results were as follows:
98.5% of the cheese (1.6 million pounds) was salvaged and cleared for distribution — that’s $6.3 million in retail value.
98.5%
salvaged
$6.3M
saved
Thanks to FlexXray’s approach, this producer avoided a massive loss, protecting both their bottom line and brand reputation. What could have been a total write-off turned into a success story of product recovery and customer confidence.
For manufacturers in any industry, foreign material contamination risks are a serious concern—but with FlexXray’s trusted solutions, companies can turn a potential disaster into a recovery success, ensuring both quality and profitability remain intact.
