Evaluating the Effectiveness of Internal Rework

Picture this: it’s a typical day at your food manufacturing facility until, suddenly, your in-line metal detector begins to reject product. Upon inspection, you notice a damaged blade from a grinder that broke down and realize that the blade had been slowly releasing metal fragments into finished product. 

As a precaution, you bracket 100,000 pounds to place on hold, knowing that about 25,000 pounds are particularly at risk of being contaminated with fragments too small for your metal detector to catch.

What would you do next in this situation? Explore your options in our white paper.

Foreign material contamination can do a number on your bottom line. It has the potential to severely disrupt your production schedule and, if not addressed properly, damage your brand reputation. 

Finding an efficient, cost-effective method that solves your product holds is critical to maximizing your ROI and reducing waste. Internal rework is a common solution; but, upon closer examination, it may not be the most effective solution. 

Every situation is unique, but at minimum, internal rework generates additional time, labor and equipment costs.

If you’re considering internal rework, there are a number of factors to consider. Here are a few key questions to ask yourself:

Do you have time to pause normal production to internally rework product? 

Do you have the additional labor needed to quickly clear your hold? 

Do you have the right equipment to effectively do the rework internally?

If you don’t have an immediate answer to any of those questions—among many others—don’t worry. We have a downloadable white paper resource available now that’ll help you consider the costs of internal rework and provide you with information on an alternative option: third-party x-ray inspection with FlexXray.

Additionally, we previously hosted a webinar titled “Rethinking Rework,” where a few members of our team sat down with Suzanne Finstad, Vice President of Food Safety and Quality Assurance at Tyson. A recording of our conversation is available for viewing now!

If you have any questions about FlexXray’s flexible service offerings, contact our team today. As the leading provider of third-party food X-ray inspection and recovery services in North America, our mission is to help you salvage good product in the face of foreign material contamination and other QA concerns.