A Collection of FlexXray Success Stories
The prevalence of foreign materials, whether metal, rubber, plastic or otherwise, poses an ongoing challenge in the highly mechanized food manufacturing field. It’s not a matter of if, but when these incidents will occur. The question becomes, “How does one effectively manage and resolve such situations?”
Below we’ve compiled a few of the most recent case studies provided by our sales representatives. Keep reading to discover the range of foreign material contamination issues FlexXray has worked to remedy across industries.
Have Quality in the Bag with FlexXray
Contributor: Cheryl Bertics
A food pouch manufacturer, referred to by FlexXray as “Producer X,” was contacted by their customer when a small piece of metal alloy was found in one of their stand-up reclosable bags being filled with candy. Neither Producer X nor their customer were sure when the foreign material entered the bag, but they needed to make sure that no metal pieces were in the remaining bags before they were filled and sent to store shelves.
Producer X immediately placed 180,000 bags on hold. With no X-ray machine on their production line, Producer X had a choice to make: either pull apart each case and manually check each bag to look for metal pieces smaller than 1 mm or utilize FlexXray’s inspection services.
FlexXray took Producer X’s product off their hands, inspected it and quickly returned it. No additional metal pieces were found in the bags and 100% of them were able to return to the market safely!
Safe Product: We’ll Drink to That
Contributor: Laura Fernandez
Throughout our years of operation, FlexXray has collaborated with numerous beverage companies facing crises ranging from lost bolts to broken filler nozzles. When a vent tube suddenly broke off during a machine washdown at our customer’s facility, 32,000 cases of soda were placed on hold.
FlexXray successfully identified the issue, discarding the affected cases and salvaging 31,000 units—saving the company more than $300,000. Beyond the monetary value, our intervention spared them the substantial opportunity cost associated with remaking the product—material resources, production time, labor expenses and the risk of encountering another foreign material incident during the remaking process.
Short and Sweet: The FlexXray Difference
Contributor: Tiffany Wade
The holidays are a busy time for everyone in the food industry — especially candy producers. Ensuring customers have quality candy on time for the holidays is no small task. We regularly inspect product for foreign material contaminants, and whether it’s routine surveillance or a specific incident, we’re readily available with a quick turnaround time for our customers.
When producer X came to FlexXray in early October, they were in a time crunch, needing product inspected and on retail shelves before Halloween. After receiving the call, we had their product inspected and ready to go within 24 hours. That quick turnaround time ensured their customers would receive product on time and of good quality.
Foreign material concerns, big and small, are an inherent challenge for manufacturers. The crucial factor lies in how a company navigates and resolves those issues. At FlexXray, our mission is to provide solutions for manufacturers that help them overcome foreign material contamination holds. If you need our expertise, reach out to us today.
