Client Case Studies

In early 2023, FreshDelight Foods sought to scale production by partnering with a co-manufacturer. Attracted by the partner’s reputation and competitive pricing, the company opted to forego a detailed Quality Assurance (QA) review, relying instead on industry recommendations and surface-level assessments.

Within months of starting production, FreshDelight faced escalating issues: customer complaints of contamination, temperature control failures, and inconsistent product quality. An FDA recall exposed deeper problems, including regulatory non-compliance, poor sanitation practices, and incomplete ingredient documentation. These lapses led to financial losses, halted production, and significant reputational damage.
Determined to recover, FreshDelight revamped its approach by prioritizing QA in selecting a new co-manufacturer. Through rigorous vetting, they secured a partner with robust food safety protocols and regulatory compliance, successfully restoring customer trust and operational stability.

Key Takeaway: Investing in a thorough FoodQure review during co-manufacturer selection is crucial. It safeguards product quality, ensures compliance, and protects a brand’s reputation—key pillars for long-term business success.

Supplier verification is a critical aspect of food safety and quality assurance within the food supply chain. Consider, for instance, GreenLeaf Salads, a small ready-to-eat salad brand known for its popular fresh-cut chopped kale salads. These salads were produced at several co-manufacturing facilities and then distributed to grocery chains across various states. At the beginning of their project, GreenLeaf Salads conducted thorough due diligence by collecting essential supplier documentation from these co-manufacturers, including 3rd party audits, Certificates of Insurance (COIs), and food safety records. However, as time went on and the busy season approached, the company neglected to keep these documents current and failed to perform periodic audits of their co-manufacturers and suppliers.

The situation took a turn when GreenLeaf Salads received a customer complaint about metal fragments found in one of their salad bags. This led to an investigation and a swift market recall due to the discovery of foreign material. Upon further investigation, it was discovered that the co-manufacturing facility had sourced kale from a supplier not listed on GreenLeaf Salads’ approved ingredient supplier list. The brand had not updated this list, and the new, unapproved kale supplier had delivered the raw ingredient bundled with metal twist ties. The co-manufacturing facility lacked the necessary control measures to remove and detect this hazard during production, resulting in the metal twist ties contaminating the final product.

GreenLeaf Salads recognized the urgent need for a dedicated Quality Assurance consultant to carefully review all of their co-manufacturers and approved ingredient suppliers moving forward. Without robust quality programs in place, companies risk damaging their reputation, incurring financial losses, and, most critically, compromising consumer safety.

Key Takeaway: Regularly updating supplier documentation and conducting periodic audits are essential components of food safety and quality assurance. FoodQure’s consistent oversight helps prevent supply chain risks, safeguard consumer trust, and maintain the integrity of food products.

The relationship between a brand and its co-manufacturing facility is crucial to ensuring product quality and safety. Often, companies face a pivotal decision: should they work to mend a strained relationship or seek a new partnership?
Take, for example, the situation faced by SnackHaven Foods, a company recently forced to recall a batch of their popular snack bars due to contamination with a milk allergen. This recall caused significant damage to the brand’s reputation and resulted in major disruption. An initial review of the co-manufacturer’s sanitation logs and allergen procedures revealed that the equipment had been swabbed for allergens and returned negative results, as required before production runs. However, a deeper investigation and root cause analysis uncovered a critical issue: the co-manufacturer had failed to refrigerate their allergen test kits at the appropriate temperature. This seemingly minor error rendered the swabs ineffective at detecting milk proteins on equipment surfaces, ultimately leading to the recall.

SnackHaven Foods faced a crucial decision: should they continue with this co-manufacturer or find a new partner? In some cases like this, with the right expertise to review processes and provide education, a relationship can be repaired and even strengthened. A Quality Assurance consultant can offer invaluable support in such scenarios. Deciding whether to salvage or sever the relationship is complex, involving considerations of finances, logistics, inventory, and, most critically, trust. Rebuilding trust and delivering effective education after a failure is essential. Whether SnackHaven Foods chooses to maintain the existing relationship or seek a new co-manufacturer, a team of consultants can assist in navigating this decision. Acting as a liaison between the brand and the co-manufacturer, consultants play a crucial role in guiding the process and ensuring that future challenges are met with improved strategies and practices.

Key Takeaway: When quality failures occur, the decision to repair or replace a co-manufacturer is critical. Informed by thorough analysis, clear communication, and professional guidance from FoodQure, businesses can strengthen partnerships, restore trust, and implement safeguards to prevent future incidents.

WholesomeBites, a gluten-free snack brand, set out to expand its product line by introducing a new range of granola bars. To enhance their market position, they aimed for gluten-free certification but quickly realized the process was more complex than anticipated. Despite having established quality control procedures, they struggled with documentation, record-keeping, and implementing specific gluten-free protocols, leading to delays and increased production costs.
Seeing the mounting challenges, WholesomeBites decided to hire FoodQure, a specialist in food safety certifications. FoodQure conducted a thorough assessment, identifying gaps in their processes, such as ingredient handling and cross-contamination protocols. They provided targeted recommendations and staff training, enabling WholesomeBites to align with the gluten-free certification standards.

With expert guidance from FoodQure, WholesomeBites streamlined its certification process, achieving gluten-free certification much faster than expected. The consultant’s support helped avoid additional delays and costs, allowing them to launch their granola bars on schedule and capture important market opportunities.

Key Takeaway: Hiring a QA consultant can simplify complex certification processes, saving time and money while ensuring products meet high standards. Expert guidance helps brands avoid costly delays and maximize market opportunities.