Egg Producer Cuts Product Loss Rate in Half

Executive Summary

A series of large commercial egg producers tasked FlexPAC with creating a solution that helped in protecting their brands. This goal of the project was to improve the quality of the product they were shipping for consumer consumption. Retail stores, as well as the USDA and SQF (Safe Quality Foods), have been demanding that their suppliers provide safe and an uninterrupted supply of good quality eggs. Prior to working with FlexPAC, these producers were experiencing a large loss of products at about 8,640 eggs an hour. FlexPAC’s solution was able to cut this large rate in half.

Challenges

The process of cleaning and packaging eggs can be extensive. Challenges that these producers faced included egg sanitation and ensuring that the eggs were to the standards of the USDA and SQF. The companies were facing a $10,000 per hour loss if eggs were not being cleaned with the proper solutions. Before working with FlexPAC, there was a 4% loss (8,640 eggs) during the sanitation process. Each time an egg had to undergo the cleaning process more than once, the risk of losing that egg was increased. Some of the eggs that needed reworked also had left over condensation on them from the cleaning process. Those that were affected by condensation needed more time in the cooler, more labor, more water rinse, and an increase in electricity costs just to be up to standard – a cost of about $400 per hour. The final challenge was at the end of the day during the actual cleaning of the facility. All machines had to be taken apart each night to get them clean.

FlexPAC’s Process

The process of cleaning and packaging eggs can be extensive. Challenges that these producers faced included egg sanitation and ensuring that the eggs were to the standards of the USDA and SQF. The companies were facing a $10,000 per hour loss if eggs were not being cleaned with the proper solutions. Before working with FlexPAC, there was a 4% loss (8,640 eggs) during the sanitation process. Each time an egg had to undergo the cleaning process more than once, the risk of losing that egg was increased. Some of the eggs that needed reworked also had left over condensation on them from the cleaning process. Those that were affected by condensation needed more time in the cooler, more labor, more water rinse, and an increase in electricity costs just to be up to standard – a cost of about $400 per hour. The final challenge was at the end of the day during the actual cleaning of the facility. All machines had to be taken apart each night to get them clean.

Results, Return on Investment, and Future Plans

FlexPAC was able to provide a solution that has helped these egg production sites save their product, time, and money. Through the wash solution provided, a clean rinse of the eggs meant that no residue nor condensation would be left over. The biosecurity process along with cleaning the trucks that were transporting the eggs caused a drastic reduction in harmful bacteria, helped to maintain a neutral pH, and helped prevent of avian influenza. With these results, FlexPAC has improved the quality and safety of the egg production process and helped to reduce production costs.