Oregon Freeze Dry Saves Money from Overfills and Rework with Synergy 2000

At Oregon Freeze Dry (OFD), the world's largest custom processor of freeze-dried products, statistical process control is key to maintaining consistent weights within its packaging operation and achieving higher profitability. In addition to providing private-label manufacturing, the company features a full-line of ingredients used by some of America's largest food companies, is a major supplier of field rations to the U.S. military, and markets its own line of backpacking foods under the Mountain House® brand.

The OFD Food Division began using Zontec SPC software in 1992 to address potential weight and filling issues. The cost of overfills and product giveaway add up quickly, impacting the bottom line. However, underfills can be just as wasteful when the cost of reworking the product are factored in. Improper weight verification can also affect customer satisfaction. Because the instructions for rehydrating the freeze-dried product is based on net contents, if the consumer adds too much or too little water, then product quality, nutritional value, texture and flavor may be compromised.

Software users become proficient in minutes

Today, OFD is using Zontec's third-generation software product, Synergy 2000™. The Synergy 2000 software handles data collection, process monitoring and corrective action on the food packaging lines and in the Quality Assurance Lab to maintain weight records for incoming raw materials from suppliers. The software is also used for analysis and reporting by the SPC Administrator and Packaging Engineers. "It's a very user friendly piece of technology. Within minutes, everyone feels comfortable using it," says Tim Stutzman, OFD Manufacturing Systems Analyst.

Stutzman has configured the program so that Packaging Operators monitor the process using a combination spreadsheet display along with the corresponding control chart for net weights. "It's very proactive," he says. "If out-of-control conditions occur, the Operator can immediately adjust the machine to bring the weight back within acceptable limits. It has saved us a lot of money preventing reworks. As you can imagine, reworks can become a major expense since it involves doing your work twice."

The software contains a built-in connectivity interface with Ohaus® Trooper and Explorer scales, and only requires that Operators press the "Print" key to send the calculated net weight into the software.

Data flexibility for immediate and long-term benefit

On the analytical and reporting side of the process, OFD queries the data and views the results in spreadsheet, chart, customizable report or e-mailable formats. The flexibility in working with the data comes in handy during on-site customer audits, when lot traceability needs to be conducted or for continuous improvement efforts. For example, Packaging Engineers study the historical data using histograms and capability studies to determine if specification limits can be tightened. If so, process targets are adjusted, refining the process over time.

The software also helps OFD customers with their commercialization process by rolling out new products faster with minimal packaging issues. "When new opportunities arise," Stutzman says, "Engineers will perform tests on the packaging lines, import the data into Synergy 2000, generate a selection of charts and analyze the results. The charts are an excellent means of communicating our process capability to the customer."

OFD's longstanding partnership with Zontec is proving to be a worthwhile investment. "Of all the SPC systems available, Zontec best fits our application. We know our weights are consistent. We know we're saving money. We know we're reducing rework. We know we're not giving away product as much. We know we're not taking on new items we don't have a process for. It keeps us focused on what's important," concludes Stutzman.