Prebiotic Drink Quality Analysis
Situation
A health-focused beverage company launched a prebiotic drink in three flavors, designed to support gut health. After production, the company noticed inconsistencies in product quality, raising concerns about potential issues in the manufacturing process.
Problem
The company faced the following challenges:
- Inconsistent quality across batches, with issues only detectable upon opening and pouring the drink.
- Uncertainty about whether the problem originated from the drink’s formula or the manufacturing process.
- Potential risks to brand reputation and customer trust due to quality concerns.
Solution
We conducted a targeted quality analysis that included:
- Microbial testing for Aerobic Plate Count (APC), Yeast & Mold, Lactic Acid Bacteria, and Acetic Acid.
- Testing 12 out of 24 cans to identify patterns and pinpoint the source of the issue.
- Providing detailed insights to determine whether the inconsistencies were formula-related or process-driven.
Benefits
- Root Cause Identification: The analysis confirmed the problem was process-related, not formula-related, allowing the company to focus on manufacturing improvements.
- Improved Collaboration: Data from the analysis enabled the company to engage their co-packer with evidence-based recommendations for addressing quality issues.
- Cost Savings: By identifying the true source of the problem, the company avoided unnecessary formula modifications, saving time and resources.
- Enhanced Product Quality: Implementing process improvements based on our findings ensured a consistent, high-quality product, strengthening customer confidence.
Our analysis provided the company with the clarity and actionable data needed to resolve their quality issues and maintain their reputation for delivering health-focused beverages.