Most brands have no idea what’s happening on the day their product gets made. They ship ingredients, they wait, and eventually finished goods show up. The middle part is a black box. Let me open it.
The Night Before
We pull your batch production record — the document that travels with your run from the first weigh-in to the last pallet label. It has your formula, your target fill weight, your lot codes, your allergen profile, every ingredient and its COA reference. We review it the night before so nothing is a surprise when the line starts.
We also confirm that everything on your bill of materials is physically on-site. Every ingredient. Your film. If something is missing, we’re calling you the night before, not two hours into a scheduled run.
Pre-Op — Before Anything Runs
The first thing that happens every production morning is sanitation verification. Before we load a single gram of your product, every food contact surface gets swabbed with an ATP luminometer. We’re looking for results under 30 RLU on every food contact surface. If something doesn’t pass, we don’t start. We reclean, re-swab, and run again until it does.
We also verify scale calibration with a certified check weight, confirm the lot code coder is set correctly, load the film roll and verify unwind direction, check your label against your allergen matrix, and confirm the auger tooling is correct for your fill weight. All of this gets documented on your batch production record before we run a single unit.
Startup and Calibration
The first pouches off the line are calibration units. We’re adjusting the auger speed, the seal temperature and dwell time, the tension on the film. These pouches get weighed, inspected, and discarded — they’re not sellable product. This startup yield loss is normal and expected, which is why we always tell customers to send 10% more ingredient than their target unit count.
When we’re hitting consistent fill weights within your specified tolerance and the seals are clean and complete, we call it production-ready and start counting units.
Every 30 Minutes, All Day
Once we’re running, the line operator pulls three consecutive pouches every 30 minutes. Each one gets weighed individually. Results go in the batch production record. If any weight is out of tolerance, the line stops. We figure out why. We adjust. We document the interruption and corrective action. Then we resume.
Seal integrity gets checked visually at every interval — we’re looking at the seal area under good lighting for channel leaks, wrinkles, or any indication the seal isn’t complete. A pouch that doesn’t seal correctly is a pouch that will fail on a customer’s shelf. We catch it here, not there.
End of Run and Closeout
When we hit your target unit count, we run the line down completely. Every gram of remaining product gets collected, weighed, and recorded. That’s your yield loss calculation — total ingredient weight in versus net finished weight out.
Your batch production record gets completed and signed. It contains every check, every weight, every interval result, every interruption, lot codes for every ingredient, the film lot, the seal parameters we ran at, and the final unit count. That record goes in your file and gets uploaded to your folder. It’s yours permanently.
What you get at the end of every run
Completed batch production record. Lot codes on every case. COA cross-references for every ingredient used. Final unit count and yield calculation. All signed, all uploaded.
That’s a production day. No black box. No mystery. Just a documented, verified process that runs the same way every time. — Ole
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