Services
Production Operations, Yield & Cost Engineering
Improve production planning and measurable losses in product, time, materials and utilities.
PrimeTech evaluates the complete production system to identify measurable opportunities for cost reduction, higher yield and lower waste while protecting required product quality and food-safety standards.
Where we help
Milk shrinkage, product giveaway, start-up and changeover losses, OEE, bottlenecks, rejects, utilities and cost of conversion.
Typical scope
Input/output mass balance; yield and loss auditing; filling variation and rework review; downtime and capacity analysis; production scheduling and line utilization; energy and CIP consumption review; recipe, packaging and raw-material cost review.
What you receive
A baseline and loss map, ranked improvement opportunities, trial plan and measures for verifying results.
Coverage areas
- Production & Product Technology
Technical & product areas
Capabilities
- Cost & Waste Optimization
Detailed scope
Material balance and loss audit
Reconcile milk and ingredient inputs with product, by-products, rework and waste across reception, separation, processing and filling.
Product yield
Examine cheese and cultured-product yield, fat/protein recovery, overfill and giveaway, start-up loss, line rejects and changeovers.
Capacity and OEE
Study equipment bottlenecks, availability, speed and quality losses; improve production scheduling and line utilization based on demand, machine capacity and cold-storage constraints.
Utilities and CIP consumption
Measure energy, steam, refrigeration, water, compressed air, cleaning chemicals and effluent drivers; rank technically feasible actions.
Product and conversion cost
Review cost sheets, recipe and packaging options, CAPEX/OPEX implications and the verification basis for any proposed savings.
Daily production management
Plan product sequence, batch sizes, line allocation, shift handover and cleaning windows against demand, raw-milk availability, tank space and cold-room capacity.
Standard work and performance
Develop operator checks, process-control sheets, downtime reasons, production reports and practical KPI reviews for output, yield, quality and schedule adherence.
Packaging performance
Study filler speed, accuracy, seal quality, material consumption, rejects and format-change losses; connect packaging performance to product losses and shelf life.
Improvement execution
Prioritize opportunities by technical feasibility and value; run controlled trials, document baseline and post-change results, and train the team to sustain gains.
Further detail
Cost Optimization
- Recipe and raw-material cost
- Ingredient utilization
- Packaging
- Utilities
- Labor utilization
- Cleaning cost
- Equipment efficiency
- Downtime and reprocessing
Waste Reduction
- Raw-material and product loss
- Start-up and shutdown loss
- Changeover loss
- CIP loss
- Filling and overfilling loss
- Packaging waste
- Rejects and reprocessing
- Water and energy consumption
Efficiency Improvement
- Bottleneck identification
- Line capacity
- Production scheduling
- Changeover time
- Equipment utilization
- Process timing
- Yield and output
- Operational KPIs
Costing & Formula Optimization
- Recipe costing
- Ingredient-cost analysis
- Yield impact
- Packaging and processing cost considerations
- Alternative formulation scenarios
- Cost reduction without unnecessary quality compromise
Factory & Line Audits
- Production and process assessment
- Equipment and line performance
- Hygiene and CIP review
- Quality and food-safety systems
- Laboratory and maintenance assessment
- Automation and utilities review
- Yield, waste and efficiency analysis
- Prioritized improvement recommendations
From Idea to Operation. From Problem to Solution. From Production to Performance.