Plant Evaluations

DSI’s Plant Evaluation can impact your bottom line by reducing your current plant loss by 30% - 50%

What is your shrink worth? For most plants, the impact exceeds well over $50 - $250K in additional profitability.  While most plant controllers can define their losses based on intake versus load-out and product consumption production records, specific loss points are often unknown.  This produces an environment where loss mitigation is difficult to achieve.

DSI has developed a plant loss evaluation program over the past 11 years that has been deployed in over 50 plants nationwide.  These plants manufacture a variety of products that range from cheese and whey products, to fluid milk and ice cream to powder, butter and cultured products.  Through these plant evaluations, a variety of loss types and industry proven mitigation plans have been developed and successfully implemented.  The net results support reduced losses, optimized production yields and reduced rework based on improved product quality.

DSI’s plant loss evaluation service can be performed in less than 4 weeks, (pending plant size and complexity), with only one week requiring on-site time. At the completion of the evaluation, a specific action plan is created with estimations showing true loss points and costs to mitigate them, allowing management to decide how to best achieve desired goals. Our evaluations are in-depth and include the following and more: 

  • CIP Circuits
  • Tank / Silo empty schedules
  • HTST water / product pushes
  • Product give-away
  • Lab sample pulls
  • Employee consumption
  • Rework and animal feed
  • Bf give-away
  • Moisture optimization
  • Data systems analysis
  • Poor SOPs and Employee Training 
  • Mitigation plans with costs & ROI’s