Mass Balance Audits

Mass Balance Audits

Mass Balance Audits that identify yield, report shrink, show how to improve plant floor efficiencies.

DSI's Mass Balance Plant Audits assist dairy and food product manufacturers identify and report shrink, yield and quality improvement opportunities directly from their plant floor systems to their financial system for accurate and timely cost analysis.


  • Current solution and constraints analysis
  • Process variance analysis:
  • By process zone
  • Cause & effect correlation
  • Probability analysis
  • Range versus impact analysis
  • Measurement system
  • Baseline & goal determination
  • Process capacity/utilization analysis
  • Current/future state data flow analysis

Customer Benefits Include:

  • Greater yields (0.1% - 2.0%)
  • Increased quality via reduced variations
  • Reduced shrink (o.1% - 5%)
  • Accurate inventory management
  • Accurate and timely manufacturing costs analysis
  • Greater component level tracking (Protein, Fat, etc.)
  • Greater customer satisfaction

Solutions recommendations:

  • Rough cost and time estimates
  • Prioritized by ROI payback model
  • Standard operating procedures
  • Data/information plan - ERP
  • Technologies Utilized & Evaluated:
  • Plant floor automation systems
  • Plant floor and Laboratory instrumentation
  • Six Sigma quality systems RDMAIC
  • Project Management Institute standards
  • Linear correlation analysis
  • Predictive model control systems
  • Lean Manufacturing methods

Dairy Manufacturing Consulting

Dairy Manufacturing Consulting

Specialized Dairy Manufacturing Consulting

DSI offers a variety of specialized dairy and food plant consulting that can be done on a one-on-one basis to fit your business needs. Over the course of working with close to 200 dairy manufacturers the past 35 years, we've had the opportunity to help plants craft best practices. We've focused on a variety of topics with our customers from milk procurement and pooling analysis to plant loss and mass balance evaluations. Our focus is to deliver concrete, obtainable steps to increase your profitability no matter what the issue. Our staff includes CPA's  and former dairy plant management staff to ensure that you get the specialized attention you're looking for. We're not your average consultants. We're dairy consultants.

  • Business Consulting - including budgeting and forecasting
  • Dairy Accounting and Benchmarking
  • Dairy Best Practices
  • Dairy Procurement Consulting
  • Plant mass balance audits and shrink/yield optimization analysis
  • Dairy Federal/State Orders training
  • FMO Pooling strategies and training