Case Study: RealTime Quality Control for High Volume Pet Treat Manufacturing
Introduction
A leading pet treat and supplement manufacturer needed a faster, more reliable way to monitor product quality across multiple production lines. Their products require tight control of key nutritional and physical attributes including moisture, protein, fat, fiber, ash, water activity, and pH and their high‑throughput environment demanded a system capable of delivering rapid, repeatable results without slowing production. To meet these needs, the company implemented Eurofins QTA’s real‑time, non‑destructive at‑line testing solution.
Client Challenge
High‑frequency production with slow feedback
Traditional lab testing created delays between production and quality decisions. Operators often had to wait for lab results before adjusting processes, increasing the risk of producing out‑of‑spec product during extended runs.
Limited sampling due to destructive testing
Conventional destructive testing consumed product and required lab resources, limiting how often samples could be taken. This made it difficult to monitor how material attributes changed throughout the day or across shifts.
Operational complexity as a large co‑manufacturer
Frequent line changes and high throughput required a reliable way to confirm quality quickly. Without real‑time data, the client lacked visibility into how product attributes drifted during production, especially during shift transitions.
Eurofins QTA Solution
Non‑destructive, at‑line testing
The client adopted Eurofins QTA’s nondestructive analytical method, enabling the same sample to be tested multiple times without being consumed. This allowed replicate testing, which is a good laboratory practice that increases accuracy and confidence in results while preserving product.
High‑frequency sampling every 10 minutes
Operators now test a sample every 10 minutes, generating:
- 6 samples per hour
- Across 3 shifts
- 1,809 analyses in the last month (including triplicates)
This provides continuous, high‑resolution visibility into product quality throughout the entire production day.
Immediate, real‑time decision‑making
With results available directly on the line, operators no longer wait for lab data. Adjustments can be made in real time, preventing long stretches of out‑of‑spec production and reducing the risk of costly rework or scrap.
Why This Is Important
Consistent quality across all shifts
Continuous sampling ensures meaningful data across all hours of operation, reducing variability and improving process control.
Reduced risk of out‑of‑spec product
Real‑time feedback allows operators to catch deviations early—before large amounts of product are affected.
Improved efficiency during line changes
As a major co‑manufacturer, the client frequently switches between product types. At‑line testing provides immediate confirmation that new runs are in spec, reducing downtime and waste.
More data without sacrificing product
Triplicate testing provides multiple data points per sample, improving accuracy while preserving product thanks to the non‑destructive method.
Direct economic value for co-manufacturers
Real‑time, at‑line testing supports co‑man economics by:
- Lowering the cost of out‑of‑spec product
- Supporting higher sampling frequency while keeping costs predictable through a flat-fee structure
- Reducing raw material waste
- Speeding up changeovers
- Increasing throughput by removing lab bottlenecks
- Strengthening customer confidence through continuous, documented quality data
Conclusion
By implementing Eurofins QTA’s non‑destructive, real‑time at‑line testing, the manufacturer transformed its quality control process from reactive to proactive. High‑frequency sampling, triplicate testing, and immediate decision‑making now provide the visibility and control required in a high‑volume co‑manufacturing environment. This approach not only improves product consistency but also delivers measurable operational and economic benefits, setting a strong model for other co‑manufacturers seeking to modernize their quality systems.
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