A large-scale snack producer wanted to increase product output without compromising quality, taste, or consumer experience. The project focused on optimizing product density and production parameters to enhance overall manufacturing efficiency and profitability.
The main challenge was to increase the individual snack’s weight — thereby increasing the product output per batch — while keeping taste, texture, and consumer experience identical.
Quality parameters such as sheet stability, baking time, and product stacking consistency were carefully monitored throughout the testing phase. Consumer perception and complaint levels were also evaluated to ensure no negative impact.
Senne conducted a structured process evaluation focusing on product formulation, baking dynamics, and line performance. Multiple test runs were performed to determine the optimal settings that could deliver a slightly denser product while maintaining consistent production flow.
Key areas of focus included:
Results:
Through small, data-driven formulation and process changes, a notable production gain was achieved without any perceived difference in the final product’s quality — a prime example of how incremental improvements can deliver major value at scale.
We work with both food and non-food manufacturing companies to identify practical, measurable process improvements.
Every change is validated through controlled tests, data analysis, and product performance checks to safeguard quality and customer satisfaction.
Every project begins with an on-site or virtual assessment to understand your current workflow and identify potential improvement areas. We then co-create a practical action plan with measurable goals, implement changes alongside your internal teams, and follow up to ensure the improvements are sustainable. Our approach is hands-on, data-driven, and tailored to your organization’s reality — not a one-size-fits-all solution.
Sustainability is key. We make sure improvements become part of your daily operations by standardizing new processes, training your team, and setting up clear KPIs for ongoing monitoring. The goal isn’t just short-term efficiency, but lasting operational excellence that your team can maintain independently.
Optimizing Snack Production Efficiency
Continuous Process Improvement
Confidential (Food Manufacturing Sector)
10 February, 2022
6 months
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