Challenge
The plant was using 400 and 800-micron liquid bags to filter the cheese after production and prior to packaging. These filter bags were changed after every run and then inspected for particles filtered to ensure the integrity of the bag.
The customer began experiencing filter bag failure (or bag rupture), which caused rework and loss of product.
When a filter bag ruptures during a production run, the plant quarantines the batch and initiates a QA review to determine whether the material can be reworked—at an added cost of approximately $11,000—or if it must be discarded entirely. In the worst-case scenario, a full batch loss can result in significant scrap costs, production delays, and downstream impacts to customer commitments.
The TFS Solution
When the frequency of bag ruptures increased, TFS was asked to review the process and filter bags used. While on site, TFS filter experts reviewed the filter bags that had failed and sent samples to the manufacturer for a thorough inspection.
After it was confirmed that nothing in the customer’s process had changed to cause the bag rupture issue, TFS arranged to have the filter bag manufacturer visit the plant to review the installation process. Upon their review, the manufacturer made recommendations to plant personnel on proper filter bag installation and made improvements in the stitching for the bags they were supplying.
Despite these adjustments, the bag failures persisted. TFS promptly identified an alternate bag manufacturer, described the concerns, and sent samples of the failed product to the new manufacturer, who then developed a bag solution with sturdier material and stronger stitching.
Results
The new liquid bag filters went through a successful trial at the plant, which resulted in the customer moving forward with the new bag filter solution, and at the same price as the previous product.
No issues with bag failure have occurred since the switch occurred, so quality issues and costly re-work and wasted product have been eliminated. The customer has since begun partnering with TFS on other filter applications throughout the plant with the goal of lowering the total cost of ownership for their filtration.