If your team is still running SPC by hand, you're losing money every shift.
You're collecting weights, temperatures, and quality checks. But without real-time control, that data can’t stop overpack, catch yield loss, or prevent product holds before they hit your warehouse. Paper logs and delayed reviews aren’t enough. And the financial fallout adds up quickly.
Here’s what manual or siloed SPC is really costing food and beverage manufacturers, and how digital SPC changes the equation.
Giveaway Adds Up Fast
Even a small amount of overpack leads to large material losses over time. With manual SPC, those losses go unnoticed until it’s too late.
- Weaver Popcorn used weight check data to reduce overfill and saved $30 million in retail revenue. That allowed them to run 115 million more pouches during a corn shortage.
- Compact Industries uncovered 12 percent overpack, or roughly 40,000 pounds per month. Fixing it saved $120,000 every month.
Digital SPC gives your operators immediate visibility. When product drifts out of spec, they catch it right then, not after the batch is already boxed and out the door.
Yield Goes Up, Labor Pressure Goes Down
Most SafetyChain customers see a 1 to 3 percent increase in yield by tightening process control with digital SPC. That kind of improvement hits multiple cost centers: materials, labor, and throughput.
Lincoln Premium Poultry recovered 2 percent of lost yield simply by catching and correcting issues in real time. The result was faster production, reduced overtime, and a lower cost per unit.
Product Holds and Rework Drop Quickly
When SPC data stays siloed in QA or trapped in a clipboard, it’s too late to stop problems from becoming holds, rework, or missed shipments.
Bakerly reduced product holds by 95 percent by giving operators real-time SPC alerts. Instead of reacting hours later, they course-corrected on the line and protected both product and schedule.
Want to Know What SPC Could Be Worth in Your Plant?
That’s why we built the SPC ROI Calculator.
Use your own production numbers to estimate how much digital SPC could save you in:
- Reduced giveaway
- Improved yield
- Lower labor costs
- Fewer product holds
You already have the data. This tool shows you what it’s worth when you finally put it to work in real time.
Try SafetyChain’s SPC ROI Calculator
Operators are logging the data. QA is reviewing it. But without real-time SPC, your team is still reacting late and absorbing the cost.
Use our calculator to run your numbers and see what better control could mean for your bottom line.
Try Our SPC ROI Calculator Now
