PET Food Processing - June 2019 - 16

PLANT PROFILE

Many of the company's tracked metrics
including sales data
and line performance
statistics are shared
with all employees at
monthly meetings.
Pictured here is
Phelps' first shift.

16

on the lines include hour by hour charts, so line workers know if they are on pace and if they're not, they'll
record the cause and our line leaders actively escalate
items to ensure we are quickly resolving issues," says
Scott Anderson, director of operations.
Quality alerts are used to document the unexpected.
"They give us an historical record of anything that goes
not to plan," says Rich Bartuska, director of safety, quality and regulatory. "We act upon the alerts and our system notifies all of the management team that this event
occurred. That's key to continual improvement. We correct the problems and look at them historically to identify any trends and eliminate those from happening in
the future."
The core management team is relatively new for a
52-year-old company with the longest tenured person having just five years with the company. "We were
brought in a couple years ago to start making the business scalable," Anderson says. "The first place we started
was to ask: Are we measuring the right things? Are we
tracking the correct data so we can be a data-based, decision making organization?"
If a processing line had a low number of racks during
a shift the previous day, the reason is identified, whether
it was due to training during that shift or a delayed delivery of meat. During the daily stand-up meeting, the
reason is discussed and, where applicable, a remedy is
quickly agreed upon. Then it is on to the next metric.
Closely watching line efficiency trends becomes a valuable tool for preventive maintenance as well.
It's clear that the company has a laser focus on overall equipment effectiveness (OEE) which translates to
overall company effectiveness. "What I like about all
that we track is that it's the facts - not an interpreta-

PET FOOD PROCESSING | June 2019 | www.petfoodprocessing.net

tion," Ruffolo says. "It's a snapshot of where we stand at
this moment and if we're heading in the right direction.
We're OK with identifying internal issues. That's how we
prevent them from becoming external issues."

Patience pays off
Between 2014 and 2016, the company's production
space grew from 10,000 sq. ft. to 130,000 sq. ft. They
first added packaging lines and eventually added a second processing line and additional ovens, then more
freezer storage and warehouse space. The sales growth,
however, didn't kick into gear until the end of 2018.
According to Ruffolo, sales from 2017 to 2018 were
more or less flat. "We had a good end to 2018 and we
are in high growth mode right now." Sales are up 37%
for the first quarter of 2019 compared to the same period in 2018.
Ruffolo attributes this growth to the investments the
company made in people, processes and equipment.
"In the last two to three years, we've gained the ability and the certifications to produce the more valueadded, clean label, limited ingredient, certified organic
treats that are now our primary business," Ruffolo
says. "In the past, it wasn't really part of what the company did partly because the market wasn't asking for
it - 50 years ago organic wasn't on anybody's radar."
Transitioning to offer USDA certified organic products,
formulating cleaner ingredient panels and streamlining processing required investment spending before
the company could pursue sales growth. "During this
time, we were not chasing every opportunity because
Right: All four of Phelps' packaging lines include multihead weighers from Heat and Control for portioning speed and accuracy.



PET Food Processing - June 2019

Table of Contents for the Digital Edition of PET Food Processing - June 2019

PET Food Processing - June 2019
CONTENTS
OFF THE LEASH - FEAR FREE
TRENDS - IN THE HOUSE
PLANT PROFILE - THE MEAT OF THE METRICS
FOOD SAFETY - VERIFIED ACCOUNTABILITY
INGREDIENTS - DEFINING CHELATION AND ENCAPSULATION
FORMULATION - FULL DISCLOSURE
EQUIPMENT - EXTRUSION INNOVATION
ON THE MOVE
OPERATIONS - CONTROL ISSUES
PACKAGING - MEDLEY OF MEALS
BEST IN SHOW
PATENTS TO PONDER
EVENTS
SIT, STAY, READ
AD INDEX
PET Food Processing - June 2019 - PET Food Processing - June 2019
PET Food Processing - June 2019 - PET Food Processing - June 2019
PET Food Processing - June 2019 - 2
PET Food Processing - June 2019 - 3
PET Food Processing - June 2019 - 4
PET Food Processing - June 2019 - CONTENTS
PET Food Processing - June 2019 - OFF THE LEASH - FEAR FREE
PET Food Processing - June 2019 - 7
PET Food Processing - June 2019 - 8
PET Food Processing - June 2019 - TRENDS - IN THE HOUSE
PET Food Processing - June 2019 - 10
PET Food Processing - June 2019 - 11
PET Food Processing - June 2019 - 12
PET Food Processing - June 2019 - 13
PET Food Processing - June 2019 - PLANT PROFILE - THE MEAT OF THE METRICS
PET Food Processing - June 2019 - 15
PET Food Processing - June 2019 - 16
PET Food Processing - June 2019 - 17
PET Food Processing - June 2019 - 18
PET Food Processing - June 2019 - 19
PET Food Processing - June 2019 - 20
PET Food Processing - June 2019 - 21
PET Food Processing - June 2019 - 22
PET Food Processing - June 2019 - 23
PET Food Processing - June 2019 - 24
PET Food Processing - June 2019 - FOOD SAFETY - VERIFIED ACCOUNTABILITY
PET Food Processing - June 2019 - 26
PET Food Processing - June 2019 - 27
PET Food Processing - June 2019 - 28
PET Food Processing - June 2019 - INGREDIENTS - DEFINING CHELATION AND ENCAPSULATION
PET Food Processing - June 2019 - 30
PET Food Processing - June 2019 - 31
PET Food Processing - June 2019 - 32
PET Food Processing - June 2019 - 33
PET Food Processing - June 2019 - 34
PET Food Processing - June 2019 - FORMULATION - FULL DISCLOSURE
PET Food Processing - June 2019 - 36
PET Food Processing - June 2019 - 37
PET Food Processing - June 2019 - 38
PET Food Processing - June 2019 - 39
PET Food Processing - June 2019 - 40
PET Food Processing - June 2019 - EQUIPMENT - EXTRUSION INNOVATION
PET Food Processing - June 2019 - 42
PET Food Processing - June 2019 - 43
PET Food Processing - June 2019 - 44
PET Food Processing - June 2019 - 45
PET Food Processing - June 2019 - 46
PET Food Processing - June 2019 - 47
PET Food Processing - June 2019 - 48
PET Food Processing - June 2019 - ON THE MOVE
PET Food Processing - June 2019 - 50
PET Food Processing - June 2019 - 51
PET Food Processing - June 2019 - 52
PET Food Processing - June 2019 - 53
PET Food Processing - June 2019 - 54
PET Food Processing - June 2019 - OPERATIONS - CONTROL ISSUES
PET Food Processing - June 2019 - 56
PET Food Processing - June 2019 - 57
PET Food Processing - June 2019 - 58
PET Food Processing - June 2019 - 59
PET Food Processing - June 2019 - 60
PET Food Processing - June 2019 - PACKAGING - MEDLEY OF MEALS
PET Food Processing - June 2019 - 62
PET Food Processing - June 2019 - 63
PET Food Processing - June 2019 - 64
PET Food Processing - June 2019 - 65
PET Food Processing - June 2019 - 66
PET Food Processing - June 2019 - 67
PET Food Processing - June 2019 - BEST IN SHOW
PET Food Processing - June 2019 - 69
PET Food Processing - June 2019 - PATENTS TO PONDER
PET Food Processing - June 2019 - 71
PET Food Processing - June 2019 - EVENTS
PET Food Processing - June 2019 - SIT, STAY, READ
PET Food Processing - June 2019 - AD INDEX
PET Food Processing - June 2019 - 75
PET Food Processing - June 2019 - 76
http://digital.petfoodprocessing.net/sosland/pfp/2020_06_01
http://digital.petfoodprocessing.net/sosland/pfp/2020_03_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_12_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_10_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_09_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_06_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_03_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_12_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_09_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_06_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_03_01
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