Product Waste from pH Control Failures in Fermentation

$10,000-$20,000+ per batch in regulatory non-compliance risk, product hold/rejection, and potential recall costs if unsafe product ships; reputational damage with customers • $10,000-$25,000 per month in accumulated batch waste from fermentation control failures across multiple shifts • $10,000-$30,000 per incident in customer credits, replacements, and returned product; reputational cost with ingredient buyers (loss of repeat orders); missed early warning signals that could have prevented waste

Customer Service escalates product complaints and manages batch rejection communications; works with QA/Production to determine root cause post-failure; issues credits/replacements manually • Customer Service Representative logs complaints in CRM and email threads; manually tracks batch numbers to production dates; escalates to production via email chains; no real-time visibility into fermentation parameters that caused quality failure • Increased manual sampling and testing to demonstrate control; Excel reports sent to customers showing pH curve data; verbal assurances from Plant Manager