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Cost Reduction

Significant Reduction in Cook Time

The Problem

An existing Midas Foods International global processor was having significant cost and processing issues doing an all-scratch 5 cheese sauce in-house.  On the input side, the high cost of some of the more exotic cheese was stressing margins.  On the processing side, the very high milk content in the overall sauce was causing char and burn on in the kettles, leaving small black flecks in the sauce.  Despite having extensive scratch sauce making capabilities with years of experience, the situation was problematic and the company was stuck.

The Midas Foods International team was brought in to assess the scope of the issue, determine workable solutions, and develop a cost-effective, manufacturing optimized solution that could work at truckload scale.  Our team met with the customer’s R&D staff to review target gold standard’s and reviewed the processing operation to determine capabilities.  We then went to work.  After a few weeks the Midas team presented a dry blend solution that used a single dry blend ingredient, water, and the addition of 1 actual cheese for pull.  After 2 iterations the project was tentatively approved and scaled up.

The Solution

What was achieved?

  • Massive reduction in raw cheese handling & packaging waste
  • Reduction in measuring and processing errors on the floor
  • Reduction in char & burn on of the actual sauce
  • Reduction in kettle cook times
  • Greater consistency in the end sauce
  • 27% cost reduction over scratch alternatives
  • Improvements in ESG scores from the massive reduction in refrigerated inbound freight

The Results

The processor developed a new, alternative processing paradigm that grew into both cook-up and instant options.  Additional projects were routed to Midas which quickly became the manufacturing partner of choice for new specialty sauces.

Ready to Start a Partnership?

We’re proud of the quality of our culinary blends and want you to experience the drool-worthy taste yourself. Contact us today to receive samples or learn how we can create a custom recipe just for you.