In the world of food manufacturing, pest infestations can be more than just an inconvenience—they can pose a serious threat to product quality, customer trust, and brand reputation. In this case study, we explore how HYSIA worked with one of the world’s largest food manufacturers to address a persistent beetle infestation and successfully restore quality standards.

The Situation

A large food manufacturing plant was facing a critical issue with stored product insects (SPI). Despite interim measures to control the situation, some insects ended up in packaged products, leading to customer complaints and significant concerns over food safety. The infestation not only impacted customer satisfaction but also posed a threat to the factory’s stringent food quality standards and the company’s global brand reputation.

Due to the complexity of the factory’s layout, the intricate nature of the food production process, and the challenge of maintaining hygiene in such a sensitive environment, the company’s internal quality assurance (QA) team, along with their pest management service provider, struggled to pinpoint the root cause of the infestation. That’s when they called on HYSIA for expert consultation and investigation.

The Task

HYSIA was tasked with uncovering the root causes of the pest infestation and designing an effective management program. Our primary goals were to:

• Identify the factors contributing to the infestation.
• Conduct a Root Cause Analysis (RCA) to pinpoint the underlying issues.
• Develop a Corrective and Preventive Action (CAPA) plan.
• Equip the factory team with the knowledge and tools to implement the plan effectively.
• Navigate the complex food manufacturing process while maintaining high hygiene standards.

Our Approach

To address the infestation, we adopted a comprehensive approach, starting with a detailed inspection of the entire facility—both inside and outside. This included a thorough examination of food production equipment and manufacturing processes.

In addition to inspecting physical areas, we reviewed process documents to identify any steps in the production flow that could have contributed to the infestation. After gathering all the necessary data, we conducted a Root Cause Analysis (RCA) to identify both primary and secondary causes.

Once the root causes were identified, we presented a Corrective and Preventive Action (CAPA) plan to the factory team. The plan included tailored strategies to address each cause of the infestation. Our recommendations didn’t just stop at pest management—we also offered training to the factory’s staff to ensure they had the skills and knowledge needed to execute the CAPA plan successfully.

We also facilitated management consultation sessions to secure buy-in from key stakeholders, which was crucial to the successful implementation of our recommendations. Throughout the process, we worked closely with the company’s pest management service provider to ensure alignment and ongoing support.

The Result

Thanks to HYSIA’s thorough approach, the food manufacturer was able to significantly reduce the beetle infestation. Most importantly, they restored their food quality standards, preventing further contamination of packaged products.

The success of the CAPA implementation not only resolved the immediate issue but also provided the factory with a long-term solution to manage potential future infestations. The company was so pleased with the results that they continued to engage HYSIA as their consultant and auditor for ongoing pest management, ensuring that their high standards of food safety were consistently upheld.

This case study highlights the importance of a strategic and detailed approach to pest management, especially in sensitive environments like food manufacturing. With proper investigation, training, and ongoing collaboration, even the most challenging pest infestations can be resolved efficiently and effectively.

If your business is facing a pest problem that traditional methods haven’t been able to solve, HYSIA can help. Our expert team specializes in Root Cause Analysis, Corrective and Preventive Action planning, and customized pest management solutions for complex environments.

Contact us today at info@hysia.sg to learn more about how we can support your pest management needs.