Case Study: McCormick & Company cuts material costs up to 30% and streamlines audits with Hertzler Systems Inc

McCormick Flavor Division reduces overpack and material costs by 10-30%

McCormick & Company’s McCormick Flavor Division (South Bend, IN) faced the dual challenge of improving customer/auditor confidence and cutting material waste and costs on high-volume sauce and condiment lines. To address audit transparency and process variation, they partnered with Hertzler Systems Inc and deployed the GainSeeker Suite to make process data available online in real time and to drive continuous process measurement.

Hertzler Systems Inc’s GainSeeker Suite provided automated data collection, control charts and real-time alarms that let McCormick tighten fill weights, reset premix specifications to true equipment capability, and move from 90 manual analytic checks per shift to targeted “bell‑weather” checks on every batch. The result: material cost reductions of 10–30% annually, overpack reductions of up to 0.3 grams across fill lines, faster audits (saving a couple man‑days each) and a measurable reduction in waste and rework.

McCormick & Company

John Campbell

Quality Manager