Case Studies

FSQ Systems Optimization for External Manufacturing Partners

2 minute read

EXECUTIVE SUMMARY: After a fast-growing frozen dessert company was acquired by a global food conglomerate, its external manufacturing network needed urgent FSQ upgrades to meet parent company standards. Catena Solutions embedded a senior FSQ expert to assess partners, close compliance gaps, and build a durable quality program, reducing non-conformances from hundreds down to one.

food safety worker looking at tablet

The Challenge: FSQ Readiness After Acquisition

Following acquisition by a multi-billion-dollar global food brand, the frozen dessert company faced immediate pressure to evaluate and elevate the FSQ systems of its external manufacturing partners. Neither the client nor the acquirer had the internal bandwidth to lead the effort.

What was needed:

  • Assess the capabilities of each manufacturing partner
  • Foster a stronger quality culture across the network
  • Prepare partners for new corporate quality standards
  • Serve as a central FSQ liaison and problem solver

The Solution: Embedded FSQ Expertise

Catena deployed a senior FSQ consultant with 15 years of large-scale quality program experience in food and beverage. The engagement covered the full scope of FSQ oversight and system integration:

  • Quality assurance leadership: Led weekly QA meetings, managed quality issues, and delivered written technical reports.
  • CAPA management: Maintained onsite assessment trackers and closed out Corrective and Preventive Actions across multiple sites from prior audits.
  • Non-conformance investigation: Investigated and dispositioned non-conformances for finished products; made sampling plan-based recommendations to correct issues.
  • Facility validations: Conducted quality validations of new Panning & Polishing Room and Packaging Line across hyper-dried and hyper-chilled product sites.
  • Foreign material & product release: Led the foreign material inspection program and managed an 8-month product release project with a specific co-manufacturer.
  • 3PL/3PW onboarding: Trained new third-party logistics and warehouse partners on FSQ standards and hold capabilities.
  • SAP S/4HANA integration support: Supported product release and transfer postings during ERP system migration.

Navigating complexity

Challenge 1: Three Leadership Changes
Despite significant turnover at the client, the consultant quickly aligned incoming leaders and kept the project on track without losing momentum.

Challenge 2: Fully Remote Environment
Distributed teams and multi-site coordination required clear communication protocols and cross-functional relationship management throughout.

The Benefit: 99%+ Conformance Rate, 93% of Tasks Completed

  • Non-conformances reduced from hundreds to one
  • Defined KPIs and clear FSQ objectives established
  • 99%+ conformance rate across the partner network
  • Strengthened FSQ culture across all manufacturing partners
  • 93% of assessment tracker tasks completed
  • Full alignment with parent company quality standards

Facing FSQ compliance gaps after an acquisition? Catena’s experts help brands reduce risk and align manufacturing partners with corporate standards. Contact us to discuss how we can support your goals.

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