Rework: What to Do?

How rework is handled and used is one very important factor

for financial success.
Brian M. Reifsteck
Consultant

removed from processing for reasons other

D ealing with out-of-spec product due
to processing or quality issues has
been a dilemma for confectionery manu-
than unsanitary conditions or that has been
successfully reconditioned by reprocessing
facturers since the first candy product was and that is suitable for use in food.” There-
developed. Who knew I would have a life- fore, rework can be readily used as long as
long relationship with rework when I it is handled under good manufacturing
became a food scientist and confectioner? practices (gmp) in a sanitary manner that
Brian Reifsteck cur-
Learning how to manage and utilize rework ensures that the rework is free from micro-
rently is developing
his own food science
when developing new products has helped bial, chemical, insect and foreign material
and technology con- me to add quality, value and cost savings contamination.
sulting business spe- for my employers. With this in mind, this
cializing in product paper will focus on the definition of rework, SOURCES AND CAUSES OF REWORK
innovation and sources and causes of rework, processing
process optimization. Rework can occur throughout the entire
and formula considerations when utilizing
He has served in process of making confectionery products.
diverse roles at Kerry rework, examples of how rework can be
Rework may be caused by accident or mis-
Ingredients, Cadbury, used and the economic impact of using, or
takes such as operator error, equipment
Kellogg’s and Sen- not using, rework.
sient Flavors. He malfunctions, ingredient quality, etc., or
began his career at deliberately generated by separation such as
Hershey Foods.
DEFINITION OF REWORK
screening for size, appearance or shape.
Confectionery rework can be defined as the
Some typical problems that occur in man-
collection and use of candy products or
ufacturing and produce rework follow:
materials that do not meet the given spec-
• R&d testing
ification, or as confectionery materials used
again in an altered form to reduce waste. • Process scale-ups and product commer-
Under the Code of Federal Regulations cialization
(CFR) (21CFR110), rework is defined as • Product changeovers
“clean, unadulterated food that has been • Equipment malfunctions ➤

46 November 2011 • The Manufacturing Confectioner