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Job 04 · QA and planning

// Co-packers · Formula and label changes

A brand's formula or label change, turned into your plant's change list before the next run.

A brand sends a revised formula, a new supplier for one ingredient, a claim it wants on the front panel or fresh artwork. Before the next run, your quality lead works out everything that touches: the spec, the allergen record, the label review, the food safety plan, the schedule and the film still in the warehouse. In a free AI proof of concept, AI drafts that change list on copies of 20 to 30 revisions your team already handled. Your reviewer, the person who knows your change control best, sets each list beside what your team actually changed.

Book a proof-of-concept call30 minutes with Rob
Past revisions
20 to 30
Changes it approves
None
Records it edits
None

// The one job

A revision arrives. A change list goes to QA and the planner.

Changes reach a plant in pieces: a redlined spec, a new formula revision, an email naming another supplier for the sweetener, label copy with a claim added, an artwork proof. Your team traces each piece through the plant's own records, decides whether old packaging is run out or held, sets the first run on the new version and tells the floor. Miss one record and the old film can run with the new formula.

For the test, AI reads copies of the brand's revision and the records it could reach, for changes your team already put through, and drafts the change list: each spec line, allergen entry, label review item, food safety plan section and changeover the revision touches, the open orders and packaging on hand it affects, and the page of the brand's document behind each item. Whatever the revision leaves unsaid becomes a question for your reviewer. No change is approved, no record is edited, and nothing goes back to the brand.

Brand's revisionFormula, supplier, claim, label
Revision number
What changed
Effective date
New artwork
ItemOldNew
Illustration, not a real revision
Traced through
plant records
Change listDraft for QA and planning
Spec and allergen
Label review
Food safety plan
Orders and packaging
RecordChangeOwner
Illustration, not a real change list

// What makes it hard

Why one line on a brand's revision reaches so many of your records

A change can reopen the food safety plan. FDA's preventive controls rule calls for reanalysis of the food safety plan, or the part that applies, whenever a significant change in a facility's activities creates a reasonable potential for a new hazard or a significant increase in one already identified. The reanalysis, and validation of any new controls as appropriate, has to be finished before the change takes effect or, where that is needed to show the controls work as designed, within 90 calendar days after production of the food first begins. A preventive controls qualified individual performs or oversees it, and the written plan is revised or the reason it needs no revision is written down. The draft names the hazard analysis and preventive control sections a revision could reach, for your PCQI to decide on.

The brand's own terms govern changes both ways. Hershey's public supplier quality expectations manual, dated August 2025, counts co-packers and co-manufacturers among its suppliers. It asks to hear in writing before any change in formula, raw materials, production line, location or process that could affect safety, quality, shelf life, the ingredient statement, the allergen profile or nutrition labeling, wants each such change approved before it goes in, and says a notice needs a phone call with a live person plus an email. The contract manufacturer quality agreement template in AURI's contract manufacturing toolkit asks the plant to run a documented change control system, allows formula and specification changes only by mutual consent, and lets the brand refuse product made under a process change it has not reviewed. So when a brand's revision forces a change on your side, such as another ingredient supplier or a different line, the draft marks it as one the brand's own terms may need to approve.

Labels carry claims whose records sit in the formula. When a food has both naturally occurring and added sugars, FDA's nutrition labeling rule calls for written records of the added sugars put in, such as recipes, formulations or batch records, kept at least two years after the food enters interstate commerce. A "healthy" claim under FDA's updated definition, which manufacturers must meet by February 25, 2028, needs records of the food group equivalents unless the label itself shows them. A new supplier for a corn, soybean, canola or sugarbeet ingredient can change whether the package needs a disclosure under USDA's bioengineered food standard, whose records may include supplier attestations. An organic plant must tell its certifier at once about any change that may affect its compliance. The draft lists the records and statements each change touches, and every claim decision stays with the brand and your QA.

Last revision's packaging is still on the shelf. Agreements decide who carries stock a plant can no longer use. An exclusive supply agreement filed with the SEC in 2004 has the maker order ingredients and packaging against the brand's yearly estimate, lets the brand buy any excess the maker can't use at the maker's cost, and has the brand repay that excess if it becomes obsolete instead. Hershey's manual asks for a changeover program that clears every printed package and label from the line at the end of a run, partial cases included. FDA has also set January 1, 2028, as the uniform compliance date for food labeling rules published in 2025 and 2026, so a revision driven by a new labeling rule may already carry its deadline. The draft lists the open orders and the film, labels and cartons on hand at the old revision, the date the brand gave, and the changeover the first new run needs, for your planner. Who pays for old stock stays between your team and the brand.

Certification schemes name this work too. BRCGS Food Safety Issue 9 has clauses titled Product design/development and Product labelling, and FSSC 22000 Version 6 lists additional requirements titled Product Design & Development and Product Labelling and Printed Materials. The draft doesn't interpret either scheme. Your reviewer, usually the QA manager or the food safety lead who runs change control today, checks that each list catches every record the revision touches, names the right formula and artwork revision, carries the brand's dates unchanged, separates what needs a PCQI or the brand's sign-off, and leaves open anything the revision doesn't settle.

// What you send

Revisions your team already put into production

Copies only
No document system login
01

20 to 30 past revisions

Brand changes your plant already runs: the revision itself, the emails around it, new artwork and any supplier papers. Include one that reached further than it first looked.

02

The records you changed

Before and after copies of the spec, allergen record, label review, food safety plan pages and schedule each revision touched. Those are the answer key.

03

Your change control form

The form, checklist or log your team uses now, plus each brand's change terms from its agreement or supplier manual. They shape the success criteria.

04

Copies, NDA first

No file moves before the NDA is signed. We don't sign in to your ERP, your document system or a brand's portal. If a brand's terms keep its revisions in the plant, your reviewer helps us build look-alikes.

// Before it starts

Agreed in writing before any revision is copied

The owner and your reviewer settle these first.

Change control test termsOwner signs off
Your reviewer
Named by the owner, often the QA manager or food safety lead
Success criteria
Written down: which records, dates and approvals each list must catch
Revisions
Picked by your reviewer: formula, supplier, claim and label changes
Approvals
Every change, plan reanalysis and label call stays with your qualified people
Price
A range for live change lists, given before any revision is shared
NDA
Signed first

// How the test is judged

What your team changed, beside each list

Revision by revision
against your own records
On the same 20 to 30 revisionsWhat your team changedThe AI draft
Every spec line and allergen entry the revision reachesFilled in on your revisionsFilled in on your revisions
Label review items, including claims and the records behind themFilled in on your revisionsFilled in on your revisions
Food safety plan sections flagged for your PCQIFilled in on your revisionsFilled in on your revisions
Changes that need the brand's approval kept apartFilled in on your revisionsFilled in on your revisions
Open orders and packaging on hand at the old revisionFilled in on your revisionsFilled in on your revisions
Changeover and first-run date carried from the brand's noticeFilled in on your revisionsFilled in on your revisions
Questions the revision leaves open, and why each is openFilled in on your revisionsFilled in on your revisions
Nothing scored yet. The cells stay empty until revisions from your own plant run through.Your reviewer scores each side, and that verdict is final.

// After a yes

About 30 days on revisions as brands send them

When your reviewer agrees, each new brand revision gets a draft change list the same way for about 30 days.

Every list waits for your quality lead, who decides what changes, signs the change record and briefs the planner. Your team answers the brand in its own words.

The two-column check carries on with live revisions, and nothing else begins until the month is up.

// Later, one at a time

What could follow change control

Possibilities to weigh
One job at a time
  1. 01

    Customer specs into your plant's records

    When a revision grows into a new item, its formula, spec and label copy drafted into your formats for QA and R&D.

    Next
  2. 02

    Customer-supplied ingredient reconciliations

    The brand's materials counted again after a change, so the next statement starts from the new formula.

    Then
  3. 03

    Certificates of analysis, lot by lot

    The first lots under a new revision checked against the brand's updated limits before QA signs a certificate.

    After that

// One hard limit

It never approves a change, a formula or a label.

The list shows what a revision reaches and where your records disagree with it. It never approves a change, a formula, a label, a spec or a reconciliation, never decides who owes for stranded stock or whether a food is safe, compliant or due for a plan revision, never edits a record, and never contacts a customer or a supplier. It works only on copies. A qualified person at your plant decides and signs, and nothing here is food safety or legal advice.

Priced per job. You get a range before the proof of concept and a fixed price before you sign.

The range comes on the call, once Rob knows how many revisions brands send you in a year, for how many brands, and how many records a typical change reaches.

// Questions

Change control questions

Does it decide whether a change needs a food safety plan reanalysis?
No. It lists the hazard analysis and preventive control sections a revision could reach, with the reason for each. Whether a reanalysis is needed, and what it finds, is for your preventive controls qualified individual.
Brands send changes as redlines, emails and new artwork. Does that work?
Yes, send them as they came. The draft compares old and new versions line by line and names the file behind every item. A change it can only infer, such as a supplier named in an email but not in the spec, goes to your reviewer.
What happens to the packaging we already have?
The draft counts what is on hand at the old revision and lists the open orders that would use it. Whether it runs out, is held or is written off, and who pays for it, stays with your team and the brand.
Will it update our spec, allergen matrix or HACCP plan?
No. It lists what each record would need and points to the source of each item. Your team edits and approves its own records, exactly as it does today.
Does it cover changes we start ourselves, like switching an ingredient supplier?
It can, if your reviewer includes some. They are drafted the same way, with a line for any approval the brand's terms ask for before the change goes in.
Rob Eason

Rob Eason, founder

// Book a proof of concept call

Test it on revisions your team already put through.

A 30-minute call with Rob: your plant and your role, the brands that revise their items most, and roughly how many revisions you handle a year. Keep revision files on your side until the NDA is signed.

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