Case study: how Freshpak future-proofed manufacturing processes through digital transformation

In this case study we explore how Freshpak replaced manual systems with a connected, digital solution - streamlining audits, improving traceability, and creating a more efficient way of working with Foods Connected. 

About Freshpak 

Freshpak is a leading supplier of chilled foods to major UK retailers and food service providers. Renowned for its high-quality standards, the business manages complex operations and strict compliance demands across manufacturing. 

With increasing pressure to improve traceability, audit readiness, and supplier management, Freshpak recognised that its manual systems - paper trails, spreadsheets, and emails - were no longer fit for purpose.  

Manual processes are holding back progress 

Before adopting a digital solution, Freshpak’s processes were fragmented and time-consuming. Departments operated on paper-based forms and spreadsheets, making it difficult to track issues, monitor compliance actions, or maintain a clear view of operational performance. 

Some key challenges included: 

• Logging fabrication issues could take up to 20 minutes, delaying resolution. 

• Internal audits required hours of preparation, with data scattered across systems. 

• Senior management lacked visibility into outstanding actions and non-conformances. 

• Teams were spending time on admin rather than proactive improvements. 

These inefficiencies created pressure, particularly during audits or investigations where fast access to accurate data was essential. It was clear that Freshpak needed a connected, digital-first approach that would enable real-time insights and faster decision-making. 

Flexible, connected, and built for the food industry 

Rather than force their processes to fit into a rigid system, Freshpak found a platform that could adapt to their existing ways of working—and help improve them over time. 

Key areas of transformation included: 

• Internal Audits & Compliance Tracking – All audit activities are now managed digitally, enabling faster reporting, easier follow-up, and better traceability. 

• Supplier Management – Issues with suppliers can be logged instantly and tracked to resolution. This reduces response times and strengthens risk management. 

• Cross-Departmental Visibility – Teams across Technical, NPD, H&S and Production now operate within the same system, using shared dashboards and real-time updates. 

• Self-Service Configuration – Freshpak’s teams can build and update their own forms, workflows and dashboards—without needing to rely on IT. 

“With Foods Connected, we found a flexible system that could grow with our intent to grow our own business.” 
– David Green, Technical Director, Freshpak 

This ability to customise the system internally has helped Freshpak build greater ownership and accountability across teams, while also reducing reliance on third-party configuration support. 

Faster processes, fewer complaints, and a more empowered team 

The impact of the transformation has been felt across Freshpak’s operation: 

Faster, Smarter Workflows 

The time to log fabrication issues has dropped from 20 minutes to under 20 seconds—a 98% reduction. With a more streamlined workflow, teams can focus on resolving problems rather than chasing paperwork. 

Stronger Audit Performance 

Audit preparation is now 40% faster, with relevant data easy to retrieve, cross-reference and present. Freshpak is consistently audit-ready and have reduced their time spent with any pre-audit preparations. 

Reduced Customer Complaints 

In 2024, Freshpak achieved its lowest ever level of customer complaints. The improved issue tracking and real-time monitoring helped the business detect and resolve non-conformances before they escalated. 

Greater Team Engagement 

Empowering team leads to build and manage their own processes has increased engagement and accountability. Staff are no longer tied to admin-heavy routines and are encouraged to contribute to continuous improvement. 

“There is nothing more empowering than seeing improvements you’ve instigated take shape.” 
– David Green, Technical Director, Freshpak  

A platform that grows with the business 

Freshpak’s digital transformation isn’t a one-off project—it’s an ongoing evolution. The company continues to expand how it uses Foods Connected’s tools across new departments and processes. 

The focus now is on: 

• Integrating more departments into the platform for full operational visibility 

• Using data insights to drive further efficiency and performance improvements 

• Maintaining a culture of ownership and accountability at all levels 

By choosing a flexible, food-specific platform, Freshpak has future-proofed its operations and built a foundation for growth. In a highly regulated and fast-moving industry, this level of adaptability is what sets them apart. 

If you'd like to discover more about how Freshpak transformed their supplier management, you can get your own copy of the full case study here.

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