quality - T-V-S Overcoming Challenges

TVS and Dover Foods Expand Capabilities & Capacity with New Machines

Jul 5, 2023 | News

Party Animal - acrylic on wood uses abstract lines and colors to create a fun and colorful cow sticking out its tongue.

To continue meeting demands of current and new customers, TVS & Dover Foods has expanded capabilities and capacity with new machines and quality equipment.

TVS has installed and launched a single serve cup line. This exciting new capability allows us to package baking mixes into preformed cups, fill the specified volumes, and apply a heat seal film as a lid. Cup sizes range 2-6oz with up to 40 CPM, and the equipment can be utilized for either gluten-free or conventional products.

Dover Foods has been investing in upgrading machinery and new quality measures. The upgraded machines include a Triangle pillow-bag machine and a Triangle stand-up pouch machine. The stand-up pouches have more than doubled production rates from 10 bags a minute to 50 bags per minute!

A case erector was also installed. It was originally used at TVS but repurposed for Dover. This installation replaces manual labor of packaging cases at the end of the stand-up pouch machine. Quality has also seen a growth in new features. A new video jet lot coding has added new capabilities for printing and multi-lot formats. As well as new metal detectors at the end of both the pillow and stand-up pouch machines. Lastly, SpeeDee branded control check weighers were added to both the Triangle machines to control the weight per fill. They also have the ability to self correct 6-7 per minute.

All the new equipment and upgrades will continue producing Mountain Maid, American Quality Foods, and other products for TVS and Dover Foods costumers.

Celebrating Michelle’s 15th Anniversary at TVS

May 19, 2023 | News

Michelle Ekeanyanwu is celebrating her 15th anniversary at TVS. However, her career at TVS well before 15 years ago, in 1993. “I worked production folding boxes for DuPont before being promoted to a Material Handler,” she reflects. “I started at TVS because I needed flexible hours. I was a stay-at-home mom with children in daycare. It was important to have a job that could fit into my life.”

Michelle came back to TVS again in 2000, once again working in production and as a machine operator. In 2008, Michelle returned briefly to production before being promoted to quality. She said, “Quality lets my abilities shine!”

As a level II Quality Technician, her responsibilities include checking labels, lot codes, pallet movements, and production counts to ensure the product meets and exceeds the customer expectations. “My favorite part of the job is catching the little things that might be otherwise missed,” she said. “I want to be here and do a good job – it feels good.”

“Ever since I have known Michelle, she has been a hard worker. She has great attention to detail and is at the top of all our protocols,” reflects Quality Director Dan Fisher. “She is always asking good questions and bringing up other thought-provoking ideas.”

One of Michelle’s favorite parts of the job is the SQF (Safe, Quality, Food) Sensor Evaluation Panel. At different points throughout the year, Michelle bakes a panel of products such as pancakes or biscuits and bakes another panel of the products with intentional mistakes such as including mushroom powder or adding extra leavening. “The best reaction was when I offered Jeni Welch an intentionally messed up biscuit,” laughs Michelle. “She was so shocked that I was going to give her something bad on purpose.”

As TVS has grown, so has Michelle. Over the past few years, she has focused on Dietary Supplements. “I am proud that I have learned all the quality aspects of encapsulation,” Michelle said. “This line was very different from our other areas and had huge packets of paperwork to fill out. I was really determined to learn and perfect this area.”

She has also obtained numerous certifications to continue advancing her career and expertise.

“I am so proud of Michelle’s hard work and growth, especially in the dietary supplement side of our business,” said Quality Manager John Safi. “In the last two years we have produced over 160 million capsules and 1.5 million jars and canisters of dietary supplements and Michelle has been the lead on overseeing quality inspections for our new automated lines. I look forward to seeing her grow at TVS for many more years.”

Michelle’s world of high quality continues to her home. She recently purchased a home and applies her quality skills to inspect the house. “I am so much happier with how TVS is moving forward with business and employee care – both at TVS and at home,” she said. “It is because of TVS that I was able to purchase a home.”

When not caring for her new home or cutting the grass, Michelle enjoys photography and taking weekend trips with her kids for short getaways.

It’s not always about working at TVS. Michelle reflects on Christmas parties with Santa Claus and bringing her children to other work events.

“I remember a celebration of life for Tamara Meadows years ago,” she says with a smile. “We released balloons in the back field to honor her life, and one of the balloons got caught in a tree. It was able to get itself free, just like Tamara’s dedication and hard work in real life. I remember thinking, ‘What other company would stop the day to celebrate life?’”

Looking into the future, Michelle hopes to see quality have a stronger presence in other departments and to keep perfecting, or home in on, what each product needs.

“My advice after 15 years at TVS is, hang in there. TVS gives you the ability to do more, move jobs, and use your abilities,” Michelle says. “I am very happy to be here.”

Cermount’s Supplements and Food Packaging Brand Expansion Promotes Pride and Purpose

Jul 7, 2022 | News

Cermount, recognized for its SQF level dietary supplements and dry foods packaging services, offers quality-centered contract manufacturing while employing an all-inclusive and mission-driven workforce. Along with its parent company, Transylvania Vocational Services (TVS), and ongoing contracts with the US Government for food banks and the US Military, Cermount has continued to thrive and expand its private label food manufacturing and supplements business during these last two years.

Cermount is invested in the future with a current facility upgrade and line expansion. New vertical and horizontal form-fill-and seal equipment, additional filling lines, and a high-speed Bosch encapsulation machine are just a few of the recent investments. Additional square footage was added to accommodate new growth and dedicated line space for dietary supplements blending, encapsulation, bottling, and powder filling opportunities.

“Cermount plans to continue to expand our facility and capabilities to accommodate the growing needs of our customers and the market,” said VP of Business Development and Marketing Beth Rich. “We also have exciting new capabilities planned for the upcoming year—such as single serve cups, different pack sizes and styles, and additional material offerings. We have been fortunate that our recent growth has allowed for us to make these types of investments back into our organization.”

Cermount is flexible with a variety of packaging options, production run sizes, and an overall ease of market entry. The R&D Team can assist new customers with custom food development or simply enhance a current formula. Overall, Cermount is responsive, easy to work with, and there to help meet the start-to-finish manufacturing needs of most any project requirements.

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“Certified Quality. Trusted Service,” the Cermount motto, is built on the mission of its parent company, Transylvania Vocational Services (TVS), providing competitive employment to adults with disabilities for over 50 years. TVS has a state-of-the-art dry food manufacturing facility fulfilling contracts for the federal government. Cermount’s new capabilities and expansion combined with TVS’s mission and expertise make for a winning combination and why both are trusted and respected by industry partners. By “manufacturing with a mission” these organizations work to enhance the dignity and quality of life of individuals with disabilities and barriers to employment. For more information visit www.cermount.com.

A decade later and Dan Fisher is stilling hanging in there like a hair in a biscuit

Jun 13, 2022 | News

It isn’t every day that you get to meet a man who has an affinity for cats and a secret hatred for Mr. Rogers – but at TVS, we have had the pleasure of working beside him for the past 10 years and we are looking forward to many more!

TVS Quality Director, Dan Fisher works to, “ensure that TVS puts out a quality safe product for our customer and consumer. Whoop, there it is.”

It’s hard to not find Dan with a smile on his face. He enjoys providing employment for individuals with disabilities and barriers to employment as well as being able to feed the world with awesome products. “It’s pretty cool,” he says. “I thank the Lord, and thank my blessings for being a part of TVS.”

Dan was hired as the Quality Director in 2012 after, “my wife and I decided it was time for me to come out of retirement,” Dan said with a laugh. His experience in quality grew at Tropicana in Florida, where he worked for 35 years. “I fell in love, had kids, and went to work at Tropicana,” he explained. “I started as a Lab Tech before moving up to the Quality Packaging Manager.”

TVS Quality Director John Safi has heard all the juicy stories about Tropicana, “they beat him to a pulp,” John says with a chuckle.

John has worked with Dan for the past 5 years. “He is a good-hearted guy and a true follower of Christ,” he says. “We have a lot of audits together, and they are more fun with each other. During one, an auditor grabbed Dan’s stress-reliver ball, shaped like a cow, and threw it at me because I kept asking questions. Dan then handed her a Tropicana stress-ball and said, ‘here – you can throw this one too,’ and she did.”

Just like the stress balls being thrown at John, the puns and compliments about Dan – they just keep coming.

Heart of gold, always positive, and “the best supervisor I’ve ever had” are just some of the other kind words coworkers had to say.

Jackie Compton has worked with Dan during his decade at TVS. “One of my favorite stories with Dan is when he was on his hands and knees chasing a fly with an electric fly swatter,” laughs Jackie. “He did get the fly after several hits and some electrical recharges.”

Over the years, Dan has traded this electric fly swatter for an electric bicycle. When not working, he can be found hitting the bike bath with his wife and friends, as well as, camping… or glamping.

Dan shares his smile with everyone around him. His light-hearted humor and extensive list of puns is the highlight of conversation. “Take the time to get to know the people. Life is short, and relationships are important,” he says.

Looking ahead, there may be opportunity to see Dan letting his hair down at the next company picnic and maybe beating Jackie again at Cornhole.

“I have a million of them,” said Dan thinking back on his memories. “But the overriding theme is all the smiles on employee faces as they come to work.” Over his decade, Dan has seen TVS grow by over a hundred employees.

Brevard used to have less people, less beer, and less bikes. But it’s all behind us now.

As for Dan’s explanation for his aversion to Mr. Rogers, he says, “It’s not a beautiful day in the neighbor, there might be cat fever going around.”

TVS increases capacity to continue assisting with international famine relief efforts

May 11, 2021 | News

Assistance to DRC refugees in the Mugombwa Refugee Camp

Brevard, NC (May 11, 2021) — Food insecurity has surged in recent years across the world. As a result of the Coronavirus pandemic, more individuals are affected or at a higher risk than ever before. To help combat this growing rate of worldwide food insecurity, Transylvania Vocational Services (TVS) installed new equipment during the 2020 year to continue meeting increased demands with the production of its SuperCereal Plus (SCP) blend.

“As a supplier of further processed grain based and dairy commodities to USDA, USAID, and the US Military, TVS is pleased to announce a significant increase in plant capacity to process and package SuperCereal Plus,” said TVS VP of Operations Steve Green. “This was made possible by forming a strategic alliance with grain suppliers in the US Midwest along with extensive engineering studies and capital investments in high speed processing and packaging equipment.”

Currently TVS’s expansion has continued to support SCP production with an overall increase of 55%. Green said, “following 10 years of direct product experience and newly increased plant capacity, we are prepared to support USAID feed programs for another decade.”

SCP is a specially formulated cereal that offers complete nutrition for children ages 6-24 months when combined with fresh drinking water and used in conjunction with breast milk.

“TVS’s SuperCereal Plus business and our assistance with international hunger relief is something that we’re particularly proud of as an organization,” said TVS CEO Jamie Brandenburg. “We worked with the USAID and the World Food Programme to aid in the formulation and development of this complete nutritional supplement, and we continue to supply this product to various parts of the world.”

The manufacturing and packaging process of SCP began collaboratively with the USDA in 2010.

“As one of the first suppliers of SuperCereal Plus in North America, we are proud to invest and grow with our distribution partners to continue supplying a nutritious feeding supplement to families and children of developing nations that are in need,” said Green.

TVS has recently produced 1600 metric tons, or 3.5 million pounds, of SCP to aid in global hunger assistance efforts. Over the years, many regions of Africa and various other areas of the world have received TVS’ SCP.

Click here to read the full PDF.