Realsy Foods
OTIF 92% to 98% | Waste 9% to 3.5%
The Situation
Realsy Foods is a health food brand selling packaged goods produced using agricultural inputs, with a focus on quality, provenance, and shelf-stable formulations. The brand sells through Amazon as a primary channel with a secondary DTC website, and has expanded into retail and food service distribution.
The business model is Amazon-first with DTC and retail expansion. The supply chain is agriculture-dependent -- raw material quality and harvest cycles directly affect production consistency. At the time of engagement, the brand was transitioning from early traction into retail and Amazon scale.
The product worked and demand was real. The supply chain, however, was unstable -- and leadership had misdiagnosed the problem as a logistics issue. The actual issue was upstream raw material variability flowing through the entire system.
- Raw material variability: inconsistency in size, moisture, and quality across batches
- No standardised intake quality checks
- Co-packing output dependent on whatever raw input arrived
- Forecasting disconnected from harvest and production cycles
- Expiry mismanagement causing silent waste
We exited cleanly after internal team build-out. The relationship arc ran from quality firefighting, to operational ownership, to planning and scaling partner.
Our Role
End-to-end supply chain ownership from raw material intake through to co-packing, inventory management, and distribution planning.
- Reviewing inbound lots against defined specs
- Rejecting inconsistent batches and working directly with suppliers on grading
- Running weekly production planning tied to forecast and harvest windows
- Managing FEFO inventory rotation across the catalogue
- Overseeing co-packing yield tracking and defect threshold enforcement
Engagement Phases
Phase 1 -- Upstream Control
0-90 DaysWent directly to source -- farms and suppliers -- before touching anything downstream.
- Mapped all farms and harvest windows
- Defined measurable raw material specs
- Introduced batch-level traceability
- Implemented intake QC checkpoints
Cultural shift: from "we use what we get" to "we control what enters the system."
Phase 2 -- Production & Planning
3-12 MonthsFixed the middle layer -- co-packing and planning.
- Yield tracking per batch and standardised processing steps
- Defect thresholds enforced at co-packer level
- Demand forecast tied to seasonality and harvest cycles
- FEFO inventory management with shelf-life segmentation
- Weekly production planning introduced
Phase 3 -- Scale
Year 2- Multi-region raw material sourcing to reduce single-origin risk
- Backup co-packers onboarded
- Packaging improvements to extend shelf life
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