I'm curious about a few things based on your post:
1) What, if any, changes were actually implemented following the researching, working with labs, chemists, etc? You mention that you were trying to understand what happened, but you did not share the outcomes.
2) What is your process for confirming mold? Are there audits of this process to insure accuracy?
3) Ted Swearingen in an email discussion with me in May 2019 stated that C&D had no real defect tracking processes prior to the 2016 mold explosion, limited defect tracking (basically customer reporting) in late 2016 which produced data suggesting your defect rate was 1:50,000, and by 2019 still only very basic defect tracking which involves logging defective tins- based on year of production- for an ever-evolving, but more clear history of defects. At the time of this email conversation, the defect rate was 1:1200, per Ted. While the historical tracking is certainly valuable, what in-process defect detection have you implemented and how are you arriving at your claim of a current .000239% defect rate?
All cards on the table, I do process engineering for a living and I have a background in QA/QC.
I look forward to your response. Thanks.
We are a business and we are not all required to provide any of this information. We are, in general, far more transparent than any of our fellow manufacturers, but there are limits to what we can or will share and particularly on a hobbyist public forum. We spend a lot of energy producing a quality product and we have spent a lot of time and money specifically addressing the issue of mold, not only for the quality of our product but for our customers and for the continuation of the hobby.
Now, here are my responses:
1) Several. You don't hire consultants and employ laboratories and chemists in order to then not take their advice. We added air filtration equipment, reconfigured drying space and pre-and post blend protocol, and re-addressed our anti-fungal approach and application. We also monitor air quality regularly with a particulate counter.
2) Mold is not invisible, and is easy to detect visually. Mold spores on the other hand, are not only invisible but they are everywhere. When a customer complains of mold, they are complaining of mold fruiting bodies, that is a mold spore has found a host material from which to consume water and is growing. In all instances of mold reports, we request pictures and we often send a return label so that we can physically assess. Mold is, in general not subtle. That said, we have utilized the mycology laboratory at Clemson, which also has a fantastic Tobacco Agriculture program, and they have helped us to identify the types of mold we commonly see, and helped in diagnosing and addressing possible causes.
3) I don't know of your conversation with Ted and I am disinclined to comment on your private correspondence with a colleague of mine from 2 years ago. The data tracking system that we have is more robust than it was then, and we have been able to build out more retroactively through various data inputs. The number I gave is literally the number of reports of ANY quality issue whether mold, cut, moisture or otherwise, divided by the total number of units produced since 2016.