This paper describes the results of a process control improvement study carried out on a food processing line making frozen french fries. A strategy for process control improvement is proposed and its success demonstrated. Initial knowledge elicitation from process experts. coupled with data analysis. revealed the existing operational strategy. The information gathered highlighted limitations of the current strategy, indicated how it could be improved upon and allowed a benefits analysis to be undertaken to financially justify the work. Results from the implementation of the control enhancements demonstrate the success of the strategy and indicate the predicted improvements were achieved. (C) 2003 Elsevier Science Ltd. All rights reserved.