Case Studies
Case Studies – Proven Success in Action
Welcome to the IntelliPlant Software Case Studies page, where you’ll discover how leading food and beverage manufacturers are transforming their operations with our powerful, industry-specific solutions. From streamlining production processes to ensuring compliance and improving traceability, these real-world success stories highlight the measurable impact IntelliPlant has made across the supply chain. Explore how our technology helps companies boost efficiency, reduce waste, and stay ahead in a highly competitive and regulated market. Explore how IntelliPlant Software’s innovative solutions have transformed operations for leading brands in the food and beverage industry.
Case Study: Dairy Producer
Problem:
HTST 2 Chart Recorder had stopped recording the Divert Temperature Setpoint. This went unnoticed by the plant for about a year. The state discovered this and was up in arms.
Solution:
We were able to show record of the Divert Temperature setpoint on Intelliplant Instant Replay, easing the state’s concerns. We replaced the Chart recorder and got the charts recording correctly again.
Takeaway:
Without Instant replay, we would have had no record of the Divert Temperature Setpoint for an extended period and the plant may have been faced with reprimands from the state. Having instant replay as a backup saved the day.
Case Study: Dairy and Beverage Producer
Problem:
Orange Juice blending with concentrate and water was consistently coming out over concentrated. Being able to catch an orange juice production was difficult as the plant would only run OJ once per week and always in the middle of the night.
Solution:
We used instant replay to re-watch the production runs to determine what was going on in the process to over concentrate the Orange Juice. We were able to find that the OJ Concentrate meter was totalizing at incorrect times which was allowing too much concentrate into the blending system.
Takeaway:
Without Instant replay, it would have been difficult for the engineer to catch each production run of Orange Juice. Being able to replay the entire process days and even weeks later was invaluable. Without it, the project would have come in over time and over budget.
Case Study: Dairy Producer
Problem:
Chocolate Milk Products were having abnormally large amounts of air and foam in them after pasteurization.
Solution:
We used instant replay to determine that the storage tank agitator was being manually forced on by the operator and left on for several hours while the tank was being filled with chocolate milk. We were able to use the recorded times in instant replay and pair those times with the security log to find the operator that was doing this with the agitator.
Takeaway:
Without Instant replay, we would have not been able to find the root cause of the problem. Troubleshooting that would have taken days or even weeks only took a few minutes. This saves on lost product and lost production time. We were able to directly retrain the operator that was making the mistake to prevent this in the future.
Case Study: Dairy Producer
Problem:
Milk Separator becoming dirty faster than expected resulting in high butterfats during operation.
Solution:
We used instant replay to track the meter gain on the discharge of the separator. We could see a trend over time that the meter was having to work harder to record a steady flow. This meant that air was getting into the separator and causing burn-on. We were then able to inspect suction sides more closely and were able to find a faulty pump seal.
Takeaway:
Without Instant replay, it would have taken longer to find and diagnose the problem. This saved massive amounts of lost product and lost production time. It also saved on the amount of mid-day washes the plant would have to do to keep the separator clean.
Dannon
Dannon relies on IntelliPlant’s CIPHD, Track ID, and Instant Replay tools to ensure compliance, streamline cleaning processes, and maintain food safety standards. By automating data collection and providing real-time insights, IntelliPlant has helped Dannon achieve greater efficiency and operational transparency.
Purple Cow Dairy
At Purple Cow Dairy, IntelliPlant’s lot tracking and traceability tools have revolutionized product genealogy. Managers can now easily trace every product batch and its equipment interactions, ensuring quality control and simplifying recall processes.
Nestlé
Nestlé’s ice cream plants benefit from IntelliPlant’s Instant Replay feature, enabling operators to review every HMI graphic screen and investigate customer complaints with precision. This tool has enhanced troubleshooting and improved overall plant performance.
The IntelliPlant Difference
- Flexibility & scalability across locations
- Food & beverage expertise
- Proven, industry-specific modules
- Easy user-centric design
- Repeatable & efficient process
Game-Changing Features
Instant Replay
Just like the name suggests, Instant Replay is your ultimate tool for operational transparency and efficiency. It allows you to visually revisit past processes, identify inefficiencies, and resolve issues with precision. This tool is essential for improving troubleshooting, ensuring compliance, and supporting operator training by providing a comprehensive visual history of plant operations.
CIPHD
CIPHD redefines cleaning process optimization, giving you robust data and insights to achieve consistent and efficient results. With tools to monitor resource usage, benchmark performance, and generate custom reports, CIPHD ensures compliance, reduces waste, and continuously improves safety and efficiency. Plus, our digital charting is recognized by the FDA!
Lot Track HD
Lot Track HD offers unmatched traceability and quality assurance by providing detailed tracking of every batch, from raw materials to final product. This tool simplifies compliance, builds trust through transparency, and optimizes production processes for enhanced operational efficiency.
Start the Conversation
Ready to take control of your plant operations? Unlock the power of real-time intelligence with IntelliPlant. Request a demo today and see how IntelliPlant is changing the game for manufacturers.