More transparency of Cleaning in Process (CIP) in the beverage bottling industry through digitization and data analysis.
The Cleaning in Process (CIP) is crucial in the beverage bottling industry, directly impacting product quality and purity. Any deviation in the CIP can tarnish a brand's reputation by affecting the taste and safety of the final product.
Navigating Complexities with Changeover Matrices
Changeover matrices dictate specific cleaning programs necessary when switching production lines to different products. However, this sequence is prone to errors which can lead to significant deviations in cleaning effectiveness. At Quantis.ai, we leverage digital solutions to illuminate these errors and provide actionable insights into CIP benchmarks.
A changeover matrix specifies which cleaning program and its program steps must be run when changing to another product to be filled. This sequence can lead to deviations and errors in the individual cleaning processes. Using the CIP use case, we show how to make errors in the CIP process visible and how the CIP benchmarks can be analyzed and monitored.
Challenges in Maintaining Product Integrity
Beverage producers with sugar-containing and flavor-intensive product portfolios must pay particular attention to the CIP process when changing products in production.
To maintain high product quality, no flavor or sugar residues must be present after the CIP process. Therefore, the process must always meet the defined cleaning requirements.
Due to compliance with production specifications, it sometimes happens that cleaning processes are manually shortened to meet the specified production time. In addition, failure to comply with temperature specifications, additions such as caustic solution, or other cleaning agents in the specified quantity can deviate, which in turn does not meet the manufacturer's quality requirements.
Our Approach to Optimizing CIP (Cleaning in Process)
Our on-site data analysis records and assesses each CIP process, allowing for immediate interventions that prevent quality compromises and defective products. This proactive approach ensures that filling batches are consistently monitored and maintained, enhancing overall production quality.
The customer's CIP matrix with the individual cleaning programs is the basis. All individual cleaning steps (benchmarks) of each CIP program with the upstream steps, such as, preparations for hot water, lye etc., are stored in Pocket Factory. Adjusted standard values, so-called benchmarks, are formed from these values.
This adjusted data is analyzed to determine whether the step sequence, time intervals and process variables in the CIP are adhered to over a specific period of time.
A log is created for each CIP operation that records all steps of the cleaning process and provides warnings if the deviation from benchmarks is too high.
Results: Empowering Proactive Quality Management
Data analysis takes place at the customer's site, each CIP process is recorded and can be retrieved. The analysis provides information about possible errors in the CIP process execution already during production. Interventions can be made quickly, and product quality impairments are detected at an early stage, preventing defective products from reaching the market.
In this way, the bottler has his filling batches under control. This is a continuous, automatic monitoring of quality and thus a useful supplement to random, manual quality testing in the laboratory.
Logging of all benchmarks of the CIP processes
Logging of all CIP processes
Warnings in case of deviations during the cleaning process
The analysis of the CIP (Cleaning in Process) as an automatic quality control during production enables a continuous improvement of the production processes.
Continuous Monitoring for Consistent Quality
The comprehensive logging of all CIP benchmarks and processes supports ongoing quality assurance, serving as a vital supplement to traditional quality tests. This level of analysis fosters a culture of continuous improvement within production processes, ensuring each product batch meets the high standards expected by consumers.
Conclusion: Elevating Standards with Pocket Factory and Quantis.ai
At Quantis.ai, our digital CIP monitoring tools not only safeguard product integrity but also empower beverage manufacturers with the data they need to make informed decisions, reduce waste, and maintain consumer trust. Join us in transforming beverage production with cutting-edge technology designed to perfect every sip.
Log Your Interest in Enhanced Beverage Production Quality
Discover how our Pocket Factory platform can transform your production processes. Contact us today to learn more about implementing state-of-the-art digital solutions in your operations.
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