Clean-in-Place goes Digital, Saving Customers Time and Resources
"You can't manage what you don't measure" – Peter Drucker famously quoted. This line is applicable to food safety in manufacturing. When it comes to food safety, much opportunity remains within cleaning processes as it happens. For food manufacturers, it means having visibility (through digital), ensuring that cleaning protocols are adhered to and complied to during each clean of manufacturing systems. Additionally, this visibility in cleaning process mitigates potential risks and promotes efficiencies and improved productivity.
I’ve seen advancements into cleaning processes in my 20 years in the F&B industry, with digital technologies, we now have the ability to not just advance, but to transform data into meaningful insights for actionable operational and strategic decisions.
Ecolab is experienced in developing digital solutions to meet operational challenges. One of our longest-standing US-based customers, Umpqua Dairy, has saved more than USD $112,000 a year using Ecolab's 3D TRASAR Technology for CIP since adopting the product. Our customers in Southeast Asia who use the same technology also experience consistent time, energy, and water savings.
How did we help Umpqua Dairy?
The Challenge. Cleaning and sanitizing in a facility with a diverse product mix can gradually increase pressure on existing CIP systems. The traditional monitoring methods were unable to provide comprehensive visibility into each one of Umpqua's cleaning procedures. Umqpua partnered with Ecolab in 2018 to find proactive ways to deliver consistent cleans using sophisticated wash data analysis with Ecolab's 3D TRASAR Technology for CIP. This gave Umpqua Dairy full visibility into their CIP operations allowing them to increase productivity, reduce costs and identify areas of water over-usage.
The solution: Around-The-Clock Monitoring
3D TRASAR Technology for CIP enabled Umpqua for the first time ever to “see” the volume of chemicals and water used across every single wash. 24/7 around-the-clock monitoring was set up to provide insights on cleaning and sanitizing concentration variations, allowing the plant to identify and prioritize opportunities for improvement.
The data was collected from Umpqua’s Programmable Logic Controller (PLC) via an Ecolab Smart Box, which sent the data to a secure server. Ecolab’s System Assurance Center distilled the server data into conformance reports. Ecolab’s on-site Account Manager then accessed the conformance reports through a web dashboard and periodically translated it into recommended corrective actions for the plant, in collaboration with the plant management, with their approval.
Results at a glance
- Eliminated need to go through 900 CIP CHARTS generated monthly by traditional CIP system.
- Increased CIP wash conformance to 94% ON AVERAGE.
- Reduced water and cleaning chemistry consumption FROM $64.81 TO $59.85 AVG. COST/WASH.
- REDUCED RINSE TIME AND WATER USAGE by identifying areas of water over usage and adjusting wash parameter programming.