A gummy manufacturer implemented Ignition SCADA software to gain visibility into production conditions and identify why gummies were melting during shipping. By tracking production metrics and adjusting the recipe based on the data collected, the company resolved the quality issue, reduced waste, and established a stronger foundation for traceability and future quality improvements.
- A major gummy manufacturer faced melting product that appeared during shipping but not during production, causing customer returns and retail complaints.
- The company implemented Ignition SCADA software to gain real-time visibility into production conditions and process data that could contribute to defects.
- Using data from the SCADA system, the manufacturer identified the root cause and adjusted the recipe, which resolved the melting issue.
- The manufacturer expanded the system to packaging operations using a phased approach, prioritizing the most pressing problems first.
- SCADA implementation reduced quality issues and waste while providing stronger traceability for future quality control efforts.
A major manufacturer of nutritional gummies faced a quality problem that did not appear during production but became obvious by the time product reached store shelves.
The gummies were melting together during shipping, leaving retailers with clustered product that did not meet quality expectations. Customers returned the gummies and reported the issue, putting pressure on the manufacturer to determine where the problem was occurring and how to prevent it from continuing.
The company needed more than a short-term correction. It needed a way to see deeper into its process and improve traceability so future quality issues could be isolated more quickly.
Looking for the Source of the Problem
For the manufacturer, the challenge was not simply that gummies were arriving at retail in poor condition, the real issue was the limited visibility the company had into process conditions that could have contributed to the defect.
Without enough connected data, it was difficult to determine whether the problem was tied to formulation or production conditions, which made it harder to trace imperfect batches and make changes with confidence.
The manufacturer worked with SPI Automation to implement Ignition SCADA software, beginning with production. The goal was to give the plant a clearer view of process data and create a system that could scale as the company’s needs developed.
Using Data to Correct the Process
Once the SCADA system was in place, the manufacturer could track production metrics and review process data more effectively. That visibility helped the company identify the likely source of the problem and trace affected batches with greater accuracy.
Using the data collected through the system, the producer adjusted the recipe, a change that resolved the quality issue that had caused gummies to melt together during shipping.
The project also gave the manufacturer a more structured way to approach quality control. Instead of relying only on end-of-line checks or customer complaints after product reached retail, the company had a better way to connect production conditions to finished-product quality.
Expanding the System Step by Step
After the production issue was addressed, the manufacturer expanded the SCADA implementation into packaging. A phased approach allowed the company to solve the most pressing problem first, then build on the system without taking on the entire operation at once.
SPI Automation worked with plant staff and leadership to design a system aligned with the manufacturer’s operations. The team helped prioritize which steps to address based on the most likely causes of the quality issue and helped define the key data points needed to track them.
The customer also worked with SPI Automation on a flexible hourly basis rather than through a large upfront contract, which reduced initial expenses, helped the manufacturer move faster, and gave the company room to expand the system as the value became clear.
Improving Quality and Consistency
The SCADA implementation helped the manufacturer reduce quality issues and cut waste. Just as important, it gave the company a stronger traceability foundation for future quality control efforts.
By starting with a specific product issue and expanding from there, the manufacturer used automation software as a practical problem-solving tool rather than a broad technology project.
The company continues to expand the system, using the initial quality control success as the foundation for additional improvements across production and packaging.
