Quality Control in the
Bottling Industry

Improve yield and reduce risk and waste.

Bottling Quality Control

Beverage bottlers face increasing pressures to provide high-quality product under tight financial and regulatory control. A quality plan is a must, and many bottlers utilize Statistical Process Control (SPC) solutions to help monitor and maintain process and product quality.

InfinityQS® SPC software provides unparalleled visibility and quality insight for some of the world’s most demanding beverage bottlers: Our solutions enable bottlers to—

  • Improve yield for increased profitability
  • Reduce risk and maintain compliance
  • Tighten net content control to reduce waste
  • Streamline data collection and reporting
Food & Beverage Manufacturing

It’s a tall order, but InfinityQS SPC software provides a single solution for many beverage bottling companies, from small independent manufacturers to large multinational players.

Interrogating Data to Find More Savings

Improve Yield and Increase Profitability

Real-time SPC enables fast response to process problems, helping bottlers keep production running smoothly and improving yield. InfinityQS SPC continuous improvement methodologies help you meet targets, increase yield, and improve profit margins per bottle.

By comparing quality across multiple product codes, production lines, and sites, you can also analyze and recreate successes across the enterprise—no need to manually manipulate data to analyze details like bottle cap torque, even for non-normal distributions, short runs, and startup activities.

  • Locate issues in real time and determine specific fixes.
  • Improve process efficiency for optimal yield.
  • Increase profit margins per bottle.
  • Repeat savings across the enterprise.
  • Develop best practices based on your highest-performing processes.

Reduce Risk and Protect Your Brand

Whether you have 1 site or 100, your success depends on an optimal, consistent level of visibility across every product, process, and line. Time spent tracking inventory slows productivity and can mean potential lost profits. But more important, insight into both raw materials and finished product is vital to your ability to respond quickly to quality issues, meet regulatory requirements, and protect your brand reputation.

  • Quickly trace quality from consumption to supply chain.
  • Track SKU-specific data across lines and sites.
  • Reduce human error with automated, semi-automated, and mobile data collection options as well as automated alerts and notifications.
  • Compile data quickly in response to compliance or audit demands.
  • Identify exactly where to make improvements to provide the best product possible.
Increased visibility—improved quality control for food

Key Capabilities: Net Content Control

For beverage bottlers, syrups and concentrates are among your most expensive ingredients. Waste during the mixing process can spike production costs, so profitability relies on eliminating syrup waste and minimizing overfill. Consider: A production line fills more than 90,000 12-ounce cans per hour. What if each can is 3 ml over target? Imagine the benefits of eliminating that overfill while still meeting net content requirements. Quality intelligence solutions from InfinityQS use SPC continuous improvement methodologies to help you meet targets, increase profit margins per bottle—and quickly see ROI.
  • Identify and eliminate syrup waste.
  • Minimize overfill without risking underfill.
Compliance with Food and Beverage Industry Regulations

Bottling Industry Compliance

InfinityQS delivers built-in functionality that helps beverage bottlers comply with government regulations and industry standards for food quality and safety.

ProFicient’s Lot Genealogy and Reporting functionality enables organizations to track raw material (ingredients) lot codes throughout bottling manufacturing operations. For investigation purposes, genealogical "trees" can be created for any lot. These reports allow you to determine:

  • Materials used in the production of a specific finished lot
  • Where incoming raw ingredients were consumed
  • Root causes of nonconforming lots
  • Information critical for responding to product recalls
  • Which final lots were created from incoming lots

Lot Genealogy reports provide a complete view of the incoming/outgoing product relationship with statistical summary information.

Dynamic Scheduler

Dynamic SchedulerYou can specify unique, time-based intervals based on the product, process, or even the workstation. Windows automatically pop up, clearly identifying when data collections are due. If a failure is detected or if no data is collected, the software can automatically send notifications, email administrators, or even force users to specify assignable cause codes and corrective actions.

Watch the video.

InfinityQS solutions boast built-in checklist and workflow alerting features needed to comply with Hazard Analysis and Critical Control Points (HACCP) and Sanitation Standard Operating Procedures (SSOP). You can incorporate workflow requirements at the shop floor level, providing automatic data collection prompts to operators. InfinityQS’s real-time Dynamic Scheduler offers visual checklists to operators, reminding them when to perform HACCP, SSOP, and other critical quality checks.

With InfinityQS, audits are easier with instant access to the quality records and electronic documentation needed to demonstrate compliance. Our robust solution can stand up to third-party certification audits such as British Retail Consortium (BRC), Safe Quality Food (SQF), and ISO 22000—or internal audits. Creating reports takes only minutes instead of hours or days, eliminating the need for spreadsheets.
 

When enabled, Database Auditing provides full traceability for any modification, edit, or change to any database record. Traceability records are easily viewed in a variety of ways, but they cannot be edited. Whenever a record modification or deletion is attempted, the Reason for Change tracking feature forces users to select a reason for the modification from a drop-down list. Additionally, free-form comments are required. When specified, a Change History and Reason for Change Report can accompany any chart printout.

Manufacturers in the bottling industry must also comply with filling requirements for Net Content (weight) Control. The Net Content Control feature supports both the U.S. Department of Commerce Maximum Allowable Variation (MAV) and European Union Tolerable Negative Error (TNE) and T1/T2 requirements, plus related Net Content Control reporting to support the needs of global manufacturers. Many Food and Beverage InfinityQS users see fast ROI based solely on reduced “giveaway” or overfilling of product using the Net Content Control functionality.

Simplify Data Collection and Reporting

Fast, accurate communications within and across teams are vital for keeping your
business running smoothly.
The sooner you detect and alert stakeholders to potential quality problems and related costs, the faster you can eliminate those problems. But the overwhelming amount of data in manufacturing today makes it difficult to catch problems quickly. Furthermore, storing data in more than one device or software system—or even paper forms—can derail efforts to avoid errors and perform extensive manual analysis.

With InfinityQS, you can automate data collection from processes across your plants and production lines. InfinityQS solutions easily integrate with a variety of measurement devices to provide real-time data from across one plant or numerous sites.

Plus, InfinityQS provides user-configurable notifications, alerts, and reports that can unveil useful information from any of your collection devices.  
  • Surface the information you need instead of wasting time sorting through irrelevant data. 
  • Support and streamline automatic, semi-automatic, and manual data collection.
  • Integrate with existing IT infrastructures and ERM systems and standardize incompatible data formats.
  • Utilize self-service, on-demand reporting and customizable notifications and alerts.
  • Automate and standardize reporting for clearer, faster communication with customers and colleagues.
  • Surface the data you need, based on your role and priorities.
  • Stop juggling multiple spreadsheets and paper collection forms.
  • Get mobile access to your data and standardized yet flexible reporting options.
The immediate impact that InfinityQS ProFicient had and the awareness it created was tremendous, much more than I ever thought possible. Now we can look at operations as a whole and make big-picture decisions about what should be done going forward. Management is using data to make informed decisions and plan for the future.
There are many advantages to having a computerized system that sometimes, in the fog of having this powerful tool with its many capabilities, one can over look.
It is ultimately easier for the operator. Even with the minimal computer skills many of the
operators had in the beginning, the overwhelming consensus is that they prefer using InfinityQS
over a paper system.
You can read the data rather than having to decipher the writing of 150 different people. The data is at your fingertips.

Take the first step from quality to excellence