Sani-Matic Transforms Compliance with Smart System

When ‘clean’ isn’t clean enough, companies trust Sani-Matic, Inc.

Clean-in-place (CIP) and Clean-out-of-place (COP) systems used in food, beverage and other industries have a vital role in processing because of the need to keep components free of bacteria. Cleaning occurs in piping, tanks, heat exchangers, and other equipment to prevent product contamination and maintain processing efficiency.

In these industries, satisfying consumers’ appetites for new products is just one part of a complex equation. Equally important is protecting the food supply and maintaining compliance with regulatory mandates, including the Food Safety Modernization Act (FSMA).

The latest standards have directly impacted equipment cleaning processes and heightened food and beverage companies’ expectations of their CIP and COP systems and their ability to efficiently clean interior surfaces.

Meet Regulatory Demands

Using a standardized control system, the right modular CIP and COP system can help meet regulatory demands while boosting efficiency.

Sani-Matic designs and manufactures automated sanitary process cleaning equipment, from COP Parts Washers and cabinet washers, such as the SaniCab and PharmaCab, to CIP Systems, and sanitary components that provide a complete clean – every time.

It’s been that way since the Sani-Matic story began in 1943. That’s when they developed a COP Parts Washer for the dairy industry and began a precedent of high-quality equipment innovation at the forefront of automating sanitary cleaning processes.

Sani-Matic’s CIP systems provide effective cleaning parameters to thoroughly remove soils, rinse effectively, shorten cycle times, reduce operating costs, increase worker safety, and provide repeatable and documentable results.

"Sani-Matic wanted to bring the best technology to automated cleaning system reporting, increase service revenue and open up new SaaS recurring revenue streams."

Better Data Opens New Revenue Sources

Sani-Matic needed an Industrial Internet of Things (IIoT) cloud-based software for generating cleaning cycle reports and analyzing operational data from CIP and COP systems.

The industries Sani-Matic serves are regulated and required to record critical data but the methods to collect this data were manual or paper-based with limited automation and data insight.

Sani-Matic wanted to bring the best technology to automated cleaning system reporting, increase service revenue and open up new Software as a Service (SaaS) recurring revenue streams, and lead the industry in technology development to promote its product and differentiate its overall systems.

Sani-Matic decided to expand its digital transformation potential with FactoryTalk® InnovationSuite, powered by PTC. This comprehensive portfolio brings edge-to-enterprise analytics, machine learning, IIoT and augmented reality (AR) to industrial operations. This powerful suite simplifies how Sani-Matic manages data and makes it easier for everyone to access, understand, and leverage the information they need to make decisions.

FactoryTalk InnovationSuite collects and consolidates information technology (IT) with operational technology (OT) from existing equipment and systems, for quicker data-driven decisions that allow the workforce to easily find the data they need to drive real improvements.

For Sani-Matic, the information locked in data streams can transform how they manage operations, solve issues and adapt to change – making it useful for the right purpose, at the right place and time.

FactoryTalk InnovationSuite makes it easy to connect data so Sani-Matic can improve operational insight across its business. Collecting and organizing data in real time adds needed context to provide actionable insights and turn those insights into actions. The solution blends advanced analytics with information from the MES to add context to analytics, supporting quality, compliance and continuous improvement initiatives. The AR features provide deeper visibility and training tools to improve workforce effectiveness.

"Sani-Matic decided to expand its digital transformation potential with FactoryTalk InnovationSuite, powered by PTC."

A centralized dashboard provides immediate visibility to specific data. With this 360° view, users can optimize overall operations by combining, comparing and analyzing information in real time across machines, lines, processes and facilities, connecting and contextualizing data from other systems through one common window to provide the information people need for their job roles.

With the SaniTrend™ Cloud installed on-site, users are able to troubleshoot more effectively, analyze their cleaning cycle OEE over time, and gain insights into system operation, including average temperatures and runtimes, to support the individual system and leverage for future product development.

“There’s a whole world of insight for our product development groups and our engineering teams internally to learn from and then, obviously, better the products for the next generations,” said Product Management Director Peter Barrie.

Additional features above and beyond just the cleaning cycle reporting include OEE trends and preventive maintenance notifications. The road map going forward includes bringing this to other industries, including biopharmaceutical, in development of 21 CFR Part 11 electronic record requirements, and expanding the service offering through use of the technology.

Expanding these offerings is an important step toward Sani-Matic’s SaaS recurring revenue and product differentiation.