Gummy Manufacturer Improves Traceability and Product Quality with SCADA

A nutritional gummy manufacturer was facing recurring challenges with product quality, traceability, and process consistency. Frequent returns and limited visibility into production made it difficult to identify issues and maintain consistent results as production demands grew.

To address these challenges, the manufacturer partnered with SPI Automation to implement an Ignition SCADA system—first in production and later expanded to packaging.

The result was greater control over recipes and processes, improved traceability, and better visibility across operations.

The Challenge: Improving Quality and Process Visibility

The manufacturer needed a better way to monitor production processes and understand what was happening on the plant floor.

Inconsistent product quality and frequent returns highlighted the need for tighter process control. At the same time, limited traceability made it difficult to quickly identify the source of issues and determine where improvements were needed.

The manufacturer needed a solution that could:

• Improve production traceability
• Provide greater visibility into plant operations
• Strengthen recipe and process control
• Reduce quality issues and waste
• Scale with the manufacturer’s evolving production needs

The Solution: A Scalable SCADA System

Building on a successful previous automation project, the manufacturer engaged SPI Automation to develop and implement a SCADA system using Ignition.

Rather than taking a one-size-fits-all approach, SPI worked closely with plant personnel, company leadership, and equipment OEMs to understand the manufacturer’s processes, challenges, and goals.

SPI initially implemented the SCADA system in production, giving operators and management better access to process information and greater control over manufacturing activities. After the initial implementation succeeded, the system expanded into packaging.

SPI’s flexible, hourly engagement model allowed the manufacturer to develop the system strategically while adapting the scope as needs evolved.

The Results

The SCADA implementation delivered measurable improvements across the operation.

Real-Time Traceability

Production data became more accessible, giving the manufacturer greater visibility into processes and improving its ability to trace production activity.

Tighter Recipe Control

Improved process monitoring and recipe management increased consistency and reduced variability in production.

Enhanced Operational Visibility

Plant personnel and leadership gained a clearer view of production processes, helping them identify issues, make informed decisions, and improve overall process control.

Fewer Quality Issues and Less Waste

Better visibility and process consistency contributed to fewer quality problems and reduced waste, helping the manufacturer improve the efficiency of its operation.

A SCADA System Built to Grow with the Operation

The initial SCADA implementation demonstrated the value of connecting production data with day-to-day plant operations. As the manufacturer’s needs evolved, SPI continued to expand the system into additional areas of the facility.

The manufacturer’s ongoing investment in the system reflects the value of having a scalable automation platform and a trusted automation partner.

By combining Ignition SCADA technology with a deep understanding of manufacturing processes, SPI Automation helped the gummy manufacturer gain greater control, visibility, and consistency—and established a foundation for continued automation and improvement.

Ignition SCADA Software from Inductive Automation

SCADA systems monitor, control, and optimize manufacturing processes—ensuring consistent quality, improving efficiency, and enabling data-driven decision-making. Ignition empowers your business without limits.

• Unlimited licensing
• Universal platform
• Web-based deployment
• Rapid development
• Trusted IT standards

Looking to Improve Manufacturing Visibility and Control?

A well-designed SCADA system can help food and nutraceutical manufacturers improve traceability, recipe control, process monitoring, and operational visibility.

SPI Automation works with manufacturers to design scalable automation and SCADA solutions around their specific processes, equipment, and business goals.