Complete CMMS solution for food & beverage manufacturing

Labeling machine failure root cause analysis transformed a struggling California beverage bottler from industry laggard to benchmark performer in just eight months. The facility had accepted a 4.1% label...

Labeling machine common failures silently erode packaging line profitability at an alarming rate. A Midwest snack food manufacturer discovered last quarter that label placement errors and applicator jams had...

During an FDA inspection at a frozen food facility in Georgia last November, the investigator asked a simple question: show me your labeling machine inspection records for the past 90 days. The maintenance...

A dairy processing facility in Wisconsin discovered their HTST pasteurizer was developing a heat exchanger fouling problem at 3:47 PM on a Tuesday. Not through a catastrophic failure that halted production,...

Pasteurizer common failures cost the North American dairy industry an estimated $340 million annually in product losses, emergency repairs, regulatory penalties, and brand damage. A single under-pasteurization...

A pasteurizer inspection report template documented the critical evidence that saved a Wisconsin dairy from a $2.3 million recall when FDA investigators questioned their thermal process validation last March....

Last March, a snack food manufacturer in Ohio watched their 500-gallon ribbon blender seize during a critical production run. The gearbox had been making subtle grinding sounds for six weeks. Operators noted...

Predictive maintenance for industrial mixers saved a Georgia dairy processor $847,000 last year by detecting a gearbox bearing defect 47 days before catastrophic failure would have contaminated 200,000 pounds of...

An industrial mixer inspection checklist prevented a $420,000 recall at a California sauce manufacturer last October when a routine seal check caught microscopic metal shavings before they contaminated 12,000...

Last Wednesday at 3:12 AM, a dairy processing plant lost $89,000 when a transfer pump seized—not because the pump failed, but because nobody noticed the warning signs developing...

At 3:22 AM on a Tuesday, a dairy processing plant in Wisconsin lost 12,000 gallons of raw milk—$48,000 worth of product—because a transfer pump seized without warning. The bearing had been degrading for 19...

A bakery in Pennsylvania replaced the same air compressor motor three times in 14 months. Each time, the maintenance team diagnosed "motor failure," ordered a replacement, and moved on. Total cost: $23,400 in...

Last year, a cereal manufacturer in Michigan installed a $127 vibration sensor on their main air compressor. Three months later, that sensor detected a 0.02 mm bearing defect—invisible to human senses,...

At 3:47 AM on a Tuesday, a frozen pizza plant in Illinois heard the sound every maintenance manager dreads—silence where their air compressor should be humming. The 75 HP rotary screw unit had seized. Within...

Three weeks ago, an FDA inspector walked into a dairy processing plant in Minnesota and asked a simple question: "Show me your air compressor inspection records from the last six months." The maintenance manager...

Last month, a beverage bottling plant in Wisconsin lost 14 hours of production—not because of a major breakdown, but because nobody checked the air compressor inspection checklist items that...

Last Tuesday at 2:47 AM, a food plant in Ohio lost $127,000. The cause? A low-water cutoff that hadn't been tested in 11 weeks. Your boiler ran 2,847 hours last quarter—every startup cycle generating data...

Your CIP system completed 847 cleaning cycles last month. Every cycle generated thousands of data points—flow rates, temperatures, chemical concentrations, pressure readings, cycle times. That data told a...

A collapsed tube bundle in a heat exchanger blocked CIP flow by 80%—and it took weeks to find. The maintenance team checked pumps, valves, and spray balls multiple times before finally tracing the root cause....

A quality manager at a Vermont dairy plant watched auditors swab seven surfaces. All seven came back positive for Listeria monocytogenes—a resident strain linked to illnesses in 2021 and 2022. The cleaning...

When FDA inspectors arrive at your facility, they don't ask if your CIP system works—they ask you to prove it. A confectionery manufacturer in Ohio learned this lesson after a $340,000 recall traced back to a...

Every minute your confectionery line sits idle for cleaning costs you $500 to $833 in lost production. Every week, you're watching $15,000 to $40,000 evaporate during CIP cycles that might be running longer than...

At 600 bottles per minute, your labeling and vision systems have less than 0.1 seconds to apply, inspect, and verify every single label. When these systems fail, the consequences cascade instantly—mislabeled...

Your spiral mixer has been making that sound for three weeks now. A slight vibration that wasn't there before. A hum that changes pitch under heavy dough loads. You've been ignoring it because the mixer still...

When the FDA inspector walked into a Nebraska bakery in February 2025, the visit lasted three days. The fine lasted much longer: $576,439 across nineteen violations. Sixteen were classified as serious. Two were...

When FDA inspectors knock on your door, you have exactly 24 hours to produce complete traceability records. For sauce and condiment manufacturers juggling dozens of ingredient suppliers, multiple production...

In 2024, food recalls reached a five-year high with 154 contamination-related incidents filed with federal regulators. The Boar's Head listeria outbreak alone resulted in 10 deaths and forced the permanent...

A single mislabeled package of ground beef containing undeclared soy protein. That's all it took to trigger a 143,416-pound recall in 2025, costing one processor an estimated $10 million in direct costs alone....

Your yogurt line runs 18 hours a day, filling 240 cups per minute. At 3:15 PM, the vision system flags a label mismatch: strawberry labels are being applied to blueberry cups. By the time an operator responds,...

The smokehouse alarm triggers at 3:47 AM. Internal temperatures are dropping in a batch of 2,400 pounds of deli ham that's been cooking for six hours. Your maintenance team has 73 minutes before the product...

The steam gauge reads zero. The wort kettle sits cold. Twelve hundred gallons of mash wait in limbo while your maintenance team scrambles to diagnose why the boiler that worked flawlessly yesterday now refuses...

At 2:14 AM on a Wednesday, the mash tun mixer at a 15-barrel craft brewery in Oregon began emitting a subtle high-frequency hum that no one heard. By Thursday afternoon, the bearing had seized. By Friday...

At 2:47 AM on a Tuesday morning, the refrigeration compressor at a Wisconsin dairy processing facility failed silently. No alarm sounded. No notification reached the night supervisor's phone. By the time the...

The moment a sanitation supervisor at a regional bakery in Utah received that FDA Form 483, everything changed. Three critical observations cited inadequate hazard analysis for ready-to-eat bread products,...

Last month, a Wisconsin dairy cooperative lost $127,000 in 47 minutes. Their 250-HP homogenizer bearing seized during peak yogurt production. The bearing cost $890. The real invoice included...

If you're running a frozen food packaging operation and your OEE hovers around 55-65%, you're not alone—but you're also leaving significant money on the table. Industry benchmarks show that top-quartile food...

Last quarter, a confectionery plant in Ohio lost $340,000 in product recalls because their CIP cycle failed to properly sanitize a chocolate enrobing line. The problem wasn't the cleaning...

What if your next FDA inspection took 4 hours instead of 4 days to prepare for? What if your maintenance team had clear, written response times for every piece of equipment—and actually hit...

Last Tuesday, a quality manager at a regional condiment plant watched FDA inspectors pull up unannounced. Within 90 minutes, they'd requested sanitation logs from 47 different cleaning...

A plant manager at a Wisconsin dairy cooperative received a call at 2:47 AM. The aseptic filler had seized mid-run, and 84,000 gallons of organic milk were now racing against a biological...

It's 4 AM and your tunnel oven dropped 40°F mid-production. Three thousand loaves are now scrap. The vendor's emergency line goes to voicemail. When someone arrives six hours later, they discover a failed...

Dairy plants operate on unforgiving timelines. Raw milk has a 72-hour processing window. Pasteurized product must be filled, sealed, and cold-chained within hours. Critical fillers—aseptic, gable-top, bottle,...

The chocolate tempering line just went down. Your refrigeration compressor is running hot, and the batch of caramel centers you started three hours ago is now a $12,000 loss sitting in a holding...

Your new sanitation technician finishes their first allergen changeover unsupervised—and three days later, a customer complaint triggers an internal investigation revealing milk protein residue on the slicer...

Your production director interrupts the Monday executive meeting with alarming news: "The tunnel oven went down Saturday at 2:47 AM—we lost 14,200 loaves, missed three retail delivery windows, and the...

Your head brewer storms into the production meeting with alarming news: "The mash tun agitator seized during last night's batch—we lost 15 barrels of premium IPA and the gearbox needs complete replacement."...

Your plant manager bursts into the morning production meeting with devastating news: "The main ammonia compressor failed at 2 AM—we've lost 47,000 pounds of frozen product worth $892,000, and the FDA inspector...

Your head brewer rushes into the Monday morning production meeting with devastating news: "The glycol chiller failed over the weekend—we lost 12 fermentation batches worth $186,000 when tank temperatures...

Your environmental compliance manager rushes into the emergency operations meeting with devastating news: "The wastewater treatment system failed overnight—we're discharging effluent at 12,000 mg/L BOD when...

The retort alarm sounds at 6:47 AM—temperature deviation in vessel #3 during the cook cycle for your signature BBQ sauce. Eighteen pallets of product sit in thermal processing limbo: too far along to restart,...

The FDA inspector stands in your production area, tablet in hand, asking for maintenance records on the spiral mixer behind her. Your maintenance manager is somewhere in the back office, searching through filing...

Commercial bakery packaging lines present a unique optimization opportunity: equipment degradation manifests as increased energy consumption before it causes visible performance issues....

Thermal processing equipment represents the highest-risk, highest-consequence asset category in dairy manufacturing. When HTST pasteurizers, UHT systems, or regenerative heat exchangers...

Maria had been quality manager at Greenfield Dairy for eleven years when the call came. A mother in Phoenix was on her way to the emergency room. Her seven-year-old had eaten a cup...

It's 2 PM on a Friday before a holiday weekend. Your flagship IPA is flying off shelves, distributors are calling for more cases, and the packaging line just stopped. The filler's rotary...