Our customer is a recognisable producer of jams, spreads, and condiments in the UK. With a long-standing commitment to quality, innovation, and sustainability, they continually look for ways to improve their environmental performance while maintaining the highest standards in food production.
The Challenge
In the production of peanut butter, a key part of the product range, purge sequences are necessary to ensure product integrity when transitioning between production batches. While essential, these purges can result in a significant amount of product waste.
Our client identified an opportunity to enhance their already proactive environmental practices by reducing the volume of peanut butter required during each cycle, without compromising on food safety or product quality.
As a manufacturer operating under strict food production guidelines, any new solution would need to integrate seamlessly with existing systems, uphold hygienic standards, and be robust enough for use in a highly regulated environment.
Our Solution
To support them in this initiative, Denca developed a bespoke software application that intelligently manages purge sequences.
At the heart of the system is a dynamic Purge Matrix, stored in a Microsoft SQL Server database, which determines the precise volume of peanut butter required for each purge based on the specific product transition.
Key elements of the solution included:
- A secure web-based application, accessible site-wide, with role-based access to ensure data integrity.
- Integration with existing PLC systems using Modbus communication, enabling real-time retrieval of purge data during production.
- Installation of a dedicated on-site PC hosting the web app, database, and communications services.
- Training is delivered to operators and supervisory staff, ensuring the system is used effectively and consistently.
The software intelligently balances efficiency with compliance, ensuring purge volumes are optimised while fully maintaining the hygiene and quality standards essential in food production.
The Results
The introduction of the Purge Matrix has enabled a significant reduction in product waste during peanut butter purging operations. This has led to:
- Measurable reduction in product loss and associated cost savings
- Enhanced environmental performance through reduced food waste
- Greater consistency and traceability in purge processes
Importantly, this improvement aligns perfectly with the client’s continuous drive for innovation and sustainability within the rigorous parameters of food safety compliance. By working collaboratively, Denca have delivered a smart, future-proof solution that supports both environmental goals and operational efficiency.
The successful implementation of the Purge Matrix stands as a testament to what’s possible when innovation and sustainability go hand-in-hand, even in the most tightly controlled manufacturing environments.
