As a farmer-owned dairy cooperative, Dairy Farmers of America (DFA) focuses on moving milk from farm to table and supports the processes required to produce quality products. The cooperative supports nearly 40 dairy brands across the U.S. A necessary component of quality is ensuring CIP processes are effective and efficient. With the help of Ecolab’s AI-enhanced CIP IQ software, partnered with 4T2 Sensors and its fluid-sensing technology, DFA says it can fix and optimize CIP procedures and save money at the same time.
“Ecolab CIP IQ has helped multiple plants within Dairy Farmers of America (DFA) to identify and troubleshoot CIP system issues. When properly monitored, the system can be used as a predictive tool to avoid product nonconformance events. Additionally, Ecolab CIP IQ has been crucial to DFA in identifying opportunities for water and chemical cost savings,” says Micah Purella, Senior Director of Quality Assurance for DFA Dairy Brands.
Ecolab’s CIP IQ digital solution is designed to help food and beverage companies maximize product quality and safety. The technology uses AI-driven insights to help provide a real-time view of CIP performance with wash conformance scoring, consumption reporting, and critical exception alerts. For example, Precise Wash, a module of CIP IQ, uses real-time soil load data from sensors to help determine when active cleaning is complete.
Furthermore, CIP IQ’s integration with 4T2 Sensors’ technology allows IQ to leverage real-time fluid sensing alongside its 3D Trasar technology to reduce water consumption and increase efficiency for food and beverage manufacturers, two benefits DFA says it gained from using the complete IQ tool.
DFA’s experience and results with CIP IQ
When it comes to using CIP tools, DFA says it is satisfied with IQ’s data feedback and resource monitoring.
“Ecolab CIP IQ is more advanced than other systems at providing real-time data in the form of nonconformance alerts and trending over defined time periods. The ability to easily track and trend chemical concentrations, temperature, time, and flow rate has been extremely beneficial in waste reduction initiatives. The program is intuitive, and the metrics gathered to trend CIP performance are valuable and concise to aid in decision making,” states Purella.
Time is of the essence with CIP processes and tools, and while IQ’s installation naturally requires a setup period, DFA is satisfied with the efficiency of the system’s deployment.
According to Purella, “Ecolab has made the setup process of CIP IQ systems efficient and alleviated the time required on part of the customer. The initial wash performance and parameter setup will require time commitment by both Ecolab and the customer, but after all refinement, the system requires minimal time obligations from customers.”
When it comes to measurable outcomes and benefits, Purella says Ecolab’s CIP IQ has saved DFA thousands of dollars in chemical and water savings, as well as product loss savings from tracking and alerting non-conforming washes.
“Ecolab CIP IQ aides to identify areas in the CIP system where issues may go unnoticed,” Purella adds. “The system allows companies the visibility needed to optimize washes, which in turn allows for increased efficiency within the manufacturing locations.”
