Case Study: From Compliance Gaps to 99% Optimal Performance in Food Manufacturing
The Challenge: Hidden Risks in Chilled and Frozen Zones
A major UK food manufacturer operating across multiple chilled and frozen production environments was experiencing an all-too-common issue: cold zones that couldn’t maintain consistent performance.
Although their legacy monitoring system recorded temperature breaches, it offered no real insight. Alerts came in - but they lacked explanation, patterns, or prioritisation. With no way to compare performance across equipment or sites, the team was blind to trends. Worse, frequent false alarms created alert fatigue, and real risks were sometimes missed.
Operations teams were stuck in a cycle of reactive fixes, while compliance demands continued to rise.
They needed a solution that could go beyond logging - one that could deliver visibility, intelligence, and optimisation.
The Sematics® Solution: Performance Intelligence for Every Zone
Sematics® deployed a fully integrated monitoring platform across the facility, tailored to the realities of food production: multiple zones, variable usage patterns, and strict temperature requirements.
But the shift didn’t just come from installing better sensors. It came from turning monitoring into insight - and insight into action.
Key Improvements Included:
| Feature | Impact |
| Smart Sensor Architecture | Deployed in chilled storage, blast chillers, and prep zones - ensuring complete coverage with minimal noise. |
| Live Performance Dashboards | Operators could instantly view zone-level status and asset trends across the facility. |
| Refrigeration Scoring Engine | Equipment was automatically graded on range stability, excursion history, and response to demand. |
| Incident Management Workflows | Excursions triggered automated escalation, response logging, and compliance documentation. |
| Root Cause & CAPA Logging | Teams could trace, investigate, and improve - not just acknowledge alarms. |
| Scheduled Sign-Offs & Reporting | Weekly and monthly compliance logs with digital approvals built in. |
Results: A Rapid Shift in Operational Confidence
Within just 3 months, the platform identified two consistently underperforming refrigeration units. Using performance scores and deviation history, the team made informed decisions to repair, reconfigure, or replace them.
By 6 months, optimal performance increased from 73% to 94% across all monitored zones.
By 12 months, the site reached 99% optimal performance, with audits and incident logs always at hand.
Highlights:
- Significant reduction in false alarms - improving response times and trust
- Fully auditable incident records, with root cause and preventative actions logged
- Facility-wide visibility from a single platform - unifying compliance and asset management
- Evidence-based maintenance decisions replacing guesswork and assumptions
Before Sematics®, we knew when temperatures went out of range - but we didn’t know why. Now, we can predict performance issues before they happen.
Head of Operations, Food Manufacturing
Why It Worked
Sematics® didn't just digitise compliance - it operationalised performance.
The platform empowered the team to:
- Spot trends
- Track deviations by zone or asset
- Focus on the issues that matter
- And prove it all in audits
From reactive to predictive. From incident logging to performance improvement.
Sematics® delivered what food manufacturers need most - control.
To learn more, visit sematics.com