Fill-weight give-away erodes margin
Over-filling to stay safely above declared weight gives product away on every unit. Without live SPC, the buffer is set by feel and never tightened.
Industry solution
Food & Beverage
Zometric helps food and beverage manufacturers protect food safety and margin at once — sanitation PM and HACCP-aligned maintenance, statistical lot acceptance, batch and lot traceability, and SPC that reclaims give-away on fill and fill-weight lines.
Key standards
- FSSAI
- HACCP
- ISO 22000
- FSMA
- Reclaimed on fill lines via SPC
- Give-awayReclaimed on fill lines via SPC
- Forward & backward traceability
- Batch + lotForward & backward traceability
- Sanitation PM aligned to plan
- HACCPSanitation PM aligned to plan
- Line OEE and downtime
- Real-timeLine OEE and downtime
Food and beverage plants answer to FSSAI, HACCP, ISO 22000 and FSMA, where a traceability gap or a missed sanitation step is a recall risk, not just a finding. At the same time, fill-weight give-away quietly erodes margin on every high-volume SKU. Zometric digitizes both sides: sanitation and preventive maintenance keep food-contact equipment compliant and running, statistically valid incoming and outgoing inspection controls supplier and finished-goods quality, and SPC on fill lines tightens variation enough to cut give-away while staying inside declared-weight limits. Batch, lot and expiry tracking gives forward and backward traceability for fast, narrow recalls.
The reality on the floor
What slows Food & Beverage quality and uptime
Sanitation and PM tracked on clipboards
Cleaning and food-contact equipment maintenance recorded on paper is hard to prove to an auditor and easy to let slip on a busy shift.
Lot acceptance without statistical rigor
Incoming ingredient and outgoing finished-goods decisions made ad hoc, with no sampling standard or switching logic, accept risk no one can quantify.
Recalls are slow and too broad
When traceability is fragmented across systems, a recall pulls far more product than necessary because the genealogy from ingredient lot to finished case can't be reconstructed quickly.
How Zometric helps
The platform, mapped to Food & Beverage
Each capability is delivered by a module you can adopt on its own and expand from.
Sanitation & preventive maintenance
A CMMS with a food industry pack — sanitation PM, time- and condition-based maintenance, asset hierarchy and spares — keeping food-contact equipment compliant and uptime high.
Delivered byMaintenanceSPC to cut give-away
Live control charts and capability on fill-weight and key parameters, tightening variation so safety buffers shrink without breaching declared-weight limits — reclaiming margin on high-volume SKUs.
Delivered byIn-Process Quality & SPCStatistical lot acceptance
Incoming, in-process and outgoing inspection on ANSI Z1.4 / Z1.9 with automatic switching, every lot linked to supplier, PO, GRN and batch for full traceability.
Delivered byInspectionReal-time line OEE
Automated production logs, OEE and downtime detection with operator-logged causes — visibility into throughput and stoppages as they happen, not at end of shift.
Delivered byProductionModule mix
Where Food & Beverage teams start
One data backbone — begin with one module and add the rest as you scale.
Maintenance Management
Full-featured CMMS built for manufacturing, with predictive analytics.
Explore module →Production Management
Automated production logs, real-time OEE, downtime tracking, job scheduling.
Explore module →Incoming, In-Process & Outgoing Inspection
Statistically valid lot acceptance — replacing paper and Excel inspection.
Explore module →Standards & compliance
Built for the standards Food & Beverage is audited against
- FSSAI
- Indian food-safety compliance with digital, auditable quality and maintenance records.
- HACCP
- Critical control points monitored with SPC and sanitation PM evidence on demand.
- ISO 22000 / FSMA
- Food-safety management and preventive-controls traceability across ingredient and finished-goods lots.
FAQ
Food & Beverage — frequently asked questions
How does Zometric reduce fill-weight give-away?
Live SPC on fill weight shows exactly how much variation the line is running, so the over-fill buffer can be tightened toward the declared weight without breaching it. On high-volume SKUs even a few grams per unit recovers significant annual margin — a packaged-food customer reclaimed over INR 1.6M annually on a single SKU.
Does it support batch and lot traceability for recalls?
Yes. Batch, lot and expiry tracking links ingredient lots through production to finished-goods cases, giving forward and backward traceability so a recall can be scoped narrowly and executed quickly.
Can it track sanitation and preventive maintenance?
Yes. The maintenance module includes a food industry pack with sanitation PM and preventive-maintenance scheduling for food-contact equipment, with digital records auditors can review on demand.
What sampling standards are supported for lot acceptance?
ANSI Z1.4 (attribute/AQL), ANSI Z1.9 (variable/AQL), IS 2500 and c=0 zero-acceptance plans, with forward-computed Tightened/Normal/Reduced switching.
Start with your line
See Zometric on your Food & Beverage data
A 30-minute discovery call maps the right modules and standards to your factory — then a short pilot proves it on your real data.