Water Meter Upgrade: Boosting Efficiency & Reducing Emergency Calls in Commercial Bakeries
Cornerstone Automation implemented a water meter upgrade with the Intellifaucet system in a commercial bakery, reducing costly downtime and water waste while significantly enhancing production efficiency.
In large-scale commercial baking, every detail matters. When one bakery faced issues with a critical part of its dough-mixing process, Cornerstone Automation delivered a lasting solution that reduced costly downtime and provided substantial savings.
Baker’s Best relied on a water meter to precisely control the temperature and volume of water added to its dough. The outdated meter was causing frequent breakdowns, wasting resources, and leading to emergency repairs. When downtime began to impact production goals, Cornerstone Automation stepped in with a targeted, efficient solution.
Tackling Persistent Challenges in Dough Mixing
The bakery’s existing water meter was a roadblock to productivity. Designed with limited capabilities, it struggled to regulate temperature accurately, leading to frequent emergency calls and disrupting production. Each breakdown meant delays and significant water waste, as hot water was quite literally poured down the drain until the correct temperature was reached.
Understanding the bakery’s goals for efficiency and reliability, Cornerstone assessed the challenges. It was clear the existing meter lacked the capacity and precision needed for this high-demand application.
Innovative Solutions with the Intellifaucet System
Cornerstone Automation proposed that the bakery upgrade to the Intellifaucet, a modern water meter specifically suited for precise control of water temperature and flow. This updated system promised accuracy, efficiency, and most notably, zero water waste. The Intellifaucet was integrated with the bakery’s existing PLC (Programmable Logic Controller) to automate water temperature adjustments, ensuring each batch met strict quality standards without waste or downtime.
Starting with a pilot installation on one production line, Cornerstone’s team successfully demonstrated the Intellifaucet’s advantages. This pilot set the stage for further upgrades across other lines, allowing the bakery to enhance productivity incrementally without a significant upfront investment.
Real-Time Control, Reduced Downtime
The Intellifaucet’s precise control eliminated the need for constant manual adjustments, drastically reducing emergency repair calls. With fewer disruptions and more reliable equipment, the bakery team could refocus on maintaining product quality and throughput. By optimizing water usage, the Intellifaucet provided a rapid return on investment, with cost savings expected within six months.
The integration with the PLC allowed for real-time monitoring and simplified adjustments to the water mixing process, setting the bakery up for scalable improvements.
Lasting Results and Expanding Success
Following the success of the initial installation, the bakery plans to extend the Intellifaucet upgrade to additional production lines, a move that will enhance consistency across all operations. Cornerstone’s solution has been extremely impactful in improving the bakery’s dough-mixing process, driving operational efficiency, and positioning the company for long-term cost savings.
“Cornerstone Automation resolved our issues and provided a solution that enhanced our production process. The savings we’ve seen in water, energy, and downtime have been substantial, and we are excited to continue upgrading our other lines with their support,” said the production manager at a leading snack manufacturer.
If you’d like to read the full technical details of this project, download the complete case study below. For information on how to improve your facility’s efficiency, contact one of our engineers today to discuss how we can improve your operations.
