Built for High-Speed
Packaging Operations
Tight changeovers, strict hygiene protocols, and constant compliance pressure. Ottovis gives your operators instant access to SOPs, allergen controls, and CIP procedures—without leaving the line.
30%
Faster Changeovers
50%
Less Contamination Risk
40%
Less Search Time
85%+
OEE Target
The FMCG Pain Points
High-speed lines demand split-second decisions. Fragmented knowledge costs you time, money, and compliance.
Line Changeovers
The Problem
20-60 minutes lost per changeover while operators search for format change procedures
Impact
£5K-£15K lost production per changeover
Allergen Management
The Problem
Cross-contamination risk when operators can't find the right cleaning procedure fast enough
Impact
Product recalls cost £500K+ and damage brand reputation
Complex CIP Procedures
The Problem
Multi-step Clean-in-Place sequences with precise timing. One wrong step = failed cleaning
Impact
Bacterial contamination or wasted cleaning chemicals
Regulatory Compliance
The Problem
FDA/BRC audits require instant documentation. Scrambling for logs wastes inspector time
Impact
Failed audits = production halts and certification loss
The Allergen Alarm at 2 AM
Line 3 is switching from regular biscuits to nut-free variety. The allergen contamination alarm goes off during cleaning.
Before Ottovis
55 min downtime02:15 AM - Alarm triggers
Allergen sensor detects contamination during CIP cycle
02:20 AM - Operator searches SharePoint
Finds 3 documents: "Allergen_Cleaning_v2.pdf", "Line3_CIP_OLD.docx", "Emergency_Procedures.pdf"
02:35 AM - Calls QA supervisor at home
"Is the 2019 procedure still valid? Do I need to re-run the full CIP or just the rinse cycle?"
03:10 AM - Line cleared and restarted
Re-ran full CIP cycle to be safe. 55 minutes of downtime.
£13,750 in lost production + supervisor woken up
With Ottovis
8 min downtime02:15 AM - Alarm triggers
Same situation: allergen sensor during CIP
02:16 AM - Operator queries Ottovis
Types: "Allergen alarm during Line 3 CIP—do I need to re-run full cycle?"
Ottovis (30 seconds): Allergen alarm during CIP indicates residual protein detection. Re-run rinse cycle only (steps 4-6) if sensor triggered during rinse phase. Full cycle only if triggered during wash phase.
📄 Allergen_Cleaning_SOP_v3.2 (updated Oct 2024) | 📊 Last similar: WO#48211
02:18 AM - Checks sensor log in Ottovis
Alarm triggered during rinse phase. Re-runs rinse cycle only (10 minutes vs. 45 minutes full CIP).
02:23 AM - Line cleared and restarted
Issue resolved independently. 8 minutes of downtime. No supervisor call needed.
£2,000 in lost production • Saved £11,750 vs. previous incident
85% Faster Resolution
55 → 8
Minutes downtime
£11.7K
Saved in this incident
No Call
Supervisor not woken
How Ottovis Solves
FMCG Challenges
Purpose-built for high-speed manufacturing with strict hygiene and compliance requirements
Instant Changeover Procedures
Complete format change instructions with equipment-specific steps, timing, and quality checks
Allergen Control & Traceability
Complete allergen management procedures with cleaning protocols and contamination prevention
CIP Sequences & Timing
Detailed Clean-in-Place procedures with chemical concentrations, temperatures, and cycle times
What FMCG Operators
Ask Ottovis
Real questions from food & beverage facilities with complete, source-linked answers
"Show me the changeover procedure from Product A to Product B on Line 3"
Changeover procedure Line 3 (A→B): (1) Complete flush cycle (20 min), (2) Replace format parts per checklist (parts location: Cage 3, Shelf B), (3) Adjust guide rails to 150mm width, (4) Run quality check sample (target: 98% fill accuracy). Last changeover: 35 minutes (WO#48921).
"What's the allergen cleaning procedure after processing peanut products?"
Allergen cleaning (peanut): (1) Full line teardown of product contact surfaces, (2) Pre-rinse with 60°C water, (3) Detergent wash (2% alkaline, 15 min), (4) Rinse until conductivity <50 µS/cm, (5) Allergen swab test before next product. Estimated time: 90 minutes.
"CIP procedure for Tank 5 after dairy product—chemical specs?"
Tank 5 CIP (post-dairy): (1) Pre-rinse 5 min (ambient water), (2) Caustic wash 2.5% NaOH, 75°C, 20 min, (3) Acid rinse 1.5% HNO3, 65°C, 15 min, (4) Final rinse until pH 6.5-7.5. Total cycle: 50 minutes. Chemical consumption: 25L caustic, 15L acid.
"Quality check steps for new batch of biscuits on Line 2"
Line 2 quality checks (new batch): (1) Weight check (target 25g ±0.5g, sample 10 units), (2) Moisture test (target 3-4%, sample every 30 min), (3) Visual inspection (breakage, color), (4) Metal detector validation, (5) Document results in QC log. Reject criteria: >2% out-of-spec.
"Where are the spare format parts for Line 3 packaging machine?"
Line 3 format parts stored in: Maintenance Cage 3, Aisle B, Shelf 2-4. Common parts: Guide rails (Shelf 2), Film rolls (Shelf 3), Sealing jaws (Shelf 4). Current inventory: 3 sets complete. Reorder trigger: 1 set remaining.
"Startup procedure for Line 1 after weekend shutdown"
Line 1 startup (post-shutdown): (1) Visual inspection (clean, no debris), (2) Lubrication check (bearings, chains), (3) Warm-up run empty for 10 min, (4) Adjust belt tension, (5) Run test batch (50 units), (6) Quality verification before full production. Estimated startup: 45 minutes.
See Ottovis answer your facility's specific questions
Book FMCG DemoFMCG Pilot
Results
Real KPIs from 8-12 week pilots at UK food & beverage facilities
30%
Faster Line Changeovers
Average changeover time reduced from 45 min to 30 min
50%
Reduced Contamination Risk
Faster access to allergen cleaning procedures reduces errors
40%
Less Search Time
Operators find procedures in 30 seconds vs 20+ minutes
85%+
OEE Target Achievement
Reduced downtime helps maintain target OEE levels
UK Biscuit Manufacturer - Pilot Results
Facility Profile
Key Improvements
Night shift operators now solve allergen alarms independently. We've cut supervisor call-outs by 75% and changeover times are consistently under 30 minutes. The ROI paid for itself in 5 months.
— Plant Manager, UK Biscuit Manufacturer
Built for
FMCG Compliance
Meet FDA, BRC, HACCP, and ISO requirements with complete audit trails and documentation
FDA 21 CFR Part 11
Electronic records and signatures compliance for FDA-regulated facilities
BRC Global Standards
British Retail Consortium food safety certification support
HACCP Compliance
Hazard Analysis and Critical Control Points documentation
ISO 22000
Food safety management system standard alignment
Audit-Ready Documentation
When FDA, BRC, or customer auditors arrive, Ottovis makes inspections painless. Pull up procedures, training records, and audit trails instantly—no scrambling for binders or outdated spreadsheets.
During Audits
Inspectors ask for a procedure? Pull it up in 10 seconds with full revision history.
Between Audits
Export compliance reports, document access logs, and training completion records.
Everything FMCG Operators
Need, One Search
From changeovers to compliance, Ottovis handles every operational scenario
Line Changeovers
Complete format change procedures with equipment-specific steps and timing
Allergen Management
Cleaning protocols, cross-contamination prevention, and verification steps
CIP Procedures
Multi-step Clean-in-Place sequences with chemical specs and cycle times
Quality Checks
Product specifications, sampling procedures, and acceptance criteria
Equipment Startups
Startup sequences after cleaning, maintenance, or weekend shutdowns
Shift Handovers
Handover templates with product status, issues, and pending tasks
Troubleshooting
Alarm diagnosis, equipment troubleshooting, and emergency procedures
Compliance Documentation
Audit trails, training records, and regulatory compliance procedures
Ready to Transform
Your FMCG Operations?
Book a 15-minute readiness clinic to see if your facility is a good fit for a pilot