Tackling Waste & Quality Control in High-Speed Candy Production
Karma Candy, a long-time confectionery manufacturer, has produced iconic treats like lollipops and candy canes for decades. Yet, even as a trusted brand, they faced challenges in maintaining consistent quality across their high-speed production lines.
For their lollipop line, defects frequently arose due to sticks being bent, improperly clamped, or candy cooling too quickly, causing sticks to break entirely. These quality control issues, compounded over three production shifts, threatened customer satisfaction and increased waste.
On the candy cane line, inefficiencies arose in the slab cooling process. Without precise timing, improperly cooled batches led to inconsistencies in the final product, creating costly delays and waste.
Historically, there was no centralized system to oversee and synchronize these processes. Workers often operated reactively, relying on manual quality control and process adjustments. This lack of coordination created a “lost output” scenario, where idle lines or improperly processed batches impacted overall efficiency.
Maneva as the “Commander in Chief”
Karma Candy partnered with Maneva to introduce an AI-powered platform designed to address these challenges head-on.
For the Lollipop Line:
Maneva installed a detection system to oversee the high-speed projection mechanism. The AI identifies defects such as bent sticks, multiple sticks clamped together, or improperly cooled candy in real time. The system’s rejection mechanism ensures defective lollipops are removed without halting production. This proactive approach reduces liability risks, including those tied to potential choking hazards.
For the Candy Cane Line:
The AI acts as a “traffic controller,” monitoring the cooling slabs to ensure optimal timing for flipping and folding. By functioning as a centralized “head chef,” the system balances the distribution of resources and timing across the production line. This minimizes idle periods and improves batch consistency.
Improved Quality, Efficiency, and Cost Savings
Although the system is still being deployed, Karma Candy anticipates several transformative outcomes:
Quality Assurance
- Reduced defect rates on the lollipop line
- Enhanced consistency across all batches, with defects flagged upstream for proactive adjustments
Operational Efficiency
- Reduced idle time and waste in the candy cane production process
- Improved worker coordination, supported by actionable insights from the AI system
Cost Savings
- Avoided $500,000 in equipment replacement costs
- Direct savings from reduced waste and optimized labor distribution
Safety Enhancements
- Minimized risks associated with defective lollipop sticks, reinforcing consumer trust in the brand
A Centralized System for the Future
With Maneva’s AI-powered platform, Karma Candy is transforming its operations into a streamlined and synchronized system. Acting as a centralized “commander in chief,” Maneva’s AI not only ensures product quality but also maximizes efficiency and minimizes waste.
This partnership marks a significant step forward in Karma Candy’s legacy of innovation, allowing them to deliver sweetness with precision and reliability.
