Sidel has launched Qual-IS, its new digitally intelligent solution to merge all activities related to packaging quality control – laboratory, traceability and sampling.

Qual-IS is accessed through mobile, desktop or human-machine interface, installed on production lines and across laboratory facilities.

The six key components are a sampling plan, laboratory management, traceability, hazard analysis and critical control points (CCPs), calibration certificates and quality status.

Before commencing production, the bottler chooses what the CCPs will be, and what happens if they are not met.

Each bottle is allocated and printed with a unique code for traceability, which holds all the information connected to that bottle throughout its manufacturing life, including preform and cap used, product recipe, production process parameters critical factors, events and alarms.

Lab microbiologists will be able to access all information associated with individual bottles by scanning the unique code previously printed. This will indicate which quality control tests are required and the value of each CCP. Information is presented in a data dashboard and reports are customisable.

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Qual-IS comes pre-loaded with both tailormade and pre-designed sampling patterns which are based on a statistical approach. Using data intelligence, these sampling patterns will automatically adjust following the results of microbiological tests and adapt to different production lines.

A calibration map can also be created for equipment used across the aseptic production line to check the calibration certificates for each instrument linked to CCPs. Operators will be able to view the colour-coded expiration date system for each certificate in the app, or alter expiries.

The solution integrates quality control procedures across all elements of the aseptic production line from preform blowing to laboratory management.

Data collected through quality control tests at the production stage and in the lab are often stored in separate databases. Qual-IS will now unite these two data collection points.

Sidel recently upgraded its StarLITE-R Nitro range of bottle bases for still nitrogen-dosed products in 100% rPET (recycled polyethylene terephthalate) bottles.