the challenge
Dr. Squatch, a leading DTC brand known for its men’s personal care line, manufactures a number of products in-house. As demand surged, the production team sought to improve, while ensuring quality and compliance. But production was held back by:
- Paper-based batch forms that slowed down every step
- Manual visual checks for mixing and cooling, with no live data
- Disconnected QA workflows and inconsistent lot tracking
- Limited visibility into production trends or process deviations
the solution
Real-Time Visibility
Procense deployed plug-and-play IoT sensors on kettles and cooling tunnels to capture:
Live data captured from a 4–20 mA analog output from OEM PLCs retrofitted for mixing controls
Mixing speed data via 4–20 mA analog output from OEM PLCs
Live temperature readings from cooling tunnels
Time-stamped data for each batch step
Digital Batch Forms
Auto-versioning and instant formula updates across SKUs
Built-in lot tracking and QC retest logging
Operator prompts with clearly defined start and stop times
Shared Dashboards
Track batch status and yield in real time
Compare performance by shift, SKU, and operator
Instantly flag deviations and out-of-spec conditions
key results
We’re saving time and gaining confidence. It’s helping us grow production without adding more stress or paperwork
Leticia Rodriguez
Lead Operator