How V-VAC Cold Storage Monitoring Solution helped a food manufacturer maintain precise temperature control for yeast storage, reducing spoilage and ensuring product quality.
The Challenge
Challenges in Maintaining Freshness In the food manufacturing industry, temperature precision defines quality. For products like bread, even the smallest deviation in yeast storage temperature can result in spoilage, inconsistency, or halted production. At one food manufacturing facility, maintaining yeast at its required 3C to 5C range became an ongoing struggle. Unmonitored door openings, compressor malfunctions, and a lack of automated alerts created unpredictable storage conditions. Each temperature fluctuation meant potential product loss, delayed schedules, and additional production costs. Before V-VAC was introduced, the facility faced: Frequent spoilage of temperature-sensitive materials such as yeast Air conditioning system failures going unnoticed Increased operational costs from unplanned downtime Decline in product quality and production reliability "Even a few degrees of temperature variation led to unexpected downtime and product losses." These recurring issues highlighted the need for a reliable, intelligent monitoring system capable of maintaining environmental stability and alerting staff instantly to any anomaly.
Our Solution
Our Approach to the Challenge To address these challenges, Volkkommen Industries deployed the V-VAC Cold Storage Monitoring Solution — a smart, IoT-enabled system built to ensure precision, control, and reliability in temperature-sensitive environments. This implementation combined advanced IoT devices with real-time analytics through the V-VAC platform. Key Components Implemented: DeltaT – Temperature Monitoring DeviceContinuously tracks temperature within the critical 3C–5C window, ensuring stable conditions and preventing spoilage. Zyphion – Equipment Status Monitoring DeviceMonitors the operational status of AC compressors and triggers alerts for downtime, overload, or power failure. Zyphion – Door Status MonitoringRecords each instance of door opening, including duration and frequency, helping minimize unwanted temperature fluctuations. All devices communicate directly with the V-VAC Cloud Platform, where live data from sensors is processed, displayed, and analyzed. The system automatically generates instant alerts via WhatsApp, email, and dashboard notifications, allowing the maintenance team to respond immediately. Turning Data into Action Beyond real-time monitoring, V-VAC empowers the facility with data intelligence. Every temperature change, door movement, or compressor event is logged, analyzed, and presented as actionable insights. Patterns such as frequent door openings or prolonged compressor downtime are easily identified. These analytics helped the facility: Detect inefficiencies in cooling behavior Schedule preventive maintenance before failures occurred Identify operator habits impacting system performance This shift from manual observation to data-driven decision-making transformed cold storage management into a smarter, proactive process.
Key Results
The implementation delivered measurable improvements across operations, efficiency, and cost reduction:
The Results
The results were immediate and measurable. After implementing the V-VAC Cold Storage Monitoring Solution, the facility achieved significant improvements across multiple fronts.
1. Reduced Spoilage and Waste
Accurate, 24/7 temperature monitoring eliminated losses from raw material spoilage and ensured stable yeast quality.
2. Enhanced Product Consistency
Stable storage conditions directly improved bread texture, taste, and consistency, reinforcing customer satisfaction.
3. Real-Time Alerts and Rapid Response
Instant notifications via WhatsApp, email, and dashboard allowed swift corrective actions, reducing downtime and ensuring uninterrupted production.
4. Compliance Confidence
The system maintained continuous documentation and ensured adherence to FSSAI and food safety guidelines, enhancing traceability and regulatory compliance.
5. Operational Efficiency and Energy Optimization
Automated monitoring reduced manual checks and unnecessary AC runtime, improving both staff productivity and energy efficiency.
6. Scalability for Future Growth
The modular design of V-VAC allowed easy expansion to other cold rooms or facilities, adapting to changing requirements without additional complexity.
Moving Toward Intelligent Operations
What began as a solution for temperature control evolved into a comprehensive system for operational excellence. With V-VAC, the facility gained not only stability and savings but also a powerful tool for continuous improvement.
Key outcomes included:
Noticeable reduction in material losses
Consistent production cycles and delivery timelines
Improved energy management and system reliability
Data transparency across maintenance and quality teams
By integrating DeltaT and Zyphion with the V-VAC analytics dashboard, the facility transitioned from reactive management to predictive precision — ensuring the freshness, quality, and efficiency their operations demanded.