iniTECH is a premier, lean-centric engineering solutions partner that has transformed the Flavor & Fragrance manufacturing space for over twenty years. They specialize in everything from creating proprietary tools and software, to optimizing existing manufacturing processes, to executing end-to-end design-build services for new plants. Their clients range from smaller, specialized facilities to global powerhouse world-class manufacturers like P&G.

Last year, iniTECH expanded into new markets – such as CPG, beauty care and nutraceuticals – and they cannot wait to bring their time-tested, lean-centric approach to new clients across these vibrant sectors. They are currently prepping a roll out of twelve global sites for Mondelez.

Upon deployment, their clients typically experience an increase of 20% to 2000% in overall productivity and throughput. These achievements earned them a spot on Inc. Magazine’s 2023 Best in Business list; iniTECH was one of only three engineering firms to achieve this honor.

The secret to their success? iniTECH CEO Rich DiBernardo can communicate the north-star philosophy that guides his team in four simple letters:
CIAO

In Italy, the word means both hello and goodbye. At iniTECH, it means so much more. As an acronym it stands for: Compliance, Integration, Automation, Optimization. These are the four interlinked tent-poles of the lean-centric facility, with each tenet supporting the others in equal part.

“These are iniTECH’s four non-negotiables,” says DiBernardo, who believes the key to staying ahead of the curve in today’s fast-changing manufacturing landscape is adaptability – particularly by way of continuous self-reflection and sustained improvement. “No two design-build jobs are the same, so there can be no single, one-size-fits-all solution. Flexibility is the name of the game. However, the formula we’ve developed can only permit such valuable adaptability down the road if there are certain required elements organized from the very start.”

Compliance is first and foremost among these non-negotiables. All processes are fully interlocked; there is no workaround for this. Decades of experience in manufacturing compliance has fostered a deep understanding of NFPA regulations, ensuring all necessary manufacturing spaces meet requirements for Class-1 Divison-1 and Class-1 Division-2 accordingly.

“Team iniTECH works day in and day out to guarantee we provide and implement the best industry-leading services,” explains Tim Cunningham, VP of Conceptual Engineering. “This ranges from kosher to halal needs to comprehensive HACCP systems and beyond.”

Integration is the digital backbone; it is approached agnostically, so every client’s in-house systems and tools can work with all ERP systems, human-machine interfaces (HMI), lab and analytical equipment, and programmable logic controllers.

BatchMetrics is a world-class MES system initially designed for the food, flavor and fragrance industries – and is customizable to fit clients’ in-house programs or individual needs. It is the brain – a global connector that links every on-site system, interlocks compliance and automates work processes that typically require operator activity.

Adrian Sawicki, iniTECH’s Business Development Engineer, compares the software’s efficacy to E-ZPass and its automated toll collection system, where people no longer need to stop and manually input receipts. “EZ-Pass changed how we drive in this country, how we travel, how we map out a route. BatchMetrics can similarly change how we manufacture, how we build, how we game plan for the future.”

Automation saves time, manpower and money. This begins with basic process automation for all systems of operation. iniTECH has built out automation systems since the 1990s and never before have their clients been so worried about the shortage of willing, capable workers. This is why iniTECH works to automate many processes, not exclusive to automated pours.

Decades of repeated exposure has helped iniTECH quantify the results of countless combinations of equipment, systems, and integrations – and allowed them to pool this data as one massive resource. Now, they are harnessing the power of this data through artificial intelligence, with iniTECH AI.

“This exciting new tool is able to ingest massive amounts of data in order to output cutting edge solutions,” says Connor Boland, Data Analytics and AI Lead. “These recommended solutions serve as a guide to how we put together our 3D model for the expansion or build.”

“Team iniTECH works day in and day out to guarantee we provide and implement the best industry-leading services,” states Tim Cunningham.

iniTECH has an extensive library of 3D components which can be accessed in order to scrutinize past projects and build high-end 3D models accordingly. These models are helpful for many reasons, often exposing issues that would arise down the road after physical ground is broken. Team iniTECH believes that time, money and energy well spent now always pays off later.

Optimization means never settling for the status quo. There is always room for improvement, which is why iniTECH focuses so heavily on self-reflection and perpetual advancement.

“Our lean-centric approach is a journey. It’s a mindset,” explains iniTECH CFO Barbara Brzuchacz. “And it doesn’t just happen overnight. It can take years to realize sometimes. Luckily for our clients, we’ve put in the work and taken our lumps over the years, so they don’t have to.”

For example, during the mid-2000s, operators in the field were not happy with the mobile carts available on the market. iniTECH realized there was an opportunity to design and build their own line of carts that could better meet industry needs. Today, they offer thirteen specialized Mobile Weigh Cart designs.

Similarly, focused on maximizing vertical square footage rather than floor space, they built the Manual Robot, which collects the 60 most used materials in a plant and creates a one-stop shop for dosing and weighing. They also produced the Speedy Susan, which drives an excess of 250 pours per eight-hour shift, saving clients countless work process steps. Several other proprietary iniTECH-engineered tools are currently being developed and patented.

Team iniTECH is a nimble and vibrant group of experts. They are leaders in design-build, ready to make every client job – from the compounder to the finite scheduler to the CEO – easier, more efficient and interlinked. Team iniTECH has implemented hundreds of systems across the globe and is proud to work alongside eight of the top ten companies in the F&F marketplace, touching over 50% of the F&F products made worldwide.

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