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The dairy sector is characterized by high cost sensitivity and mass production, while innovative packaging and a growing variety of flavors are increasingly shaping the market. To meet all general and customer requirements, digitalization is providing the dairy industry with new ways to optimize the entire value chain.
Based on our extensive range of products, systems and solutions designed specifically for the dairy industry, both process and discrete workflows can be optimally coordinated. This lowers costs while maximizing quality and increasing flexibility.
The Digital Enterprise enables manufacturing companies to streamline and digitalize their entire business process, seamlessly integrating suppliers into the mix. They can begin at any point of their value chain, from product design to service, and can extend digitalization gradually, depending on their current needs.
The first phase involves digitally developing a new product. The SIMATIC IT R&D Suite flexibly supports the recipe and makes it possible to run simulations in order to virtually optimize recipes prior to production. At the same time, it checks whether the new product meets all regulations. The packaging and labels are also developed and tested virtually with Teamcenter NX.
The second phase begins with digital production planning based on our COMOS engineering tool, which acts as a central platform where all data are consistently available. The plant is then tested and further optimized with our Tecnomatix Plant Design software to maximize throughput and availability.
SIMATIC PCS7 and the Totally Integrated Automation Portal (TIA Portal) quickly, flexibly and efficiently handle the mechanical, electrical and automation design, in both the bottom up and top down approaches, with integrated engineering. Engineering efficiency can be increased for the production process as well as for bottling and packaging in the manufacturing part through integrated workflows.
In phase 4, SIMATIC IT acts as a bridge to the actual production process, which is optimized continuously. The universal database makes it possible to easily connect the ERP system to the automation technology and thus increase transparency through detailed reports and overviews.
Relevant KPIs for the production line and the process part are displayed and evaluated by specific apps on the basis of the cloud-based, open IoT operating system, MindSphere. This facilitates new services such as predictive, preventive and error clearance services that generate real added value through higher plant availability.
Many of our products and solutions are already being successfully used in the food and beverage industry. Below is a selection of these applications.
Introduction of a laboratory information management system (LIMS) via SIMATIC IT Unilab
Automatic data collection for the numerous quality tests
10 to 25 percent less time required for testing with an efficiency increase of more than 15 percent
SIMATIC PCS 7 process control system supported by a standardized dairy library (Advanced Process Function technology package)
Integration of the entire automation system into the dairy’s control room
Long-term cost savings, since manual intervention was minimized
High productivity and efficiency through coordinated hardware and software technologies
Continuous data exchange with the controller for access to the latest data – for every employee
Intuitive operation with visualization of all processes on a central HMI panel