Providing solutions to ensure bakeries and confectioneries run smoothly
From receiving raw ingredients to shipping the finished product, bakery and confectionary manufacturers require seamless, uninterrupted production process tools. In today’s market, the demand for product diversity is increasing while the expectation for quality foods has never been higher. Digitalization can help to create consistent and efficient automation from field level to ERP. When efficiency is high, production costs are low.
Siemens offers an array of solutions to make production control smooth sailing from beginning to end. That is why a leading manufacturer of confections chose Siemens to upgrade its plant operating systems. Through a single-process controller and plant-wide data transparency, the company was able to increase process efficiency, support new growth, and allow local maintenance, implementation, and support. Read the case study detailing their progress below.
Bakery & confectionary solutions in practice
Find out more about the specific solutions from Siemens for bakeries and confectionaries. See the major benefits offered by digitalization.
The comprehensive approach to optimize the entire value chain
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 production process in detail
The first phase comprises the digital design of new bakery products. The SIMATIC IT R&D Suite flexibly supports formulation and enables simulations to optimize recipes in a virtual environment. At the same time the new product is being validated to comply with all regulation. The packaging and labeling are also developed and tested in a fully virtual environment with Teamcenter NX.
The second phase starts with the digital planning of the production line wit Line Designer and validating the production capacities for bakeries with Plant Simulation. This enables to exercise different what-if scenarios and to design the optimal production line.
The Totally Integrated Automation Portal (TIA Portal) can quickly, flexibly, and efficiently handle the mechanical, electrical, and automation design. Integrated workflows increase the engineering efficiency for the production process as well as for packaging.
The production phase is the longest phase in the entire lifecycle of a plant. Most of the data is generated during this stage. This information is needed to ensure that the plant is always operated in the optimal range and to make the best business decisions. This requires the complete transparency and availability of this data across all corporate hierarchies. SIMATIC IT acts as a bridge to the actual production process, which is optimized continuously. This provides for the consistent exchange of data between the ERP system and production.
Specific apps based on MindSphere, the cloud-based open IoT operating system, can help to continuously improve production. This facilitates entirely new possibilities, such as predictive, preventive, and corrective maintenance concepts that offer real added value through greater plant availability.
Industry Services for Bakery products and Confectionary
Siemens offers services that increase the availability and efficiency of Bakery and Confectionary plants. Various services improve the system transparency and help to detect defects on electrical and mechanical components before they occur. They help to reduce energy and maintenance costs - you can schedule maintenance at the right time within the production cycle.
Energy Analytics can tell you where and why you are wasting energy, as well as advice you on what measures you can take to reduce the energy consumption.
- Cloud-based service requires minimal amount of your own resources
- Data analytics and energy expert know-how provide insights on existing energy saving potentials
- Cost savings of up to 15% are possible by reducing energy consumption
Industrial Network Validation helps to find hidden network problems before bigger production ussues occur. Additionally you get transparency about the potential network availability and your network is future-proof for Industry 4.0 challenges.
- Detection of weak points in the design, installation and data communication of the network
- Disclosure of network communication reserves for future extensions
- Recommendations for optimizing the network and the connected components
Migration of “mature” long-serving Automation Systems will prolong the life of your machines and increase productivity at reasonable costs!
- Higher productivity and production output with fewer unplanned shutdowns
- Lower life cycle costs, e.g. maintenance and spare parts costs
- Fit for the future due to SIMATIC Products with Open system architecture and unified Interfaces
Industrial Security Services help to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept.
- In-depth understanding of current security status
- List of proposed measures with budget estimation for realization
- Machines are hardened against unwanted changes
- Unwanted changes are stopped
- Logging & notification of change attempts in a central dashboard
Modern production requires fast support and professional trouble-shooting to reduce production losses and ensure high reliability and availability.
- Defined response and on-site time
- Increase of machine availability
- Reliable planning
- Asset reduction on stock and cost reduction
- Planning ability and cost transparency
Helping our partners find success
Many of our products and solutions are already being successfully used in the bakery and confectionary industries. Below is a selection of these applications.
Margarine optimization via SITRANS Flowmeter
Since 1899, the Vandemoortele bakery has been providing the high-value frozen bakery products.
The company owes its success to high standards of quality and innovative production technologies.
The company used SITRANS FC430, a Coriolis flowmeter, to optimize margarine utilization.
Pulling gum sheeter technology into the digital era
Global confectioner broke away from legacy, mechanical-based chewing gum sheeter machines.
Using an open architecture system produced significant reductions in engineering and implementation costs.
here was also a decrease in consumption, plant noise, footprint and spare parts.
Transitioning from candy reseller to manufacturer
A family-owned company, Queen City Candy had already invested nearly 35 years in building a thriving business.
Queen City wanted to transition from its role as buyer, packager, and reseller of top retail candy to candy manufacturer.
The company now produces approximately 60 percent of what they sell, and is still growing.