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Today’s large-scale dairy producers must balance dynamic market demands that require speed, responsiveness and agility with perennial business demands of efficiency, profitability, and growth as well as regulatory compliance for cleanliness, quality and traceability. To meet regulatory and customer requirements, digitalization is providing the dairy industry with new ways to optimize the entire value chain. Our breadth of dairy production expertise ensures that your dairy workflow achieves perfect quality with increased flexibility and reduced cost. Both process and discrete workflows can be optimally coordinated.
That’s why when a major OEM of liquid level and net-weight filling and capping machines faced a challenge brought by a dairy and beverage processing customer, they chose Siemens. The company required a high-speed bottling and capping machine capable of processing up to 850 bottles per minute–one bottle every 70 milliseconds. The machine needed to be integrated with several other pieces of equipment on the production floor. Read about the successful implementation of Sinamics G120 drives in the article linked below.
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.
Siemens offers services that increase the availability and efficiency of Dairy & Juice 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.
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.
Migration of “mature” long-serving Automation Systems will prolong the life of your machines and increase productivity at reasonable costs!
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.
Reduced production losses, high availability and reliability as well as fast support and professional trouble-shooting are required by modern production.
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