Facilitating seamless interaction of dairy production processes

Dairy Manufacturing

Complete dairy technology solutions to meet your production requirements, from milk reception to finished goods

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.

Milk bottling facility speeds process
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Digital Enterprise

The holistic 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.

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Siemens offers the right solution for each step in the production process.
Learn more about our solutions for the dairy industry
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The production process in detail

 

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.

 

 

 

Our software tools in detail

 

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.

 

 

 

Our software tools in detail

 

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.

 

 

 

Our software tools in detail

 

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.

 

 

 

Our software tools in detail

 

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.

 

 

 

Our software tools in detail

Industry Services for Dairy

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.

Benefits:

  • 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.

Benefits:

  • 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!

Benefits:

  • 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. 

Benefits:

  • 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

Reduced production losses, high availability and reliability as well as fast support and professional trouble-shooting are required by modern production.

Benefits:

  • Defined response and on-site time
  • Increase of machine availability
  • Reliable planning
  • Asset reduction on stock and cost reduction
  • Planning ability and cost transparency

References

Our solutions in practice

Many of our products and solutions are already being successfully used in the food and beverage industry. Below is a selection of these applications.

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