Food and Beverage Production, Filling Facilities

In food and beverage filling facilities, production speed, hygiene control, and batch traceability must be ensured simultaneously. Manual processes both increase food safety risks and reduce production capacity. This example describes the digital transformation process of a beverage filling facility.

Client Profile

Beverage production and filling facility. Daily production capacity of 50,000+ units, 70 employees, 3 filling lines.

Challenges Faced

• Lack of Batch Tracking: It was not clear which raw material batch went into which finished product. In recall situations, the entire production line had to be stopped.
• Filling Line Inefficiency: The causes and durations of line stoppages were not systematically recorded.
• Quality Control Delays: Laboratory results were received on paper, not integrated into production.

Solution Approach: Filling Facility Production Management

• End-to-End Batch Traceability: Batch-based recording of every step from raw material to finished product. Identification of affected products within seconds during recall situations.
• Line Performance Tracking: OEE measurement, downtime and root cause analysis, automatic maintenance alerts.
• Digital Quality Integration: Direct transfer of laboratory results to production, automatic line stoppage in out-of-tolerance situations.

Achieved Results

• Batch-based traceability time reduced from 2 days to 5 minutes
• Line efficiency (OEE) increased by 15%
• Quality-related production stoppages decreased by 60%
• Recall scope narrowed by 90%