Industry 4.0 in Food and Beverage Manufacturing
Calbee UK and New Belgium Brewing Co. are firms in the food and beverage manufacturing industry that apply industry 4.0 in their production processes.
1. CALBEE UK CASE STUDY
- Established in 2014, Leads-based Calbee UK is a manufacturer of healthy savory snacks.
- Prior to implementing industry 4.0 in its production, the company had limited staff and no existing manufacturing process or business process in place.
- Calbee UK implemented Epicor Tropos, an ERP system designed to leverage the technology pillars that are driving Industry 4.0.
Industry 4.0 Application
- The company applied Epicor Tropos to achieve “a high level of end-to-end traceability,” which is the ability to trace its products from raw materials to finished products, stock control, regulatory compliance, purchasing, and finance.
- The system is also used by Calbee UK to gain access control over the other stages in the manufacturing process, including “placing orders, product manufacturing, packaging, and labeling.”
- In just under five months of implementation, Calbee UK saw its “first product come off the production line with traceability, stock control, purchasing, and finance capability-all supported.”
- Tropos has enabled the company to automate and meet regulatory compliance, as well as achieve recipe-based production.
- The company is now able to process customer orders within 5 months.
2. NEW BELGIUM BREWING COMPANY CASES STUDY
- Colorado-based New Belgium Brewing Co. is one of America’s largest craft brewers.
- The company produces and distributes some of the top craft brews, including Fat Tire, IPA, Pilsner, wheat beers, and ales.
- Prior to implementing industry 4.0 in its production, New Belgium’s brewing operations were rapidly approaching their limits/capacity.
- Therefore, it digitalized its operations by implementing AVEVA Manufacturing Execution System (MES).
Industry 4.0 Application
- The system was implemented on New Belgium’s factory floor to offer real-time visibility into the performance of the plant and predict when it would require maintenance.
- AVEVA MES collects and analyzes New Belgium’s manufacturing data to understand “actual production capacity for predictable order fulfillment,” thereby maintaining production and sales targets.
- By implementing AVEVA MES, New Belgium reduced downtime by over 50%, while still improving overall product quality.
- This increased production from 150,000 cases/week to 200,000 cases/week, without raising costs.
- Overall Equipment Effectiveness (OEE) increased from 45 percent to 65 percent in just over two years