In manufacturing complex products (food, beverages, chemicals), every batch is a recipe requiring pinpoint accuracy. Initial variations, mid-process instability, and final deviations compromise quality and increase waste. Without intelligent automation, manual control is slow, inconsistent, and costly.
The client faced critical challenges: improving process control to increase product standardization, reducing raw material waste, and cutting energy consumption. Batch-to-batch variability was unacceptable for their quality standards.
The manufacturer implemented digital advances based on Cyber-Physical Systems (CPS): digital specialists bridging the digital and physical worlds. Each CPS acts as a specialist in its function: a „drying specialist“ optimizes gas usage just as a chef adjusts temperature; a „control specialist“ manages humidity like an assistant regulating the environment. Each specialist ensures its sector operates harmoniously with the rest, and when integrated, they multiply overall results.
The integration of 10 cyber-physical systems across 6 different processes transformed the operation:
Product variability reduced by 49%. Lower variability translates to quality, savings, and safety.
An 8% reduction in fuel gas consumption and a 0.8% drop in steam usage.
A 5% decrease in raw material loss, eliminating time wasted on rework.
Operational interventions reduced by 17%.
Accelerated training times. What used to take over a year is now resolved in a few weeks.
The team achieved decision-making excellence backed by qualified data, enabling flexible and adaptable management. These CPS solutions have been supporting the manufacturing process for over 4 years, delivering digital transformation in practice.
Saripe® MES — Production management featuring automatic downtime detection, real-time OEE monitoring, and digital quality checklists that coordinate digital specialists.
