FOOD & BEVERAGE INDUSTRY

PRODUCTION OPTIMIZATION SOLUTIONS FOR RESPONSIBLE AND PROFITABLE OPERATIONS

TRENDS & ISSUES IN THE FOOD &
Global market forces are driving the continual evolution of the food and beverage industry. Consolidation, changing consumer preferences and increasing government regulations are dramatically impacting manufacturing and business strategy. In this fiercely competitive marketplace, you must offer a greater variety of products to meet consumer demand. At the same time, you must consistently and cost-effectively produce high quality products. To be successful , you need to focus on three key business issues: financial performance, sustainability, and brand equity.

FINANCIAL PERFORMANCE
In today’s global marketplace, where growth via acquisition is prominent, the key to sustained positive financial performance is the ability to understand and respond to consumer demands and competitive pressures while reducing cost of production.

BEVERAGE INDUSTRY
SUSTAINABILITY
Manufacturers want to have a positive impact on society and the environment. In addition, they want to turn sustainability challenges into business advantages. At the heart of a well-planned sustainability program is the belief that corporate investment in environmental and social responsibility must strengthen business performance to be successful. It must reduce environmental impact, achieve genuine economy in the use of resources, deliver a return on investment, and enhance the equity of your company. Through automation, three major sustainability objectives can be addressed: • Energy conservation and efficiency • Environmental responsibility and resource management • Safety for workers, machinery, processes and products

BRAND EQUITY
Customer loyalty is key to the success of your business, and maintaining customer loyalty is achieved through consistently manufacturing high-quality products, batch after batch. In doing so you add value to your brand. Therefore, protecting your brand equity is the core to financial strength,whether you are providing a local product, a high-value import, or a global mega-brand.

RESPONDING TO YOUR DAILY CHAL
COMPETITIVE SITUATION
Producing quality goods at the lowest possible cost is a major concern. Manufacturers are responding by identifying opportunities to improve production efficiency by using information systems that monitor operations and provide the capability to analyze results and determine the root cause of problems. The performance of assets is being improved as maintenance regimes are stepped up with improved support and better management of spare parts. And, you are reducing utility costs by installing information systems to monitor utility usage and identify opportunities to reduce costs. the gamut – from those who want healthier choices to others who want more convenient packaging and unique flavors. This increased volume and diversity of products is causing plants to design their lines based on shorter production runs with more changeovers. Meeting these demands requires operational flexibility. You must be able to easily add new products to the mix, change recipes on the fly and quickly implement new operational procedures. In addition, you must execute these changeovers while meeting high sanitation and environmental requirements. All of this has to be done smoothly to reduce time-to-market and limit the impact on operations.

MULTIPLE AND VARIED PRODUCTS
We live in a mass-customized society – one where consumers want it their way, with the quality and cost levels that they have come to expect. This creates significant pressure on food and beverage manufacturers who have the difficult task of meeting the ongoing evolution of consumer demand. Today’s consumers run

CUSTOMER SATISFACTION
While speed and flexibility are crucial, plants must also take the steps needed to ensure the highest quality possible. The key to maintaining brand equity, which is paramount in this industry, is product consistency — not only batch-to-batch, but facility-to-facility. To meet these

LLENGES consistency requirements, companies need advanced automation and information technology. This technology will help ensure that each batch and each operation is performed the same as the previous one, while simultaneously allowing operators to compensate for process changes and raw material variability that can impact the finished product. and in-process material through the entire facility to meet regulations and provide information if a product recall is required. You may be looking at the vulnerability of the networks, automation and information systems and implementing changes to protect your systems from intruders.

SUPPLY CHAIN INTEGRATION
Distribution is another key challenge. Many plants have evolved from make-to-stock operations to a demand driven model where the completed product is shipped directly to retail outlets. Products no longer sit in a distribution center after production. Each order passing through the plant is for a specific customer, and has a defined delivery date. This means you must manage operations to ensure that production orders are scheduled and executed on time, and delivery requirements are consistently met.

PRODUCT SAFETY AND SECURITY
As concerns over food safety and transparency continue to grow in the minds of consumers, you are required to improve the processes you have in place that monitor quality and track material through the facility. At each critical control point of the production process, systems are being installed to monitor operations in order to verify that operations have been properly executed. Systems are being implemented to track all raw

ROCKWELL AUTOMATION IN THE FOOD
To address your daily challenges, you need to implement automation and information technology to maintain product consistency and improve manufacturing flexibility and agility. However, that alone isn’t enough. Today’s truly successful manufacturers understand the value in integrating the factory from beginning to end, bridging islands of automation and carrying data throughout the plant to provide information for improving operations and reducing costs. The solution lies in an integrated information and control architecture offered by Rockwell Automation. It provides a foundation that enables flexible and agile manufacturing, while simplifying the exchange of real-time data between plant floor processes and information systems. Unlike traditional architectures, the Integrated Architecture™ from Rockwell Automation reduces the total cost of ownership by using a single automation infrastructure for the entire range of manufacturing applications.

INTEGRATED ARCHITECTURE
Integrated Architecture from Rockwell Automation uses sophisticated control, networking, and visualization technologies that help increase your productivity and reduce your total cost to produce your product. It allows you to install a single automation layer across the entire plant. This layer supports the needs of the batch operations (mixing, blending, mashing, fermenting, etc.); continuous operations (baking, cooking, forming and pasteurization); and discrete control in the packaging area, including machine control and motion. Integrated Architecture not only provides an information-enabled automation platform, but also provides the connectivity and control for all operations. This includes field instrumentation, pump systems, conveyor systems, steam and heating operations, valve control and process monitoring. It provides a single interface for programming changes and helps bridge the gap between the enterprise level and the plant floor by unleashing the relevant real-time information and exposing it to the people and systems that need it.

& BEVERAGE INDUSTRY
Control Room Receiving Material Handling

Shipping

Raw Material

Processing Packaging Batching/Blending

Rockwell Automation, the leading supplier of automation and information solutions to the food and beverage industry, has helped thousands of manufacturers meet challenges and gain a competitive advantage through better control of the factory floor and better integration of manufacturing information. As a comprehensive global service and support organization, we work with you to identify issues, perform evaluations and provide recommendations and project plans to give you an inclusive plan for success. In addition to Integrated Architecture, we provide the following automation & information solutions that complement Integrated Architecture, and help you solve your business issues.

INDUSTRY APPLICATIONS
• • • • • • • • • • • • • • • • • • • Asset Utilization Digital & Batch Blending Brewhouse Control ERP Connectivity Formula Management HACCP Management KPI Dashboard Packaging Line Performance Mixing Optimization Oven Optimization Tracking & Tracing Process Historian Recipe Management Regulatory Data Management Routing Scheduling/Order Management Power & Energy Management Solutions Production Management Batch Processing

AUTOMATION & INFORMATION SOLUTIONS
• Logix Controllers • PowerFlex® Drives • Essential Components • Process Solutions • FactoryTalk® Software • Intelligent Motor Control • Safety Solutions • Services & Support

REFRESHING RESULTS
The Rockwell Automation solution has helped us make a cultural change, bringing various departments together to communicate, collaborate and make improvements based on real issues,” said Cambron. “We’re already seeing the benefits of this analysis and we look forward to building upon it in the future.” ~ Clos du Bois “We’ve had a long relationship with Rockwell Automation and the majority of our applications are built on their control systems,” said Bramow. “Rockwell Automation listened to our problems and offered a solution that could be tailored to help us overcome our unique challenges. We also had peace of mind knowing that we had local support during and after the installation. We didn’t get that assurance from the other vendors.” ~PepsiAmericas “We selected Rockwell Automation not to just be a short-term, one-project supplier, but to be a long-term partner,” said Bramow. “This solution has helped strengthen our competitiveness in the industry and it has enabled us to take a more proactive approach to optimizing our operations.” ~PepsiAmericas We chose RSBizWare Batch to write the recipes for the milk preparation process and to control the clean-in-place (CIP) process for each tank,” said Kurio. “RSBizWare Batch follows the ISA S88 model, providing us with a ‘cut and paste’ approach to easily develop and reconfigure recipes. We are currently using eight milk recipes and 10 CIP recipes.” ~ Canbra Foods “We’ve been able to achieve additional savings through increased batch accuracy,” Kurio added. “On top of that, worker safety has improved since they no longer have to handle 30- to 40-pound bags of material.” ~ Canbra Foods “Our goal is to produce accurate, easy to use blending machines, with a good degree of reliability,” said Rasner. “Being able to include technology such as the ControlLogix controller enables us to meet this goal, and have the flexibility to expand and enhance the technology to meet the customer’s evolving needs.” ~ CRG Logics “Rockwell Automation took the time and energy to understand the challenge we were facing and offered us a variety of solutions,” Williams said. “While I expected the high product quality, I was impressed by the support and quick responses I received from the Rockwell Automation representatives. From that standpoint, it was the customer service component that truly cemented our decision.” ~ Diedrich Manufacturing

Publication FOOD-BR001C-EN-P – May 2008

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