Article

Dairy & Industry 4.0: understand the relationship

Dairy

Traceability and yield control to produce more and better

Project Data

Much has been said about Industry 4.0 or the fourth industrial revolution, but how can we bring these concepts to a dairy today? How can we apply them and generate results? In this article, I try to answer these questions and share a little of my vision on the subject.

The term industry 4.0 emerged in 2011 in Germany as a result of a project uniting companies, universities and government. The idea was to modernize and improve the local industry, computerizing it and using the growing technology available.

According to a report presented by the Boston Consulting Group (BCG) there are ten technologies that characterize the 4.0 Industry.

The 10 Technologies of Industry 4.0

  • Intelligent robots, capable of interacting with other machines and with human beings, acting in a more flexible and collaborative way;
  • Additive and Hybrid Manufacturing, allowing production through 3D printers;
  • Virtual Simulation, this step allows processes and products to be tested and tested during the design phase, reducing costs with eventual failures and project time;
  • Horizontal and Vertical Integration of Systems, ERP, MES, SAP systems that integrate the entire production value chain, through analysis and decision making based on data;
  • Internet of Things, allows connectivity between the various devices, making access and control more flexible throughout the production process;
  • Big Data & Analytics, intelligent systems that identify process failures, improving production quality in real time, saving energy and improving efficiency in the use of all productive resources;
  • Cloud Computing, access to the database and support from any location on the planet, allowing the integration of systems and plants in different locations, sometimes distant. Control and support, in the same way, can be carried out globally;
  • Cyber Security, increasingly secure and evolved communication systems ensuring accountability of the production process (doing it right the first time, every time);
  • Augmented Reality, support that allows the user to act within cyber-physical systems (CPS) with an assertive vision and mentoring, indicating step by step all the necessary instructions and commands for a repair, or a new parameterization of the process. With industry 4.0 there will be an increase in productivity and a reduction in costs in manufacturing processes, with a better use of resources and energy savings, being therefore a system to assist in sustainable development.
  • Ethics, universal principles, actions that we believe in and do not change regardless of where we are. Thus, it is common today for ethics to be defined as "the area that deals with the study of moral norms in human societies. For industry 4.0 ethics is of fundamental importance in business transparency, culture between companies and in the formulation of consultancy prices.

It is important to emphasize that no matter how technology-based this revolution is, its purpose is to solve problems, improve efficiency and make businesses evolve! Interpreting the revolution as an evolution of industrial production systems, we can list some anticipated and already studied benefits, for example:

  • Increased visibility in the supply chain through traceability, allowing greater control over food and increasing safety;
  • Maximum performance by using all the knowledge of the production process (production data) and eliminating the centralization of information on people;
  • Improvement of indicator management;
  • Access the information in real time and anywhere, generating greater agility in decision making;

But how do you make dairy products make those gains without making big investments? Let's look at the current context. Today, dairy products are required by the SIF to measure and present the information of the production process. Large networks audit to make sure the company has efficient control of the production process and, finally, we have a consumer increasingly demanding and concerned about the origin of products. All this makes dairy products generate a lot of information. The problem is how to store it. Today, much of this information is found in paper sheets and Excel files. More time is spent organizing this information than actually analyzing it.

How do we begin to use the industry 4.0 concepts to achieve the benefits mentioned above?

We will highlight 3 technological pillars among those presented: Horizontal and Vertical System Integration; Big Data & Analytics and Cloud Computing (items 4, 6 and 7). Many dairies already have these technologies in their daily lives, and those who do not can invest little and have a return on this investment in a short time. In this context, let's take as an example the work that HMI Stefanini does together with Infinite Consultants and present iTrack: a system of traceability and production analysis, where all information is collected, organized and presented in a structured way for decision making based on data.

The workflow of the system works as follows:

  • Input of raw milk analysis information (storage balloon);
  • Batch creation defining which milk/whey or product batch was used as raw material and its quantities;
  • Selection of ingredients and yeasts used in manufacturing and their quantities (preparation of ingredients in the laboratory);
  • Physical-chemical and microbiological analysis of the product;
  • Launch of the manufacturing steps and variables followed in the production process;
  • Post the daily and batch losses;
  • Packaging;
  • Expedition;
  • Switch;

All steps and variables to be filled are created according to the actual plant flow, and the system is easily adaptable to changes and/or new products and production flows. These releases make the tool have very important information of the process. By centralizing and organizing them, we have the following reports:

Income Report: Each bar represents the average income of the day

Non-conformities: as we register a POP for each product, the system generates the non-conformities of the process automatically.

Context and Challenges

Ascending traceability: Identification of all ingredients and yeasts used for a batch. This generates agility and reliability in the Recall process.

Packaging Projection: The system knows the maturation date of a product. As soon as it is manufactured, the system makes a projection of when it will be packed.

Solutions Used and Equipment Provided

Process losses: Real time loss monitoring and identification of improvement points.

Prerequisites for using the system:

The system runs on an Amazon AWS cloud. Thus, no dedicated machine or server is needed for the application. The only thing needed is a tablet, computer or cell phone with internet access.

In conclusion:

Systems like iTrack scan everything that happens in the plant. It is a fully integrated system with market systems such as Magistech, Milk's Rota and SAP. This makes the dairy products enter once and for all the 4.0 Industries era, making them stand out in the market and obtain competitive advantages.

Among the gains that the tool can generate we can mention:

Measurable short-term gain points:

  • Decrease in income variability. An improvement of 2% in the yield generates an increase of 24 thousand per month in revenue (considering dairy products of 30 thousand, average price 13 kg)
  • Decrease in process losses;

Points that are difficult to measure but have value to the business:

  • Increased product quality and repeatability;
  • Decrease in non-conformities;
  • Ascending Traceability - Identification of all batches/products/brands that have been used to produce a product;
  • Data driven decision support;
  • Basis of the recall process;
  • Access in real time and anywhere;

IHM Stefanini and Infinite Consultores offer several services that will help you and your industry to keep up with market trends. Shall we talk?

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Solutions and Innovation Consultant

Pedro Couto

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Dairy & Industry 4.0: understand the relationship

January 25, 2021

published by

Solutions and Innovation Consultant

Pedro Couto

Much has been said about Industry 4.0 or the fourth industrial revolution, but how can we bring these concepts to a dairy today? How can we apply them and generate results? In this article, I try to answer these questions and share a little of my vision on the subject.

The term industry 4.0 emerged in 2011 in Germany as a result of a project uniting companies, universities and government. The idea was to modernize and improve the local industry, computerizing it and using the growing technology available.

According to a report presented by the Boston Consulting Group (BCG) there are ten technologies that characterize the 4.0 Industry.

The 10 Technologies of Industry 4.0

  • Intelligent robots, capable of interacting with other machines and with human beings, acting in a more flexible and collaborative way;
  • Additive and Hybrid Manufacturing, allowing production through 3D printers;
  • Virtual Simulation, this step allows processes and products to be tested and tested during the design phase, reducing costs with eventual failures and project time;
  • Horizontal and Vertical Integration of Systems, ERP, MES, SAP systems that integrate the entire production value chain, through analysis and decision making based on data;
  • Internet of Things, allows connectivity between the various devices, making access and control more flexible throughout the production process;
  • Big Data & Analytics, intelligent systems that identify process failures, improving production quality in real time, saving energy and improving efficiency in the use of all productive resources;
  • Cloud Computing, access to the database and support from any location on the planet, allowing the integration of systems and plants in different locations, sometimes distant. Control and support, in the same way, can be carried out globally;
  • Cyber Security, increasingly secure and evolved communication systems ensuring accountability of the production process (doing it right the first time, every time);
  • Augmented Reality, support that allows the user to act within cyber-physical systems (CPS) with an assertive vision and mentoring, indicating step by step all the necessary instructions and commands for a repair, or a new parameterization of the process. With industry 4.0 there will be an increase in productivity and a reduction in costs in manufacturing processes, with a better use of resources and energy savings, being therefore a system to assist in sustainable development.
  • Ethics, universal principles, actions that we believe in and do not change regardless of where we are. Thus, it is common today for ethics to be defined as "the area that deals with the study of moral norms in human societies. For industry 4.0 ethics is of fundamental importance in business transparency, culture between companies and in the formulation of consultancy prices.

It is important to emphasize that no matter how technology-based this revolution is, its purpose is to solve problems, improve efficiency and make businesses evolve! Interpreting the revolution as an evolution of industrial production systems, we can list some anticipated and already studied benefits, for example:

  • Increased visibility in the supply chain through traceability, allowing greater control over food and increasing safety;
  • Maximum performance by using all the knowledge of the production process (production data) and eliminating the centralization of information on people;
  • Improvement of indicator management;
  • Access the information in real time and anywhere, generating greater agility in decision making;

But how do you make dairy products make those gains without making big investments? Let's look at the current context. Today, dairy products are required by the SIF to measure and present the information of the production process. Large networks audit to make sure the company has efficient control of the production process and, finally, we have a consumer increasingly demanding and concerned about the origin of products. All this makes dairy products generate a lot of information. The problem is how to store it. Today, much of this information is found in paper sheets and Excel files. More time is spent organizing this information than actually analyzing it.

How do we begin to use the industry 4.0 concepts to achieve the benefits mentioned above?

We will highlight 3 technological pillars among those presented: Horizontal and Vertical System Integration; Big Data & Analytics and Cloud Computing (items 4, 6 and 7). Many dairies already have these technologies in their daily lives, and those who do not can invest little and have a return on this investment in a short time. In this context, let's take as an example the work that HMI Stefanini does together with Infinite Consultants and present iTrack: a system of traceability and production analysis, where all information is collected, organized and presented in a structured way for decision making based on data.

The workflow of the system works as follows:

  • Input of raw milk analysis information (storage balloon);
  • Batch creation defining which milk/whey or product batch was used as raw material and its quantities;
  • Selection of ingredients and yeasts used in manufacturing and their quantities (preparation of ingredients in the laboratory);
  • Physical-chemical and microbiological analysis of the product;
  • Launch of the manufacturing steps and variables followed in the production process;
  • Post the daily and batch losses;
  • Packaging;
  • Expedition;
  • Switch;

All steps and variables to be filled are created according to the actual plant flow, and the system is easily adaptable to changes and/or new products and production flows. These releases make the tool have very important information of the process. By centralizing and organizing them, we have the following reports:

Income Report: Each bar represents the average income of the day

Non-conformities: as we register a POP for each product, the system generates the non-conformities of the process automatically.

Ascending traceability: Identification of all ingredients and yeasts used for a batch. This generates agility and reliability in the Recall process.

Packaging Projection: The system knows the maturation date of a product. As soon as it is manufactured, the system makes a projection of when it will be packed.

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