Opportunities for increasing efficiency while at the same time reducing energy consumption are a frequently discussed topic, not least in the food industry, where productivity and profit margins tend to be low compared with other manufacturing industries. Pressure is also growing on prices in the bakery market, driven primarily by direct competition with discount retailers.

Meaningful key performance indicators, like the collection and correct evaluation of process- and production-relevant data, and efficient production are the determining factors for long-term corporate success. A fundamental basis for continuous improvement is data transparency. The embracing of automation technology is a key factor to enable a sustainable future business. The intelligent use of automation technology can make a significant contribution to ensuring a company’s competitiveness. Automation suppliers and machinery manufacturers need to promote a certain level of technical understanding and an open-minded attitude to technological innovations among customers.

As a longstanding partner for bakery technology, Mitsubishi Electric offers a comprehensive portfolio of automation solutions for bakeries. The range extends from the automation of inverter-controlled dough mixer applications to increasing the effectiveness of the overall system (Overall Equipment Effectiveness, OEE) up to production-enhancing robot technology.

Connecting islands of production

For example, using the MES-IT interface module, continuous communication can be realised simply even in a heterogeneous and legacy production plants by interconnecting island solutions. Fully Industry 4.0 compatible, the module acquires production data and test results at each stage of production and transmits them in real time to higher-level systems. These enable the systems to produce clear, meaningful evaluations by using Excel, SAP or pre-prepared reports. The link to existing systems can be established quickly without interrupting machine sequences.

Preventative maintenance

Preventive maintenance is another big issue in the food industry. If a machine fails without warning, the complete batch normally must be disposed of and the cost absorbed. Flexible maintenance and service concepts like FAG SmartCheck or the life-cycle software tool MAPS offer a remedy. FAG SmartCheck, for example, detects and reports the first vibrations in a drive long before any noise is emitted. Early warning of machine failure significantly reduces plant downtime and lost production.

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