SIG is set to deliver the first integrated APM (asset performance management) and FSM (field service management) digital solution for the food and beverage industry. Developed in partnership with GE Digital, the Plant 360 Asset Management will feature a range of on-demand digital services designed to help manufacturers reach new levels of efficiency, productivity and connectivity in their operations.
SIG Plant 360 Asset Management is being co-developed with GE Digital in response to increasing demands in the food and beverage industry, particularly the need for higher productivity, quality and uptime. With this innovative and integrated solution comprised of GE Digital’s APM and ServiceMax’s FSM software, SIG will offer state-of-the-art digital tools to help its customers boost production, reduce downtime and ensure even greater quality to meet ever-changing consumer needs.
“Equipment manufacturers like SIG are increasingly leveraging Industrial Internet of Things solutions to differentiate themselves through superior after-sales service,” said Dan Lohmeyer, SVP Digital Product Management at GE Digital. “GE Digital’s Asset Performance Management and ServiceMax’s Field Service Management software help OEMs ensure their installed base of equipment is performing optimally, and their field service resources are managed efficiently. Our integrated solution allows SIG to detect and correct potential equipment issues in advance, before they result in unplanned customer downtime, delighting end-customers through improved OEE and driving improved NPS scores for SIG.”
A modular solution for maintenance
Plant 360 Asset Management is a modular solution designed to improve filling line reliability and availability while reducing costs. The Connector module enables the collection of digital data, which is loaded into the Predix Cloud – GE Digital’s cloud platform. From here, the data can be retrieved and evaluated at any time by SIG’s reliability engineering team. This module can also be used for SIG’s other Smart Factory solution, Plant 360 Controller, which enables manufacturers to monitor, control and optimise every angle of their filling plant operations.
The Smart Maintenance module is based on a software-supported holistic process called Maintenance & Asset Data Analytics as well as an Asset Management Cockpit. This ensures customers have one data source for all maintenance-related activities. The third module is called Smart Performance and is based on Asset Health Monitoring and Predictive Asset Data Analytics, which will provide an optimal platform for predictive maintenance in the future.
Optimising assets at every stage
Together, the three modules will enable higher asset reliability and availability. The solution ensures a direct link between condition-based and predictive maintenance alerts in APM and the work being scheduled for field-service engineers in FSM. This helps translate alerts into efficient action on the ground and ensures field service teams receive as much advance notice as possible of an issue, which they can address before it impacts a customer’s operations. For example, defined wearing parts will no longer be replaced at fixed maintenance intervals. Instead, they will only be replaced when the data indicates a certain degree of wear.
“With Plant 360 Asset Management, any changes to equipment strategies – for example, changing service intervals or maintenance steps – can be quickly reflected in new FSM work,” said Klaus Andresen, Senior Vice President Global Technology at SIG. “This improves the efficiency and effectiveness of the overall SIG maintenance process. Data captured by field-service workers is immediately available for analysis by APM and the global SIG reliability engineering team, allowing us to better and more quickly detect emerging issues and trigger preventative steps.”
SIG Plant 360 Asset Management is being launched for the first time in the Middle East with Almarai, one of Saudi Arabia’s largest food and beverage producers, as start of the global rollout.
Robert Ross, Manufacturing Manager Dairy and Juice at Almarai: “Digital Solutions are vital for us to analyse exactly what is happening in our plant and going forward to produce reliably. The aspirational partnership with SIG & GE will greatly help us in root cause analysis and in providing valid answers. This will ensure reliable production and to improve our OEE. We are very proud to be an early adopter of this cutting-edge solution.”Plant 360 Asset Management is one of several value-added solutions within SIG’s Smart Factory segment, which is designed to help manufacturers meet the challenge of increasing output and driving down costs in today’s competitive environment. The solution-driven Smart Factory platform aims to deliver IoT-enabled systems and technical services that transform filling plants into connected factories that offer the highest efficiency, flexibility and quality.
Unlocking the potential of connected packs
Solutions in connected packaging
With the support of SIG’s Connected Pack solutions, Brazilian dairy producer Languiru Cooperative has become one of the leading market players in the southernmost state of Rio Grande do Sul at a time of increasing competition and growing consumer demands. And to reaffirm its ongoing partnership with SIG, Languiru has commissioned another filling line from SIG.
Since implementing SIG’s pioneering digital solutions in 2017, Languiru has experienced a number of achievements. These include greater consumer trust and quality perception in their products, improvements in productivity, and now a market share growth that puts Languiru in the region’s top three largest dairy producers, according to Kantar WorldPanel. Before its traceability project with SIG, Languiru was the fifth largest dairy producer in Rio Grande do Sul.
Languiru operates in an environment where consumers are demanding more transparency in business, more product information, and more digital communication with their brands of choice. Alongside this, food and beverage producers like Languiru need to reliably manage products in their supply chain, and ensure visibility at all times to guarantee efficiency, control and safety.
As a response to these market challenges, Languiru set out to create a new dairy concept: Qualidade do início ao fim, which translates as “Quality from beginning to end”. But in order to realise this promise, the producer needed a solution that not only makes product data easily accessible, but can also drive consumer engagement, trust and brand recognition.
Quality from beginning to end
To technically realise its vision of “Quality from beginning to end”, Languiru turned to SIG’s integrated Connected Pack platform – a drive to deliver unique digital coding technologies and track-and-trace solutions that ensure 100% connectivity and transparency together with greater digital interaction and engagement.
“Languiru has always stood out for the quality of its products, and the use of SIG’s innovative Connected Pack technology has enabled us to strengthen this perception and show consumers that Languiru milk is truly differentiated,” said Languiru Cooperative president, Dirceu Bayer.
As of May 2017, Brazilian consumers of five different Languiru milk products can access quality data, brand information and interactive quizzes directly on their smartphones by scanning a unique on-pack QR code. This QR code system was unprecedented in the food industry when it launched and proved SIG’s early commitment to the connected packaging trend.
“We have no doubt that with SIG we have a greater competitive advantage within the market compared to many other brands,” added Languiru’s Bayer. “SIG understood our demands and developed a tailor-made solution for Languiru that demonstrates quality and therefore adds value to our brand.”
Adding value throughout the supply chain
With a direct link to consumers, Languiru also has the opportunity for digital marketing activities, such as games, quizzes and promotions. In addition to this, in-line monitoring capabilities and vast data collection in the product journey has enabled Languiru to optimise production and logistics, and manage quality risks more proactively. The process of product traceability in the supply chain has now been reduced from five hours to five minutes, making recalls significantly easier. And in 2018, Languiru recorded a productivity improvement of more than 5% at its dairy plant, resulting in less waste and improved costs.
Languiru has also commissioned a third SIG filling machine. This new line ensures that 100% of Languiru’s long-life milk and chocolate milk product Chocolan has surgical traceability with unique QR codes securing end-to-end traceability for consumers and Languiru.
“For SIG, our greatest achievement is the success of our customers. Being part of the growth of Cooperativa Languiru and its consolidation as a market leader in long-life milk in Rio Grande do Sul is very gratifying and shows SIG’s commitment to be not only a supplier but a solution partner,” said Ricardo Rodriguez, CEO of SIG Combibloc Americas.
Traceability from the start for Origem
In August, Languiru launched a new premium milk called Origem. The milk is produced by only five farms, which all have the Good Practices of the Farm seal – a local initiative recognising dairy farms with best practices and processes – and are filled within 24 hours. The originating milk doesn’t have stabilizers, which maintains its purity, freshness and flavour characteristics.
With SIG’s Connected Pack technology, consumers can obtain information about the milk and the farm where it was produced, as well as information from producers, time of collection and satellite images of the farms.
Unique QR codes tied to the originating milk, as well as Languiru’s regular line, offer detailed information on factory quality tests and support traceability all the way to the shelf. This means Languiru can offer consumers an even more premium product with differentiation for those seeking a product of proven quality.
SIG’s Connected Pack is one of three value-adding segments that are part of its Value Proposition to help food and beverage producers meet increasing industry demands. Other solution-driven segments available include Product Innovation & Differentiation, and Smart Factory.
High transparency and gloss
New cpp film supporting circular economy
Coveris, a European manufacturer of flexible packaging solutions, is launching a new, sustainable and high-performance version of its CPP film. The latest invention is a cast polypropylene film (CPP), the Coveris Print Layer (PP CPL), designed for flexible packaging of a wide range of food, pet food and non-food products.
With its improved structure, it offers outstanding stiffness that perfectly protects the product from external damage. The key factor behind CPP’s excellent performance is the ability to withstand re-shrinking at high temperatures (0% at 150°C). In addition, the mono-material is retortable and provides strong heat-seal resistance up to 180°C.
Thanks to its 100% PP based structure, it successfully minimises material waste and thus underlines Coveris’ commitment to the circular economy. “In summary, our latest film solution outperforms the standard CPP film’s characteristics and compensates some of the disadvantages the manufacturer experienced in the past. By combining the benefits of normal CPP and BOPP film, it offers ideal properties for flexible packaging of food, pet food and non-food products on the market,” comments Jan-Torsten Vollmer, Head of R&D and Quality Management at Coveris Kufstein.
The new Coveris Print Layer is also perfect for polypropylene laminates. It offers high transparency and gloss, which help brands boost their presence on the supermarket shelves. The new CPP film is available for both flexo and rotogravure printing, which ensures that the graphics catch the customer’s attention.