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PROCESS AUTOMATION REAP THE REWARDS OF MODULAR PRODUCTION
With features including a user-friendly interface that can be customised, COPA-DATA is certain MTPs can help unlock the full potential of modular production in the food and beverage industry
modular production allows for greater flexibility, scalability and customisation in the manufacturing process. This also helps reduce lead times and improve customer satisfaction by ensuring that products are always available and meet consumer expectations.
Mohammed Ahmed, regional sales manager at automation expert COPA-DATA, explains how modular production can help food and beverage manufacturers stay profitable and competitive in today’s climate
T
he Office for National Statistics (ONS) reports that, in 2023, UK food prices rose at the fastest rate in over 40 years. This growth also applies to Input Producer Price Index (PPI) data, which reflects the price that UK manufacturers pay for materials and fuels used to produce their products.
Food and beverage manufacturing is undergoing a digital transformation, and businesses must either adjust to these changes or risk falling behind the competition. A major challenge for manufacturers is keeping up with changing consumer demands and preferences, while also staying cost-effective to avoid knock- on price increases for the consumer. But what sort of preferences are we talking about? One example is that many consumers are looking for products that are organic, gluten- free and do not contain genetically modified organisms (GMO).
Food and beverage manufacturers must keep up with these changing consumer demands, but also do so cost-effectively while staying afloat in a highly competitive sector. This can be tough due to the rising costs of ingredients, labour and energy that all impact profitability. Traditional food manufacturing processes are often rigid and inflexible due to strict regulations. Manufacturers must meet high-quality standards and comply with a range of safety standards to guarantee their products are safe for consumption.
In the UK, food and beverage regulations are set by the Food Standards Agency (FSA). The Food Safety Act 1990 stipulates that food manufacturers should not include or remove anything from food, treat food in any way that can be damaging to people’s health, and serve or sell substances to a quality that is expected of consumers.
By understanding evolving tastes, dietary trends, and health concerns, manufacturers must develop products that meet consumer demands, drive sales, and foster brand loyalty in a dynamic marketplace. But how can they do this with often rigid and inflexible manufacturing systems? The answer lies in embracing the continuing digital transformation — and, particularly, by embracing modular production and module type packages (MTP).
Modular production technologies can add
efficiency and flexibility to production processes. MTPs, especially, are designed to be flexible and easily reconfigured, to produce different products or adjust for changes in demand and consumer preferences. The MTP approach is a manufacturing process in which a product is assembled from individual modules or sub-assemblies. These modules are pre-designed and pre- manufactured and can be combined and reconfigured in different ways to create a variety of end products. The concept of
By breaking down the production process into smaller, self-contained modules, manufacturers also reduce the need for excess inventory and streamline production processes. Additionally, modular systems are inherently scalable, which allows manufacturers to adjust and expand their product lines without needing to invest in new production facilities or equipment. COPA-DATA’s automation software platform, zenon, has been designed to enable manufacturers to implement modular production and MTP without any hassle.
MTPs can reduce production costs by 40 per cent, which is particularly useful when producing small batches. It allows manufacturers to, for example, produce product A on the first two days in a week, then switch to product B for one day, then transition the setup to produce product C for the remaining two days.
For example, the UK’s brewing industry has changed drastically in the last decade with the rising consumer demand for craft beers from independents, rather than large and global manufacturers. COPA-DATA’s zenon was developed to help manufacturers adapt to these changes while better utilising data to manage operations, handle recipes and apply data to production. zenon connects machines and plants through targeted data acquisition and creates the IIoT backbone for the future.
Let’s say a brewery needs to produce several types of beer with varying alcohol content, the process of switching between different equipment can lead to downtime and reduced efficiency.
This is where a modular approach can help. By using a zenon MTP, breweries can switch between distinct types of beer production, without the need for additional equipment or lengthy downtime.. This can increase flexibility, reduce costs associated with equipment purchases and manual labour, and optimise production processes.
COPA-DATA
www.copadata.com
FEBRUARY 2024 | PROCESS & CONTROL 9
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