FOOD & BEVERAGE INDUSTRY FOCUS TRANSFORMING RAW DATA INTO A DIGITAL ADVANTAGE


become ubiquitous in industrial environments. However, more sensors lead to more raw data, which presents issues of how to store and use the data. WiFi connected versions of motion and


temperature sensors themselves, when combined with cloud based storage, may solve the problem of data capacity. Vast amounts of data can be instantly communicated, stored and even analysed in the cloud, supplying useful information about traceability and production costs. Although almost 60 per cent of US food


and beverage manufacturers use the Internet of Things (IoT) to track and trace ingredients, less than half are using the advanced analytics the IoT makes possible. Cloud analytics, real-time monitoring,


Robert Glass, global food and beverage communications manager at ABB, explains the opportunities digitalization presents for the food and beverage industry, and says it all starts with putting the data generated by the plant to good use


W


ikipedia now has over 41,000,000 articles in 294 languages. If printed,


the English articles alone would form 2,512 volumes. Without digitalization and the widespread use of computers, this amazing wealth of knowledge would be impossible. So what opportunities does digitalization offer the food industry? Digitalization encompasses a


transformation in the way industrial environments work. For the food and beverage industry, this means companies can better comply with legislation through a transformation in areas including connectivity, smart sensors, traceability, cloud computing and monitoring. The Centre for Disease Control and


Prevention (CDC) estimates that one in six Americans suffer with a food-borne disease each year, and 3,000 deaths are attributed to food-borne illness. When lives are at stake there’s no room for error. Therefore, one of the largest concerns for


the food and beverage industry is using technology to find the best method to keep well maintained traceability records, showing the journey from farm to fork. Similarly, in the EU, the General Food


Law Regulation (EC) 2002 requires business operators to keep detailed records of food they supply to others and food they receive from suppliers. Digitalization aids this process by automatically collecting data such as food temperatures throughout production. Well-kept traceability records and sensor


data can increase transparency between businesses, producers and consumers. This allows plant managers to respond faster in emergencies and use evidence to rebuild


public trust following recalls. The processed and raw data can be


stored and recalled if there are any issues further along in production. Cloud technology has made it easy to store and analyse data, removing any potential for human error by raising alerts and red flags. Sensors can aid traceability in two ways:


they improve the accuracy of automated processes and they can track and store manufacturing data. Time-temperature history, physical shocks and other important credentials can be continuously measured and synchronised across the factory thanks to the IIoT. Sensors used during food production can


monitor products throughout the manufacturing and distribution supply chain. Sensors can form part of a device such as a smart container, or act standalone, depending on the needs and conditions of the manufacturing process. In the future, smart containers may be


able to self-diagnose and correct, for example by self-heating the container so that it remains above a threshold set out by health and safety guidelines such as Regulation (EC) 852/2004. A similar product, self-chilling beverage cans, produced by collaboration between Crown Cork & Seal and Tempra Technologies are paving the way. For the first time in 2016, over half of


the world's developing population had internet access. As internet access widens and the price of networked devices drops, the volume of network traffic will rise. Alongside this, the falling cost of


producing devices such as WiFi-enabled temperature sensors mean they will


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Raw technical data has its uses, but it is enhanced when the sensor data is combined with maintenance management or financial data


virtual commissioning and digital twinning — the ability to recreate the plant virtually — are just some of the techniques that can help reduce unplanned downtime, improve safety and mitigate emergencies. Crucially, plant managers can use the


cloud to adapt to seasonal changes in demand, flexibly altering production setups, factory layouts and reassigning staff without causing wider disruption. The huge amount of data produced by


the connected factory can be used for many purposes in the food and beverage sector. For example, understanding why one machine is running hotter than another, or why one is not picking as many products, can help operators understand machine efficiencies, and improve plant maintenance. Many plants are using their own mobile


Robert Glass, global food and beverage communications manager at ABB


networks to take monitoring to the next level. For example, on farms, sensors are used to monitor soil conditions, using the data to predict when animals are in heat and text the farmer with the information. Further down the production line, food retailers such as Ocado have built their own high speed 4G networks to communicate with thousands of robots. Raw technical data has its uses, but it is


enhanced when the sensor data is combined with maintenance management or financial data. It is this consolidation that allows the information to come into its own and be useful for prediction, past analysis and optimisation. Although many businesses will be wary


of the perceived complexity of undergoing digital transformation, it can bring about a true competitive advantage. Plant managers of the future should not only recognise the trend toward digitalization, but they should embrace the opportunities it brings.


ABB new.abb.com/food-beverage


PROCESS & CONTROL | MAY 2019 21


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