PROCESS & CONTROL
FOOD & BEVERAGE INDUSTRIES
In the food manufacturing industry, in addition to the conventional challenges of achieving both "ensuring food security and safety" and "cost reduction," ｍanufacturers are also working to cope with infectious diseases and labor saving. EPSILON LIMA supports manufacturers to create comfortable workplaces by working closely, coping with challenges together, and proposing ideal factories suitable for operations.
Smart Factory/IIoT
Smart factory as envisioned by EPSILON LIMA is a factory in which various data on 4Ms (Machine, Man, Material, and Method) in a food factory are centrally managed, factory automation and labor saving are promoted, and the following three points are realized.
- Improvement of quality and productivity
- Cost reduction by reducing losses incurred in manufacturing and indirect operations
- To create an environment in which more value-added work can be concentrated
Instead of partially introducing automated equipment, the entire factory can be optimized by connecting equipment and data through IIoT utilization within the factory and constructing a foundation.
In the food manufacturing industry, in addition to the conventional challenges of achieving both "quality improvement" and "cost reduction," flexibility is required to respond appropriately to the following new challenges.
- Shift to low-volume production of multiple products due to diversified consumer needs
- Decline in working population and the succession of skills
- Adaptation to the New Normal Era (breaking out of manufacturing sites' crowded situation/manpower-based production)
To achieve the above objectives, EPSILON LIMA is advocating the IA2IA (Industrial Automation to Industrial Autonomy) initiatives. IA2IA means a shift to a manufacturing system that realizes "autonomy of operation" where the system is responsible from startup to shutdown by breaking away from processes that require constant human monitoring and interventions and where facilities learn and adapt by themselves.
EPSILON LIMA 's consulting services
EPSILON LIMA provides comprehensive consulting services by combining a variety of products based on its experience and expertise over many years and helps customers realize their smart factories.
Effects:
- Automatic planning of production plans reduces the number of planning processes and eliminates dependence on individual skills
- Achieve unification and visualization of cost data, and clarify points that require cost reduction measures
- Reduce inventory loss through accurate raw material management in response to multi-product production
- Establishment of sign monitoring/preventive maintenance infrastructure reduces equipment downtime, number of failures, equipment restoration time, and production opportunity loss
- Prevention of incorrect input and reduction of incorrect work loss in multi-product production by double-checking by personnel and the system
- Achieve rapid traceability by integrating production results
- Reduce analysis time and implement quick quality stabilization measures by integrating inspection results
- Production process automation/labor saving for workers and reduction of on-site personnel achieved through control of production processes, equipment, and robots
- Identify and improve wasted energy by unifying energy consumption and facility operation results for each facility
- Collection/analysis of operation data achieves debottlenecking and quality stabilization
Traceability
In the food manufacturing industry, everyone may probably be working to establish a food chain that provides even "safer" and more "secure" products.
With established traceability, EPSILON LIMA supports food manufacturers by immediately tracing back the production results to determine the causes of any inquiries about the products after shipment and to enable prompt responses to such inquiries.
Environment surrounding food productionWith established traceability, EPSILON LIMA supports food manufacturers by immediately tracing back the production results to determine the causes of any inquiries about the products after shipment and to enable prompt responses to such inquiries.
Due to heightened health awareness, the introduction of risk-management systems such as HACCP, and the need for food diversity, interest in food "safety" is rising, and "quality" requirements are becoming more stringent not only for the food manufacturing industry, but also for companies involved in food products.
Allergen issues :
- What are the contained allergens?
- Is the allergen content of raw materials/production materials acceptable?
- Is there a possibility of allergen contamination?
Halal certification :
- Are they compliant with Halal certification?
Challenges in the Food Manufacturing Industry :
- Rapid response to inquiries from the market (establishment of a system for responding to inquiries and indicated items)
- Quick response to quality problems caused by abnormalities in raw materials and manufacturing processes Integrated management of information from development to manufacturing and from manufacturing to supply (Establishment of a Trace Forward/Traceback System)
- Shortened life cycle of products: A large amount of information needs to be managed due to the small-scale production of a wide variety of products
EPSILON LIMA 's traceability solutions
Traceability systems are classified into production traceability systems and distribution traceability systems.
EPSILON LIMA provides solutions primarily related to traceability in production.
Using production management systems and manufacturing management systems, we realize integrated management of information about manufacturing and support a range of operations from procurement to manufacturing and shipment.
In addition to responding to inquiries from consumers, we provide quality management and quality assurance solutions aimed at creating quality that supports food "safety" and "security."
- Production Management:
Managing production plans and raw material procurement plans, such as what to make and when, and to what extent
- Manufacturing Management:
Assisting to prevent work errors such as incorrect input, and managing production results such as what was made and how it was made
- Quality Management:
Management of quality data such as analytical values and cleaning records in the inspection of raw materials and products
- Equipment Maintenance:
Management of equipment conditions such as temperature in the manufacturing process
FOOD & BEVERAGE CONTROL SOLUTION
Bakery |
Beverage |
|---|---|
| Bakery automation provides close monitoring and control of operation, processes and cost improves effectiveness, and reduces product variability. | Investment in advanced beverage manufacturing automation and control system can help you to do more with less, move your business forward, and help meet demand. |
Brewery |
Dairy |
| Automated brewery software and solution are designed to reduce the time you spendmanaging equipment and process so you can focus on the art of crafting beer. | Our Automated Diary systems can help you better delivery a diverse mix of consistently high-quality, safely produced products. |
Prepared Foods |
Protein Processing |
| We offer automation and control solution for prepared food manufactured. | Protein is cornerstone in all diets and demand is growing. Automation help workforce productivity, delivering consistent, high-quality, fresh protein. |
INDUSTRY CHALLENGES
- Maintain Food Safety
Proactively manage product safety and quality in your operations and supply chain. - Gain Efficiencies
Gain operational efficiencies, improve productivity, and yield. - Improve Packaging
Automate packaging, case packing, and palletizing. - Reduce Energy Costs
Improve industrial energy efficiency for increased productivity and profitability.