1、Unlock the value of connectivity.Industry 4.0 Technical thought leadership paperFood safety&qualityHow to be and stay in control of food safety and quality.This paper explains how Industry 4.0 is helping manufacturers improve food safety&quality.It clarifies the fundamentals and shows how Tetra Pak

2、is helping our customers protect whats good.Part of a series of papers,this one will be of interest to anyone with a stake in the food and beverage industry and especially those looking for ways to respond to the increasing pressures they face as a result of changing business realities.2/Industry 4.

3、0 Technical thought leadership paperConnecting the food industry.Being in control of food safety and quality is essential for food and beverage brands.One mistake can lead to significant waste or worse loss of business.Quality control systems have remained largely untouched over the past decade.Now,

4、food and beverage manufacturers have the opportunity to align their quality strategies,operations and overall business strategy to enhance performance.Connecting the food industry gives organisations the ability to increase the volume,business output and transparency of relevant data to assure end p

5、roducts are of the desired quality 100%of the time to consumers.This enables quality to be a key strategic capability and differentiator for food and beverage manufacturers.At Tetra Pak,were working to make food safe and available everywhere,and supporting our customers on their journey to unlock th

6、e value of connectivity and data across the food industry.Together,we can discover new ways of meeting increasing demands from consumers,retailers,regulators and shareholders.3/Industry 4.0 Technical thought leadership paperIndustry 4.0Industrial practice has evolved by adopting new technologies and

7、 innovation since the Industrial Revolution over three hundred years ago.The term Industry 4.0 was coined to describe the fourth great leap in technology since the dawn of the industrial age.Industry 1.0Mechanical productionEnabler:SteamIndustry 2.0Mass productionEnabler:Electricity and division of

8、labourIndustry 3.0Automated production Enabler:Electronics and ITIndustry 4.0Digitalphysical production Enabler:Robotics,sensors,AI,cloud computing and blockchainFood safety&qualityEvery day,food and beverage manufacturers face demands for everhigher standards of food safety&quality from consumers,r

9、etailers,regulators and shareholders.Consumers expect that the packaged food they buy will taste good and be safe to eat or drink.Retailers need to make sure that the packages on their shelves are attractive and have not been damaged on their way through the supply chain.Regulators are demanding,and

10、 increasingly legislating,to make sure manufacturers meet everhigher food safety standards.And shareholders want to make sure their companys reputation,growth and profitability are not put at risk by excessive waste or costly quality issues.Current quality and food safety management practices fall s

11、hort of delivering reliably on these increasingly demanding needs and the industry is suffering as a consequence.Industry 4.0 the revolution in manufacturing made possible by the advances in technology around data collection,analysis and automations has the potential to address these demands and cha

12、nge the way the food and beverage industry assures quality,safe end products.4/Industry 4.0 Technical thought leadership paperHow is connectivity done today?Whilst complex supply ecosystems exist for food,the communication of data throughout the nodes is not synonymous.Too much data remains in forma

13、ts;paper,excel or legacy database systems for example,that are prohibitive for efficient sharing or performance is too poor for companies to be transparent.The consequences are poorer performance across all the nodes and suboptimum processes in the nodes.FarmNonfood suppliersPackagingSupermarketCons

14、umersFood serviceDistrubutionProcessingIngridient supplierThe complexity of supply ecosystems Value chain vs.EcosystemRather than using the term value chain,that implies a linear consistent flow of value generation from raw materials to consumers,an ecosystem would seem to better describe the realit

15、y for the food industry today.Ecosystem,implies a large series of multiple interaction points of intersecting value chains that alter and adapt continuously.This can be seen as an important consideration particularly when trying to capture data through provisioning connectivity.For example,raw mater

16、ials are purchased as commodities and therefore origins constantly vary,a single SKU can simultaneously follow different distribution channels and production processes.Each point in the ecosystem is referred to as a node just as with a fully distributed IT network.Communication between nodes can be

17、material and/or detail.5/Industry 4.0 Technical thought leadership paper Fig.2:Connect,Collect and Compare.the three Cs at the heart of an Industry 4.0 solutionIn requiring this complex ecosystem of interactions between many different entities,every node of this ecosystem is required to drive decisi

18、ons and communicate the process and/or result to the other parts.Without Industry 4.01,this increasingly complex ecosystem will only become less efficient and risk quality.Industry 4.0 needs to be leveraged to allow each part of the ecosystem to connect their processes,collect data,compare it to req

19、uirements,share that data and then make business decisions based off the comparison.Smart manufacturingSmart factoryIn a smart factory,quality and performance are monitored in real time so productivity is maximised,high quality maintained and costs are kept under tight control.Production staff are a

20、lerted to any issues so they can plan what to do to fix them before an unplanned stop occurs and food safety is compromised or waste is produced.CollectCompareConnectConnectProcessing AreaPackaging LinesOutbound LogisticsInbound Supply Chain1 For a comprehensive review of the opportunities Industry

21、4.0 offers the food&beverage industry,visit to download a White Paper and view a webinarpresented by Johan Nilsson,Tetra Paks Vice President Industry 4.0 Solution&Digital6/Industry 4.0 Technical thought leadership paperThe advances of food and beverage manufacturing are made possible by Industry 4.0

22、,which relies on nine foundational technologies,shown in fig.3.Of these,the following have the most impact on efforts to improve productivity:Artificial intelligence.Neural networks running at the edge in IIoT sensors automatically interpret multivariate datasets and decide without human interventio

23、n whether a process is running correctly or not.These results and the updated learning from the growth in analysed data can then be communicated to data lakes in the cloud for more advanced resource intensive analysis.The goal of these data pipelines is to provide more data to feed predictive qualit

24、y models so they may learn more and increase their accuracy and efficacy.Augumented reality(AR).Use of wearable devices and intelligent vision systems to support operational personal in active quality decision making,for example when viewing the unique identifying code on a package through an AR hea

25、dset e.g.Microsoft HoloLens,additional quality data available is displayed.Industrial internet of things(IIoT).Monitoring key parameters,such as the temperature,pressure or flow rate at a critical point will allow a manufacturer to assure a stable process and quality output.Industry 4.0 has advanced

26、 sensing technology and made possible the ability to collect and analyse huge volumes of data generated at the sensor(edge)so,a manufacturer can monitor and control the quality of their production in real time.While blockchain technology is maturing,we see that it has the potential to be a tenth fou

27、ndational technology with relevant applications for food safety and quality.Being able to securely store and share in a permissionless manner sensitive quality data across independent nodes(businesses)in a complex ecosystem has a value that we are only just starting to comprehend.Whether it is geogr

28、aphical origins,independently notorised certificates or raw process data,the overhead to share is minimal.Given its inherent properties,blockchain technology has the ability to meet consumer demands for transparency,sustainable production and complete food safety&quality.Smart manufacturingBig Data&

29、AnalyticsArtificial Intelligence(Ai)Advanced RoboticsAugmented RealitySystem IntegrationIndustrial IoTSimulationAdditive ManufacturingCyber SecurityFig.3:Nine technologies underpin Industry 4.0.7/Industry 4.0 Technical thought leadership paper2 Quality management system integrationData is fed into t

30、he manufacturers quality management system where it is analysed and compared against the required standard.Predictive algorithms are developed that compare the data gathered by the monitoring systems and then compare it with the quality standard.This will identify where and when deviations are occur

31、ring to provide an early warning of potential process deviations.Process parameters can then be reviewed and,if necessary,changed before quality deteriorates.For instance,an integrated management system might be monitoring the sterilisation temperatures in a packaging machine on a batch-by-batch bas

32、is.By analysing the data using statistical process control techniques,a manufacturer can determine whether their process is stable and,if a temperature goes beyond the defined limits,alert operators and management so a process change can be made before quality dips.3 Maintain a stable,high performan

33、ce processBy collecting,connecting and comparing quality data,the preceeding steps will ensure that a production process is stable,under control and producing output at,or ideally above,the required standard.The availability of data from across the plant will not only allow the manufacturer to maint

34、ain the required quality standards,but will also automate their record keeping and simplify the quality audit process.In addition to minimising the risk to the manufacturers reputation and cost due to the production of poor quality or unsafe product,a solution like this will also support efforts to

35、improve traceability from the upstream supply chain,down through the production process and on into the distribution network.1 Take control of your dataThis should start with a clearly defined quality standard that will ensure production quality and also reflect relevant legislation or regulations.T

36、his will allow a manufacturer to design a monitoring system that defines the critical control points and,if necessary,add new sensors or integrate machine control systems to make sure the appropriate data is collected.A typical quality monitoring system will generate huge volumes of data,so cloud co

37、mputing and edge techno-logies are used to share data across sites and beyond a companys borders,allowing it to analyse data and make decisions in real time at an affordable cost.Improve food safety&qualityThree-step approachWith every change journey,there needs to be a first step and a core of proc

38、ess understanding and data needs must be established.8/Industry 4.0 Technical thought leadership paperCustomerA large bottled water producer in China.ChallengeThe customer wanted to improve performance while maintaining quality,by introducing Total Productive Maintenance(TPM),but they had no automat

39、ic system for data collection.TPM improves performance by identifying losses and waste,and then eliminating them.One method it uses is optimizing cleaninginplace(CIP)time while maintaining strict quality standards.This requires minutebyminute data collection,which is timeconsuming if done manually.T

40、he data also has to be consolidated,so that the producer can take action and adjust parameters.A less labourintensive way of introducing TPM was required.SolutionA solution with Digital CIP Analysis automatically recorded,consolidated and visualized detailed information such as faults,alarms and pro

41、cess deviations.Moreover,information was gathered second by second,and the digital tool then analysed the top five alarms that were stopping CIP.This improved data collection which enabled the customer to optimize CIP was delivered without increasing the number of staff.ResultWith improved informati

42、on about CIP,the customer was able to reduce the number of alarms set off.This has decreased the time required for CIP,thereby increasing performance and reducing utilities consumption.By implementing Digital CIP Analysis,Tetra Pak helped this customer to drive improvements resulting in a 30%lower C

43、IP cost most importantly,without compromising quality.Moreover,this solution has reduced TPM implementation time by 50%,because data was collected automatically rather than manually.The customer now plans to deploy this solution in its plants in other parts of the world.Automated digital analysis op

44、timizes CIP while maintaining strict quality standardsCase study30%lower CIP cost 50%reduced TPM impementation time9/Industry 4.0 Technical thought leadership paperThe food and beverage industry has,in general,been slower thansome others to adopt an Industry 4.0 mindset,and to date has madelimited u

45、se of the foundational technologies.Tetra Pak is changing the game.By leveraging our decades of global food and beverage industry experience,our unrivalled food safety&quality expertise and our investment in digitalisation,we are able to partner with food manufacturers of any size,and in virtually a

46、ny corner of the world,to plot a path to realise the benefits that Industry 4.0 offers.Tetra Pak has more than sixty years of experience helping customers across the food and beverage industry to develop and improve their quality management solutions.When coupled with the expertise gained by pioneer

47、ing Industry 4.0 solutions in food and beverage manufacturing plants all around the world,we recommend that the best way to move forward is to start by reviewing current practice to identify and prioritise the vital few,highpriority issues.For instance,although your ambition might be to develop a fu

48、llyautonomous quality management system that spans the entire production process,in reality this will be nigh on impossible unless you are starting from scratch and designing a green field facility.Therefore,a viable first step will be to establish a core system covering the main food processing and

49、 packing lines.As a leading equipment manufacturer in both areas,Tetra Pak will be able to advise what process parameters should be monitored,offer tried and tested sensor upgrade packs and connect all the equipment on a line in the Tetra Pak Quality and Performance Monitoring Centre.Issues will be

50、identified and reviewed by experts to diagnose the problem and work with your staff onsite to plan a solution.From theory to practice.10/Industry 4.0 Technical thought leadership paperOur implementation process.From theory to practice.Tetra Pak has developed our unrivalled expertise and reputation f

51、or protecting food safety and driving up quality by working with leading food and beverage manufacturers all around the world.By embracing Industry 4.0 we are taking this to another,higher level.Join us to start your journey to protect your food safety,improve quality and deliver improved business r

52、esults.Our approach starts with a workshop led by Tetra Pak experts and joined by your production,maintenance and business leaders.Together we will identify the key challenges and agree on the key objectives for an improvement strategy.To make sure the workshop is able to achieve this,Tetra Pak expe

53、rts will visit your site before the meeting to make a preliminary review.They will review your current performance and,by referring to best practice and drawing on experience gained by helping customers all around the world to increase flexibility,identify the vital few areas where an Industry 4.0 s

54、olution will add value.Following the workshop,a joint team will be formed to finalise the long-term strategic goals,agree on the short-to-medium priorities and start developing a detailed implementation plan for the first steps.12311/Industry 4.0 Technical thought leadership paperRead more at https:/ Tetra Pak International S.A.We reserve the right to introduce design modifications.Tetra Pak,PROTECTS WHATS GOOD are trademarks belonging to the Tetra Pak G