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National Symposium on

Automation & Digital Transformation of

Food & Beverage Industry
26th & 27th February 2016

Automation & Enterprise

Trends -
F&B Industry
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Standards G. Ganapathiraman
Certification GM & VP
Education & Training India & SE Asia
Conferences & Exhibits RamanG@arcweb.com
Basics of Modern Industrial Automation
About ARC Advisory Group

 Established in 1986 in Boston, USA

 Global:
 US, Canada, Germany, Belgium, Japan, China, India, Brazil, Argentina,

 Activities:
 Focused on Industry and Infrastructure

 Corporate Advisory Services,

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 Market Research Reports, MIRA, STAR & Guides

 Forums,

 Custom Projects
Basics of Modern Industrial Automation
Research Domains

 Analytics and Big Data

 Asset Lifecycle Management
 Energy Management and Sustainability
 Governance and Risk Management
 Industrial Networks and Cyber Security
 Industrial Internet and M2M
 Manufacturing IT and Cloud Computing
 Machine Control and Safety
 Operations Management
 PLM and Virtual Manufacturing
ARC’s Collaborative
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 Process Automation and Safety Management Model

 Sensors, Transmitters, and Actuators
 Smart Cities and Infrastructure
 Supply Chain and Logistics
Basics of Modern Industrial Automation
Key Industries Covered

 Aerospace and Defense

 Automotive and Heavy Machinery
 Chemical, Cement, and Glass
 CPG, Food, and Beverage
 Electric Power and Smart Grid
 High-Tech and Discrete
 Infrastructure and Smart Cities
 Life Sciences
 Logistics and Transportation
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 Mining and Metals

 Oil and Gas
 Pulp and Paper
 Water and Wastewater
Basics of Modern Industrial Automation
Top Ten Business Challenges

Achieving and Sustaining Exceptional Business


Increasing Asset Reliability

Reducing Complexity and Customization

Create a Proactive Culture to Capitalize on Emerging

Insulate Businesses from Unprecedented External
Unify Business and Manufacturing with a Common Business

Utilize Automation to Satisfy HSE Requirements

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Protect Operations from Cyber Threats

Provide and Sustain a Skilled Workforce

Predicting and Realizing Value from Automation

Basics of Modern Industrial Automation
F&B Industry Overview

 The global food and beverage manufacturing industries produce over US$ 3.5
trillion worth of product.

 Manufacturers operate in highly competitive markets, competing against global,

regional, local and private label manufacturers on the basis of price, quality,
convenience, variety, nutritional value, and distribution.

 Innovative new products and packaging remain vital to meeting changing consumer
and retailer demands, changing demographics, and local and cultural preferences.

 Continued emphasis on product and packaging innovation, adding value to retailers,

and more effective communication through packaging are the keys to maintaining
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brand value.

 The food and beverage industries are remarkably diverse with many small to large,
simple to complex manufacturing facilities. To further emphasize the size and
diversity, the top 50 food manufacturers' share of global packaged food retail sales
Basics of
KeyModern Industrial
Questions F&BAutomation
are Trying to Answer
 How do I address the fluctuating price and availability of commodities?
 How do I reduce my energy and other utility costs and ensure the long term availability of
these resources?
 How do I find and evaluate new technology that will support innovation and speed time-to-
 How do I find and evaluate technology that will improve my manufacturing efficiency and
 How do I come up with new ideas or equipment that allow multi-tasking and that can reduce
change over time?
 How do I reduce my manufacturing cycle time?
 What are the best metrics to support future manufacturing requirements?
 What are the leading best practices in the food and beverage industries, in manufacturing in
general, and for sustainable manufacturing?
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 What is my competition doing?

 How do I support my ever-expanding manufacturing and business automation systems and
 What are other companies doing to improve the skill sets of their operators and staff?
Basics of Modern Industrial Automation
Major Trends – Global Scenario

 Emerging Markets, Urbanization, Changing Demographics

 BRIC and CIVETS countries identified as emerging markets due to actual and growing purchasing
 Urban population growth explosion
 Addressing the needs of each demographic will be the key to future success
 Changing Consumer Purchasing Patterns
 Consumers becoming more value-conscious, health-conscious, and socially conscious
 Manufacturers are responding to rapidly changing consumer purchasing patterns with an even
wider variety of product and packaging innovations
 Packaging Becoming a Key Differentiator
 In response to escalating productivity and efficiency demands from food and beverage
manufacturers, packaging machinery OEMs have begun to embrace global equipment standards
 A growing trend toward integration, automation, and standardization is beginning to take hold in
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the packaging machinery manufacturing sectors

 The Walmart Effect
 Mega-size, “power” retailers, at the forefront of recognizing consumer purchasing patterns, are
driving the demand for more sustainable manufacturing practices among their suppliers since they
recognize that these can help them increase their respective market share and lower their
business costs
Basics of Modern Industrial Automation
Major Trends – Global Scenario

 Rising Food Safety Due Diligence and Cost of Quality

 Governments all over the world are intensifying their efforts to improve food safety in
response to an increasing number of food safety problems and rising consumer

 Regulatory Requirements and Global Standards

 The requirements for a food safety plan include several elements, each of which
appear to be more comprehensive than current requirements and are likely to drive
investments in new automation and/or IT assets

 Drive Toward More Sustainable Manufacturing

 Sustainable manufacturing and supply chains practices that reduce waste, minimize
the use of valuable and limited resources, and minimize impact on the environment,
as well as taking on more social responsibility

 The Transparent Enterprise in the Information Age

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 Manufacturers are being held to unprecedented levels of accountability throughout

their supply chain and manufacturing operations
Basics of Modernof Automation
Industrial in the
F&B Industry
ISAB /F&B Symp /20160226 /Slide No. 10
Basics ofInhibitors of Automation
Modern Industrial in
Automation the
F&B Industry
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Basics of Modern Industrial Automation
Strategies for Success
 Mergers, Acquisitions, Joint Ventures, Divestitures Splits, and Outsourcing
 Two of the most common reasons for acquiring a company are to strengthen a product line or
gain a distribution channel
 Three important trends include a new focus on vertical integration, manufacturers in emerging
economies acquiring companies in developed economies, and bigger are no longer
necessarily better
 Expansion of Distribution Channels and Markets
 There is a growing number and type of retail outlets. Consumers are less and less restricted
to shopping at supermarkets and power retailer big box stores, which can be miles away.
 Portfolio Rationalization and Optimization
 P&G’s Swiffer, Tata Motors’ Nano, Nestlé’s yogurt manufacturing project in India are all
excellent examples of innovative thinking. Each company determined what the consumer
needed, but didn’t have, developed a product, and created a whole new market.
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 Productivity, Cost Containment, and Customer Satisfaction

 CPM/MES, EAM, RPO, Energy saving hardware products, Process Engineering Tools
 According to several ARC surveys, the primary drivers for deploying CPM software are to
help improve plant performance, ensure product quality, and improve product tracking and
Basics of Modern Industrial Automation
Strategies for Success
 Packaging and Supply Chain Optimization
 Packaging remains a largely manual, standalone operation lacking the horizontal and vertical integration
needed to properly manage and monitor operations performance or deliver timely and accurate information
to business operations
 Food and beverage manufacturers and their technology and equipment suppliers are responding with
 New packaging operations management software
 New, more efficient packaging machinery with advanced controls and integral robotics systems
 Machines and equipment with modern communications capability
 The continued development and deploy-deployment of machine control and information standards
 Food Quality and Safety
 Companies are actively deploying new electronic product quality risk, and compliance management
 These include new electronic product quality, risk, and compliance management systems (QRC) and
subsystems that include:
 Document management systems
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 Laboratory information management systems (LIMS)

 Real time electronic hazards analysis and critical control points (HACCP) systems
 Corrective and preventative action systems (CAPA)
 Real time on-line SQC/SPC
 Model-based and multivariate predictive controls
 Product genealogy and tracking and tracing systems
Basics of Modern Industrial Automation
The Connected World is on the Horizon

Cloud, Virtual

People Processes Information

Collaboration, Analytics, 3D

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Assets Together, These

Mobile, IoT Technologies can
Help You Transform
Your Business
Basics Industrial
of Modern Industrial
The New Frontier

Monitoring & Services

Advanced Analytics

Network Platform
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Most Industrial IoT Building Blocks are Already in Place

Basics of Modern Industrial
Industrial InternetAutomation
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Reduced Downtime and Faster Service are Top Drivers

Source: ARC Industrial Internet of Things Survey

Basics IoT
of Modern Industrial Opportunity
is a Business Automation to Improve
Machine Utilization

Identifying Problems will Allow the Industry to do More

with Less Machinery

 Reduce Operating time to produce work piece

 Improve Machine Production Output
 Improve Utilization of Labor
 Identify operational issues
 Identify poorly operating machines
 Increase the performance of the operator
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 Close the loop with product design

 Close the loop with CAM systems
Increase Utility of Machine Tool by
Basics of Modern Industrial Automation
Enabling Operators

 Machine utilization continues to rely on operators, but skill level is

 Operators often first to identify processes need attention.
 Operators are an Intelligent Sensor

Process Engineers

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Continued workforce reductions make it necessary to capture the knowledge of

process engineers and maintenance workers to maintain quality.
Basics of Modern Industrial Automation
Empower the Operator

Low Skilled Operators Need to be

Connected to an IoT Infrastructure to
Improve Performance


Operation by
Inspection Skill
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skilled workers
target Know-how

Judgment based on implicit knowledge

Basics Knowledge DiscoveryAutomation
of Modern Industrial Through Analytics Embeds
Rules in Machinery & Production Systems

 Consistent quality
 Non dependence on skilled workers


Data sensing No skilled workers

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Knowledge-info Control Technologies

From machinery

Extract Learn Infer

Basics Knowledge Discovery
of Modern Industrial & Analytics
Automation –
Summing Up

 Analytical tools that rapidly recognize trends in production

 Shorten the time from problem identification and corrective action

 Rapidly identify startup problems to ensure faster time to market

 Create an environment that is data driven instilling a consistency

in corrective actions
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 Decouple operator ability of providing early detection of machine

degradation from manufacturing performance
Basics of Modern Industrial
Analytics Automation
Drives Knowledge
Discovery and Creation
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Improving Manufacturing Metrics

Basics of Modern Industrial Automation
Let’s Change the Mix of Maintenance
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The Emerging Smart Production
Basics of Modern Industrial Automation
Environment (IIoT, I4.0, etc.)
New or Changing …
- Software: Analytics, APS, MES/MOM, EAM/CMMS,
LIMS, PAM, Security, etc. Connected
- Mobility and enhanced worker connectivity Enterprise
- Remote services; Product ‘as-a-Service’
- Smart sensors, assets, network connectivity, cloud Remote
Monitoring &
… All along with traditional automation Services
and enterprise systems Enterprise
Self-Planning Smart Apps
Video Presence
Systems Tools (Expert Help)
Collaboration Advanced
Flexible Worker Location/Nav Analytics 3rd Party
Schedules Services
Access Control Connectivity
Services Platform
IIoT Smart
Connected Module
Plant Systems
Worker and Assets
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Smart Smart Machines Products
Warehouse - Connected
- Software-defined
Connected - Agents, Apps
Supply Smart Logistics Smart Smart
- Sensors e.g. vibration,
ultrasound, infrared Smart Containers
Chain Components Carriers etc. Smart
Smart Metrology
Basics of Modern Industrial Automation
The Connected Plant

XYZ Company XYZ Company XYZ Company XYZ Company

Maintenance Engineering Purchasing Corporate Service

Mfr. Provider


New IoT
Analytics and
Business Share Asset Monitor
Systems Data with 3rd in-service
Applications Parties Secure Connection Products

Secure Network
XYZ Company

Smart Machine

IoT Smart Local IoT Compute and

Module Communicate module
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Physical asset with

sensors, actuators

Emerging Option: Connect Big

Assets Using New Technologies
Plant Operations
IoT Industry Groups
Basics of Modern Industrial Automation
Many focused on network connectivity for home

 AllSeen Alliance (2013) – Qualcomm, LG, Haier, Panasonic, Sharp

 Industrial Internet Consortium (2014) AT&T, Cisco, GE, IBM, Intel
 IPSO Alliance (2008) ARM, Atmel, Ericsson, Freescale, EDF
 Open Interconnect Consortium (2014) – Intel, Broadcom, Dell, Samsung
 Thread Group (2014) Google/Nest, ARM, Samsung
 ZigBee Alliance (2002) Freescale, TI, Philips, Schneider Electric
 Z-Wave Alliance (2005) ADT, Ingersoll Rand, Linear Technologies
 Smart Manufacturing Leadership Coalition (SMLC)
 Industrie 4.0
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Basics of Modern Industrial Automation
Industrie 4.0 in the Process Industries
 Industrie 4.0 has been conceived from a discrete industry perspective

 The process industry has many concepts of Industrie 4.0 in place

 Autonomous optimization, controllers are coordinated via the DCS concept (APC, RTO),
integrated supply chain and production optimization, etc.

 The process industries has its own buzzwords and initiatives, also visible
at the ACHEMA fair
 Modular automation and production technologies, to build small, flexible, reconfigurable
production units (F3 Factory model)
 Predictive maintenance strategies (asset health diagnostics/analytics, useful life
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prediction, planning predictive maintenance, life cycle cost management

 Remote operation (workforce reduction, reduce night and weekend shifts)
 Digitalization (seamless engineering, operations and maintenance)
 US initiative SMLC (common IT platform, advanced modeling, and more)
 Exception is the German process industry (BASF, ThyssenKrupp) have a process
interpretation of Industrie 4.0
Basics of Modern Industrial Automation
IIoT Impact on Industrial Companies

 More Sensors, More Data, More Automation

 More Analytics, More Visibility
 More Software Applications
 New Product Requirements
 New Production Equipment Capabilities
 Software defined, autonomous, intelligent
 New Architectures
 Cloud, Mobility, Virtual, Distributed
 New Service Requirements
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 New Customer/Supplier Relationships

 New Ecosystem/Supply Chain
 New Business Models
Basics of Modern Industrial Automation
Enterprise Software Business Is Evolving

New Model: Sell Apps that…

 run as a service in a private or public Cloud
 require monthly payment
 can be implemented in weeks or days
 can support diverse user ecosystem
 are upgraded by the supplier
 provide tools for global collaboration
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Basics of Modern Industrial Automation
Automation Systems are Evolving

Attribute From To
Focus Technology Business
Structure Hierarchical Flattened
Cyber Security After Thought Secure by Design
Data Multiple copies Single Version of Truth
Integration Project-based Standards-based
MOM Applications Separate Integrated
Control & Safety Separate Integration Options
Control & Electrical Separate Integration Options
Engineering Design Tied to Hardware/ Late-Binding for
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Software Hardware/Software
Supported By Users Suppliers

Technology is no longer a barrier

Automation Products & Software
Basics of Modern Industrial Automation
for the F&B Industry
Products What is included
DCSs Distributed control system hardware, software, and related services.
PLCs PLC hardware, software, and related services.
Machine Machine safeguarding solutions cover all key product segments used in machine safeguarding
Safeguarding applications.
AC Drives Low and high power variable frequency AC drives (inverters, sensor-less, flux vector), peripheral
hardware, drive systems, bundled software, integration, and other relevant software and services.
General Motion controllers (single and multi-axis), intelligent drives, servo and stepper amplifiers, servo
Motion and stepper motors, bundled and unbundled software, integration, and other relevant services
Control provided by GMC suppliers
Unbundled EAM, PAM, RPO, PET, CPM for process, HMI, and LIMS
Control All Control Valve, Actuator, and Positioner (CVAP) hardware, software, and related services.
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Transmitters Pressure and temperature transmitters. Includes hardware, software, and services.
Level Continuous ultrasonic level and radar level devices for continuous level measurement applications.
Measurement Includes hardware, software, and services.
Flowmeters Magnetic, Coriolis, ultrasonic, and vortex flowmeters. Includes hardware, software, and services.

Analytical Process electrochemical systems (PES) and process infrared systems (PIRS) analytical products.
Includes hardware, software, and services.
Reference: Worldwide F&B Study, ARC Advisory Group
Basics of Modern Industrial Automation
IIoT and Transformational Change
 IIoT increases the value of existing infrastructure
 More uptime
 Better performance
 More responsive
 IIoT presents a new set of opportunities - and risks – for Operations:
 Leverage data and analytics
 Leverage 3rd parties for non-core operating activities
 Leverage IT organization and technologies
 IIoT enables machine makers to reinvent their relationship with
 Connected products enables ongoing relationship
 Engineering, marketing and manufacturing must collaborate
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 Business model morphs to Products and Aftermarket Services

 PaaS
 Unpredictable disruption is predicted
 What is your strategy?
Embrace Technology Friendly Culture
Basics of Modern Industrial Automation

Thank You!
ISAB /F&B Symp /20160226 /Slide No. 33

For more information, contact the author at

RamanG@arcweb.com or visit our web pages at