With the Digital Enterprise from Siemens, Nestlé transformed its factory in Juuka, Finland, from outdated into trendsetting

From outdated to trendsetting

Turning Nestlé’s aged food plant in Juuka, Finland, into a digital factory of the future with the Digital Enterprise
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Full modernization

Producing high-quality products sustainably and efficiently

Nestlé’s plant in Juuka, Finland, is producing high-quality gravies, demi-glace, and fonds for chefs and restaurants. Modernizing the old, remotely located plant was a challenge but with help of Siemens’ Digital Enterprise portfolio it quickly became a success story for Nestlé.

How to turn a factory upside down

Producing high-quality products for demanding chefs and restaurants became increasingly difficult and less efficient at the factory in Juuka due to its age and dated automation.

 

Finding a one-stop supplier of automation and digitalization solutions for the remote location was challenging for Nestlé’s Head Engineer, Peter Süss. Only Siemens was able to provide a complete solution with its Digital Enterprise portfolio for the food and beverage industry. To take the whole factory into the modern age, drives and PLCs had to be replaced by the latest technology from Siemens’ Totally Integrated Automation (TIA) portfolio. Digital Twins of the factory enabled to plan and optimize it before starting to build it and to test the automation systems before installation.

Data-driven production

Value hacking with the Digital Twin

The collaboration between Nestlé and Siemens ensured that both machines and people were taken on the digital journey. The project also made it possible to make best use of the abundance of data generated on the shop floor.

From data to sustainability

To take the Juuka factory to the digital age, Siemens started a value hacking approach to create measurable value. Together with Nestlé, challenges were identified and prioritized to create metrics, technical solutions, and value propositions to tackle the challenges. This also included the staff at the Juuka site, making sure that everybody had the right mindset and commitment for the digital transformation.

Several Digital Twins were created by Siemens that helped streamline the project: One is a digital model of the plant that was used to simulate the material flow in the factory. The plant simulation allows Nestlé to test and validate different production scenarios. The other Twin is using the performance data that’s collected from the factory’s live operation. It can be used to optimize processes and performance.

 

The results are tangible: Nestlé was able to establish a more sustainable production process in Juuka and to reduce wastewater and chemicals utilization. Production became more stable and reliable with an increased yield and optimizing the production scheduling process helped free up resources for other, more important tasks.

Digital Enterprise – Infinite opportunities from infinite data for the food and beverage industry

In a true Digital Enterprise, combining the real world with the digital world creates a seamless integration of the entire value chain from design to realization, while a continuous flow of data enables ongoing optimization. The Digital Twins of product design, manufacturing and field usage data from the IIoT allow work across development boundaries, enabling cross-domain engineering, virtual validation and continuous product and process improvement through a closed-loop feedback system supported by cloud-based analytics.

 

By vertically integrating IT and OT, the Digital Enterprise brings together areas that were previously separate. This aggregates mass industrial data into valuable information that can accelerate and improve our decision-making processes. Direct connections between control level, command level and decision level enable dynamic implementation of initiatives and fast reactions.

New insights

Transparency all over

The digital transformation at Nestlé’s Juuka site has significantly increased transparency of processes, resulting in 50,000 to 100,000 Euros of savings for raw materials and median heating time of kettles could be improved by 23 %. This became possible because data from production was collected and transferred to MindSphere, Siemens’ industrial IoT as a service solution, where it was analyzed. Increased transparency also helped optimize cooking and clean-in-place (CIP) processes, further reducing production costs.
Figures prove the benefits of the Digital Enterprise at the Nestlé factory in Juuka

Tangible benefits from digitalization

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Decrease in median kettle heating time
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Cost reduction in water and chemical utilization per year
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Annual savings by reducing the number of employees in production planning

Digitalizing the Nestlé factory in Juuka created an abundance of data on the shop floor. By analyzing it, new insights were created that allowed direct actions with tangible results. Knowing where to optimize energy consumption and how to maintain the same high quality with less resources lead to significant savings and overall improved sustainability.