Schneider Electric Case Studies Building smarter machines to maximize profitability

	Building smarter machines to maximize profitability Schneider Electric

Building smarter machines to maximize profitability

Schneider Electric

Technology Category	Analytics & Modeling - Real Time Analytics Functional Applications - Remote Monitoring & Control Systems Networks & Connectivity - WiFi
Applicable Industries	Food & Beverage
Applicable Functions	Discrete Manufacturing Quality Assurance
Use Cases	Machine Condition Monitoring Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	Berto Coffee Roaster, a leading company in Indonesia’s food processing sector, recognized a huge opportunity in the local coffee industry and decided to focus on building high-quality coffee roasting machines. However, their existing roasting machine was manually controlled and required a skilled operator to check every step, resulting in a lot of wasted time in the production process. With the arrival of Industry 4.0, the market demanded a fully automated coffee roaster that required minimal operation and low maintenance costs while also increasing production output, quality, and consistency. It became critical for Berto Coffee Roaster to add more value to their roasting machines designed for the export market. Read More
About Customer	Berto Industries is a leading company in Indonesia’s food processing sector. Founded by Robert Patilaya in 1984, the company started as a small manufacturing company. More than 30 years later, Robert and his son, Marcel, recognized a huge opportunity in the local coffee industry and decided to focus on building high-quality coffee roasting machines. Since 2017, they have been operating as Berto Coffee Roaster. To maintain their position as a leading local coffee roasting machine builder, they understood that they needed to continually innovate. Their journey to revolutionize the coffee processing industry led them to Schneider Electric. Read More
Solution	Schneider Electric integrated the Altivar Machine ATV320 variable speed drive into Berto’s roasting machine to optimize and provide automation capability. Combined with the Modicon M221 logic controller, the system became faster and more reliable, significantly improving the output quality and giving consistent and repeatable results throughout every operation. To maintain quality and production output, Schneider Electric provided better visibility into the machine’s condition and performance using EcoStruxure Machine SCADA Expert and EcoStruxure Machine Advisor. With these technologies, operational technicians can diagnose machine performance virtually and in real time, using a tablet, without having to open engine components manually. Using EcoStruxure Augmented Operator Advisor, they can conduct predictive analysis and uncover potential issues before they occur and cause expensive downtime. Schneider Electric also equipped the machines with a Magelis HMI for easier control and status viewing. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Functional Applications - Remote Monitoring & Control Systems

Networks & Connectivity - WiFi

Applicable Industries

Food & Beverage

Applicable Functions

Discrete Manufacturing

Quality Assurance

Use Cases

Machine Condition Monitoring

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

Berto Coffee Roaster, a leading company in Indonesia’s food processing sector, recognized a huge opportunity in the local coffee industry and decided to focus on building high-quality coffee roasting machines. However, their existing roasting machine was manually controlled and required a skilled operator to check every step, resulting in a lot of wasted time in the production process. With the arrival of Industry 4.0, the market demanded a fully automated coffee roaster that required minimal operation and low maintenance costs while also increasing production output, quality, and consistency. It became critical for Berto Coffee Roaster to add more value to their roasting machines designed for the export market.

About Customer

Berto Industries is a leading company in Indonesia’s food processing sector. Founded by Robert Patilaya in 1984, the company started as a small manufacturing company. More than 30 years later, Robert and his son, Marcel, recognized a huge opportunity in the local coffee industry and decided to focus on building high-quality coffee roasting machines. Since 2017, they have been operating as Berto Coffee Roaster. To maintain their position as a leading local coffee roasting machine builder, they understood that they needed to continually innovate. Their journey to revolutionize the coffee processing industry led them to Schneider Electric.

Solution

Schneider Electric integrated the Altivar Machine ATV320 variable speed drive into Berto’s roasting machine to optimize and provide automation capability. Combined with the Modicon M221 logic controller, the system became faster and more reliable, significantly improving the output quality and giving consistent and repeatable results throughout every operation. To maintain quality and production output, Schneider Electric provided better visibility into the machine’s condition and performance using EcoStruxure Machine SCADA Expert and EcoStruxure Machine Advisor. With these technologies, operational technicians can diagnose machine performance virtually and in real time, using a tablet, without having to open engine components manually. Using EcoStruxure Augmented Operator Advisor, they can conduct predictive analysis and uncover potential issues before they occur and cause expensive downtime. Schneider Electric also equipped the machines with a Magelis HMI for easier control and status viewing.

Impact #1	Increased profitability by selling a complete solution, bundling with software, apps, and services
Impact #2	Significantly improved performance and productivity of coffee roasting machines
Impact #3	Reduced machine maintenance costs by up to 20 percent

Impact #1

Increased profitability by selling a complete solution, bundling with software, apps, and services

Impact #2

Significantly improved performance and productivity of coffee roasting machines

Impact #3

Reduced machine maintenance costs by up to 20 percent

Benefit #1	Potential ROI up to 173%
Benefit #2	Maintenance time reduced by 50%
Benefit #3	Machine maintenance costs reduced by up to 20%

Benefit #1

Potential ROI up to 173%

Benefit #2

Maintenance time reduced by 50%

Benefit #3

Machine maintenance costs reduced by up to 20%

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Overview

Building smarter machines to maximize profitability

Operational Impact

Quantitative Benefit