How to implement an IoT project in your food and beverage plant
Are your food and beverage products slipping in quality?
Are your monitoring and control processes failing?
To get back on track, you need to embrace change. Technologincal change.
One of the finest solutions you can bring on board to detect and solve the unfolding issues is the Internet of Things (IoT).
How can implementing IoT for smart factories help you restore competitiveness and responsiveness? I’ll tell you in this blog.
Without further ado, let’s begin.
IoT in the food and beverage sector
Have you faced contamination issues caused by production line breaches? Did it take days to detect what was happening?
These are typical signs of living with loopholes in your manufacturing process. You simply cannot anticipate threats or solve them quickly. Nevermind if they are recurring or new.
Setting up an IoT network is a top-notch solution to protect your plant from those awful, dangerous, and costly situations.
In a food and beverage plant, the IoT network is an array of connected sensors (ethernet or WiFi) installed in key assets to collect critical information. The data gathered is processed and analyzed via the cloud or edge computing to derive meaningful insights. Based on the analysis, automated actions can be triggered, such as adjusting a thermostat or sending alerts.
The IoT is an empowering tool for driving cost savings and improving efficiency, quality, and safety in ways you didn’t think were possible.
IoT is an undeniable resource to move the food and beverage industry towards a resilient future, amid evolving production scenarios.
Implementing IoT in your food and beverage plant
IoT devices integrate into various stages of food production, according to specific operational and business needs.
In crops, IoT monitors conditions, automates irrigation, and optimizes harvest times.
In manufacturing, IoT enables real-time tracking of inventory levels, machinery performance, and environmental conditions.
To implement IoT, you first need a customized action plan centered on your threats, triggers, and goals.
There are seven steps to follow to end with a winning implementation strategy:
1. Technology selection: Choose the IoT network that aligns with your identified needs.
2. Run a pilot test: Evaluate the effectiveness of the IoT network in a controlled environment.
3. Data infrastructure: Develop or hire infrastructure to handle the volumes of data generated by your IoT devices.
4. Training and support: Seek a training program for your staff so they can effectively use and maintain the IoT systems.
5. Scalability and flexibility: The IoT implementation should be fit to accommodate future growth and technological advancements.
6. Compliance and security: Implement security measures to protect your infrastructure and data against cyber threats and ensure compliance with industry regulations and standards.
7. Continuous improvement: Perform regular analysis and updates based on performance data.
At this stage, you are likely going to need a partner for specialized support for your IoT for smart factories project.
Is there a “best” time to adopt IoT?
Are you losing sleep over:
Loss of quality,
Frequent downtimes,
Understaffed team,
And a lack of operational facts?
Then, adopting IoT is a solution you can trust to smooth your routine toward peace of mind.
Important considerations
While IoT offers numerous benefits, it also presents challenges such as data security and privacy concerns. It's essential for businesses to implement robust security measures to protect sensitive information.
Besides the issue of cybersecurity, other aspects subject to careful consideration are:
● Integration complexity: Combining IoT with existing systems can be a hassle, requiring extra planning to ensure compatibility and seamless operation.
● Data management potential: The amount of data generated by IoT devices demands robust capabilities.
● Costs: Initial setup and maintenance costs for IoT infrastructure should be estimated with a clear ROI calculation to ensure your business’s earnings can’t handle the investment.
For more context about costs:
The initial setup (cost of sensors, connectivity infrastructure, and integration with existing systems) could range between $20k and $200k, depending on the facility’s size and requirements. Ongoing costs (maintenance, data storage, and software subscriptions) are between $10k and $50k per year.
ROI and end benefits of IoT in food and beverage plants
Managers use IoT to forecast demand, prevent overproduction, and reduce waste, as well as:
● Optimize processes and energy consumption.
● Predict maintenance.
● Reduce downtime.
Let’s draw an example from an orange juice plant that operates 300 days a year with a production rate of 10,000 liters per day.
Another fantastic benefit of IoT in food and beverage plants is the potential to increase food safety. The sensed and analyzed process conditions help prevent compositional changes and ensure product storage and transport within safe parameters.
Parting thoughts
IoT has the potential to boost your confidence and response to real-life scenarios. It empowers you to move from a cloudy zone and transform your food and beverage plant into a reliable, compliant, and profitable facility.
Still, moving forward is not a speedy call to make. You should factor in key aspects, including integration needs, CAPEX, and OPEX.
Counting on expert support to navigate any transition is vital to end up with the right solution for your specific case.
Until next time,
Raul Verdusco.
CEO & Founder of Verdusco Automation.
