9SEPTEMBER, 2021The manufacturing skills gap is not a new problem. But the pandemic has shown that we, as leaders in the sector, must approach it with a stronger sense of urgencymore product, or selling more contracts. Data gained from IoT can help the plant manager have a better view of the entire production for better asset utilization.Manages the Human Element More EffectivelyThermal processing for industrial products like rubber and charcoal briquettes, or products like petfood and breakfast cereal, that need to be shelf stable, require controlled drying parameters to remove the precise amount of moisture. However, one processing deviation can dramatically affect batch specifications, requiring an operator to over dry, just to compensate. This can mean reduced yield as well as compromised product. Therefore, when a dryer operator is asked to get as close to the target moisture point as possible, there is a natural tendency to over dry. When pet food, for example, is overdried, too much water is evaporated which has to be replaced with raw ingredients. Access to full time, real-time monitoring with hardware, software, and ongoing process expertise, combined with technical support, enables the operator to consistently reach the desired moisture target and do it with confidence. As the inline moisture sensor takes a reading, an algorithm written to control the dryer can control temperature setting to consistently achieve the desired output. This digital relationship gives the operator confidence that systems are calibrated and that processing is efficient.Verifies Processing ParametersIn the food industry, there is an important need to control pathogens like Salmonella and Listeria, and to validate that a thermal process is delivering the desired kill step according to defined parameters, such as retention time, product temperature, process air temperature, air velocity, product moisture content and process air humidity. IoT connectivity, with sensors correlated to a known validation, can monitor critical processing parameters in real time so that you never have to wonder if you are producing a safe product. Should a process interruption occur, an IoT-connected tool in cloud-based management services can send the operator a warning. This might happen because of a change in temperature, moisture or time retention. Or, perhaps a burner goes out. An alert gives the operator an opportunity to do something about it, to have the product closely checked or keep it from being shipped. For food processing applications, this can ensure food safety. It can also save product that would potentially have to be discarded. Discovers Hidden Opportunities to Improve EfficienciesIoT enables you to ask a question that you did not know needed to be asked. With continuous online access to expertise and data on the cloud, a solutions provider can see and interpret processing data. Service records can be viewed and data interpreted on a time stamped basis, which allows the processor to see the big picture, to take action based on history. Here is an example. If a plant manager notices a production line was energized two hours out of an eight-hour shift, he can ask what happened. Perhaps some adjustments are made to reduce that time. Then the next day, it is clear there was only one hour of energized time showing. The plant manager can acknowledge the energized reduction, but also ask what was done differently. The opportunity to continuously ask a question, based on data, keeps the plant striving toward efficiency.Connects Data with People, Which Improves PerformancesIoT is a tool that when leveraged correctly, will engage people across multiple platforms and connect them to valued partners. IoT can drive competitive insights based on facts, to better integrate an organizational structure and its capabilities. It can create trusted, human connected solutions that improve businesses and customer experiences. It can also leverage partnerships and breaks down barriers between people, to bring full employee engagement to quickly solve problems.The Partner Never Goes AwayLook for the digital relationship that can offer you the most contact points, the most intimacy, and the most shared information in the production process. In the initial period, a service will be discovered and shaped, to find ways to become more sustainable in the processes you already know. These won't be new solutions, but they will offer a more consistent way to execute them in real-time. When you find a partner who will always be there, you will find extraordinary value.Paul McKeithan is Head of Digital Business Development for Bühler Group, headquartered in Uzwil, Switzerland. Bühler is a global industrial solutions provider for processing food, feed and advanced materials. Every day, billions of people come into contact with our technologies to cover their basic needs for food and mobility, and more. We strive to create innovations for a better world, with a special focus on healthy, safe, and sustainable solutions. .
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