Automation

4 min de lectura

11/05/2026

Greater Efficiency, Less Space: The Rise of Compact Palletising  

Compact palletising has emerged as a response to this reality: automating the stacking of sacks in confined spaces without compromising stability, productivity or pallet quality. In this article, we analyse the technical fundamentals, competitive advantages and operatio...
Automation Quality Assurance Station  

3+ MIN

24/04/2026

Quality Assurance Station  

Developed in collaboration with Extru-Tech, a recognized leader in extrusion technology, our Quality Assurance Station (QAS) represents a significant leap forward in how manufacturers execute and document in-process quality checks.
  The QAS is a semi-automa...
Automation Unleashing the Power of High Impact and Low Effort Innovation

3+ MIN

25/03/2026

Unleashing the Power of High Impact and Low Effort Innovation

By Felipe Martínez R.

Automation The Digital Transformation at the Heart of Pet Food  

3+ MIN

18/03/2026

The Digital Transformation at the Heart of Pet Food  

Automation Veterinarians Should Know How Pet Food is Made and Its Innovations

2+ MIN

03/03/2026

Veterinarians Should Know How Pet Food is Made and Its Innovations

By Candela Bonaura

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Latest content from Automation

Digital Transformation: Fairview Mill’s Journey to Data-Driven Manufacturing
Automation

3+ MIN

30/01/2026

Digital Transformation: Fairview Mill’s Journey to Data-Driven Manufacturing

In 2024 Fairview Mills had a strategic goal to begin their digital transformation journey to ease the use of their plant-level systems, digitize the paper-based processes, and connect data across multiple locations for faster decision making.   MES Project Goals Provide Real-Time, user-friendly data for the whole team Data Centralization Paperless Plant Floor Make data-based decisions on the floor
  NorthWind designed and implemented an MES solution that digitized their production workflows, automated data collection, and provided real-time visibility into operations. The system was built on the Ignition platform using the Perspective module, creating a centralized source of truth for production data and eliminating paper-based processes.
Our Approach
NorthWind began with a thorough assessment of Fairview Mills' operations, working closely with operators, supervisors, and management to understand their specific challenges and requirements. The implementation team conducted extensive user interviews to identify pain points and opportunities for improvement.
  The project followed a phased approach, with weekly feedback sessions to ensure the system met the user's needs. NorthWind's team worked one on one with Fairview's operators and supervisors to ensure adoption and provide training on the new system.
The MES implementation included several key components:
Customized Dashboards for Different User Roles Operator dashboards showing current production status, upcoming work orders, and required forms Supervisor dashboards providing comprehensive visibility into all production areas Management dashboards with efficiency metrics and production performance data
  Digital Form Builder
NorthWind developed a flexible form builder that allowed Fairview to convert their 25-30 daily paper forms into digital formats. The system includes:
  Automated form triggers based on time or production events Digital signature capabilities for quality verification Searchable form history for easy retrieval during audits User-friendly interface allowing Fairview staff to create and modify forms without developer assistance   Real-Time Production Monitoring Custom efficiency tracking tailored to Fairview's specific metrics Production status visualization across all manufacturing operations Automated downtime tracking and reporting Integration with existing control systems   Enhanced Communication Tools Digital user notes replacing handwritten notes between shifts Centralized communication for production issues and status updates Visibility of customer specifications and order comments for operators
  Process Setting Management Digital 'cheat sheets' for machine settings by product Recommended values for operators to reference Consistent process parameters across shifts   The Impact   Eliminated 15+ daily paper forms, significantly reducing administrative burden and improving data accuracy Reduced production reporting time by 45-60 minutes per shift for supervisors through automated data collection and reporting Enhanced quality control with digital verification and improved process consistency Improved shift-to-shift communication through digital user notes and centralized information Streamlined audit processes by making documentation instantly searchable and accessible Increased visibility into production metrics allowing for real-time decision making rather than relying on day-old data Enabled real-time decision making rather than relying on day-old data, allowing management to respond immediately to production issues and opportunities Created a foundation for future digital initiatives including ERP integration and advanced analytics   Future Outlook
With the successful implementation of their MES foundation at the Fairview Kansas facility, Fairview Mills is now positioned for the next phase of their digital transformation journey.
  Integration with their ERP system for seamless data flow Expansion of the MES to additional production facilities Further automation and AI for scheduling processes
  Fairview Mills has expressed extreme satisfaction with MES solution NorthWind delivered. 'The MES implementation has fundamentally changed how we approach manufacturing at Fairview Mills,' stated Darrin Hermesch, Director of Operations. 'We're now making decisions based on real-time data rather than gut feel, and our operators have the information they need at their fingertips. This digital foundation positions us for continued growth and efficiency improvements in the future.'   Learn more about NorthWind's MES Solutions or reach out to schedule a walk through of a system. Source: NorthWind
Technology for a Sustainable Future: How Automation is Driving Eco-Efficient Packaging in the Pet Food Market
Automation

3+ MIN

16/01/2026

Technology for a Sustainable Future: How Automation is Driving Eco-Efficient Packaging in the Pet Food Market

Sustainability is no longer just a brand differentiator; it has become a strategic pillar for the evolution of the global pet food market. Today's consumer is not only looking for the best nutrition for their pets; they also expect the food and its packaging to respect the environment. Sustainability, convenience and responsibility go hand in hand, demanding innovation across the entire production chain, from formulation to packaging, transport and distribution. It is in this context that industrial automation reveals its true value.
  Moreover, the humanization of pets is one of the main growth drivers in the global pet care sector. Recently, the global pet care market — which includes food, services and pet products — reached USD 197.6 billion, underscoring the importance of meeting rising consumer expectations.

  The Pet Food Packaging Market   The pet food packaging segment continues to show strong momentum. The global pet food packaging market is estimated to have reached USD 11.38 billion in 2024 and is expected to grow at an annual compound rate (CAGR) of 6–7% over the next few years (Global Growth Insights).

This market expansion is driven by key consumer and industry trends such as:
  Rising demand for premium products Preference for sustainable, recyclable, or mono-material packaging Greater convenience for end users Broader variety of package formats and sizes
  Adopting more advanced and sustainable packaging is no longer just a market expectation — it is also a powerful competitive advantage for brands seeking differentiation. As the pet food market continues to expand, demand for scale, efficiency, and customization grows as well, making automation, quality control, and modern filling and palletizing systems essential for success.   Automation as a Lever for Positive Environmental Impact   Integrating automation transforms sustainability from an intention into measurable results:
  Less product and packaging waste Reduced energy and resources per unit produced High consistency and repeatability, even with delicate materials Support for a greater variety of sustainable packaging options Ability to achieve ESG targets without compromising efficiency
  Automation ensures that environmental best practices move hand in hand with operational performance — delivering eco-efficient, reliable, and scalable packaging.   Premier Tech Solutions: Sustainability with Full Efficiency     OML 1140 — Automatic Bagging System for Pre-Made Bags
  Compatible with 5 to 50 kg bags Works with kraft paper, PE, PP, recyclable or mono-material films High throughput with consistent accuracy Magazine capacity of up to 600 bags for greater autonomy Modular design ready for future formats and sustainable materials   APC-1120 — Compact Automatic Palletizer
  Stable and secure stacking for protected transport Flexible setup for different logistics patterns, weights, and bag types Durable structure with low maintenance requirements Excellent cost-benefit for gradual automation transitions
  Together, OML 1140 and APC 1120 create a complete and eco-efficient packaging line — from filling to pallet — enabling brands to meet market demands sustainably and competitively.   Sustainable Benefits That Strengthen Business Performance   Significant reduction in waste and rework Lower use of raw materials and product loss Increased autonomy and continuous productivity Lower operational and energy costs Compliance with environmental regulations and market expectations Enhanced brand reputation with consumers and distributors   Sustainability and performance become strategic partners in growth!   Commitment to the Industry of the Future   At Premier Tech, we design technology that allows brands to scale their business without compromising environmental and social values — promoting innovation, sustainability, and competitiveness.
  If your company is ready to take the next step toward a smarter, more conscious supply chain, Premier Tech is ready to support this transition. With the right automation, challenges become new opportunities!   Source: Premier Tech
AI is Transforming the Pet Food Industry
Automation

2+ MIN

09/12/2025

AI is Transforming the Pet Food Industry

The Current Challenge in Pet Food
Producers today face constant variations in raw materials, rapid formula changes, precise moisture control, and multi-ingredient dosing—along with growing demands for energy efficiency and sustainability. Addressing these challenges requires advanced automation that combines the physical robustness of machinery with the predictive power of AI.
The 'Eyes and Ears' of Industry 4.0
The use of sensors in plant engineering to measure variables, evaluate signals, and communicate with higher-level systems has long been a standard procedure. ANDRITZ takes it a step further by employing micro and wireless sensors, which expand data collection capabilities in critical plant areas. This enables much more detailed monitoring to optimize operations.
How AI Turns Operations into Tangible Benefits
The benefits that Metris brings to pet food plants are clear and measurable: production performance has increased by 7% to 16% thanks to automation and end-to-end process optimization, while energy consumption has been reduced by 3% to 17%, contributing to more sustainable operations. Additionally, the use of simulation and digital twins resolves up to 90% of issues before physical start-up, significantly reducing commissioning times. At the same time, proactive cybersecurity ensures asset protection through comprehensive monitoring under international standards such as IEC 62443, in collaboration with OTORIO.  
How Metris Boosts Pet Food Production
At ANDRITZ, automation in pet food production already enables precise dosing, moisture control, traceability, and flexibility in formula changes. Integration with Metris enhances these operations, making them even smarter. The platform allows for automatic adjustment of moisture and dosing based on the actual condition of each batch, predictive machine monitoring through sensors like Metris Vibe—which detect vibrations or temperature changes before they impact production—and direct interaction with the system via Copilot, which helps anticipate problems, suggests adjustments, and responds to operational queries in natural language.
Conclusion
With platforms like ANDRITZ Metris, the move toward more efficient, resilient, sustainable, and autonomous pet food plants is already a reality. At Clivio Solutions, we are ready to support the pet food industry in embracing the digital era by connecting technology, expertise, and results.
  By Clivio Solutions
Source: All Pet Food Magazine
Control System Upgrade Streamlines Pet Food Production
Automation

3+ MIN

03/12/2025

Control System Upgrade Streamlines Pet Food Production

The facility was operating with outdated electrical equipment that had become increasingly difficult to maintain. The existing automation was minimal, with operators manually adjusting critical parameters like water and steam rates based on moisture content readings. What automation did exist was fragmented across multiple PLCs scattered throughout the plant, creating 'islands of automation' that required operators to physically walk the production line to monitor and adjust different systems.
  The original Motor Control Centers (MCCs) were particularly problematic. During NorthWind's initial design assessment, the team discovered that the MCC layout was confusing and poorly documented, with unclear connections between buckets and the systems they controlled. This disorganization made troubleshooting time-consuming and complicated routine maintenance tasks.
Our Approach
NorthWind developed a comprehensive control system modernization strategy that addressed both the electrical infrastructure and control system architecture. Rather than working with the existing MCCs as initially planned, NorthWind proposed designing and building new Motor Control Panels (MCPs) that would house all motor control equipment for each system in one organized location.
  A key advantage in NorthWind's approach was the coupling of automation and electrical installation services. Instead of the manufacturer having to coordinate between separate vendors, NorthWind's integrated teams worked directly together to identify and resolve equipment changes, determine I/O panel locations and quantities, and design the network architecture. This collaborative approach minimized the burden on the manufacturer's team and allowed for rapid problem-solving without overwhelming the end user.
Phased Implementation
The implementation was carefully phased to minimize production disruption.
  Phase 1, completed in August, involved removing the existing MCC and Dryer I/O panel and installing new MCPs and I/O panels to control the existing dryer and newly installed coater. Despite an ambitious two-week timeline for equipment removal, installation, electrical work, I/O checkout, and commissioning, NorthWind's automation and installation teams coordinated efforts enabled I/O checkout to begin two days ahead of schedule and equipment commissioning to start three days early.
  Phase 2, which began 2 months after Phase 1 implementation, focused on the complete replacement of the second extrusion line. The NorthWind team maintained the project schedule and even performed some initial I/O checkout ahead of schedule. Their on-site presence throughout the installation process allowed them to identify and address system changes proactively, preventing potential delays during commissioning.
  On the automation front, NorthWind transformed the manual processes into an integrated control system. The new system automatically adjusts water and steam rates based on recipe setpoints, eliminating the need for manual valve adjustments. Instead of scattered PLCs and HMIs for each subsystem, the facility now has one unified control system per line with HMIs that monitor all systems, allowing operators to control and monitor the entire process from centralized locations.   The Impact   The modernization project delivered significant benefits to the pet food facility:
  Streamlined Operations: The unified control system eliminated the need for operators to physically walk the line to monitor different systems, improving efficiency and reducing labor requirements.
  Enhanced Maintenance Support: Updated electrical and controls hardware, along with accurate documentation, significantly reduced troubleshooting time and simplified maintenance procedures.
  Improved Process Control: Automated adjustment of critical parameters based on recipe setpoints ensures consistent product quality and reduces operator intervention.
  Operational Consistency: Similar controls for both production lines facilitate operator training and flexibility, allowing staff to seamlessly transition between lines.
  Reduced Downtime: The organized electrical system design minimizes the time required to locate and replace components, improving overall equipment effectiveness.
  Future-Ready Infrastructure: The control system upgrade provides a foundation for further automation and data collection initiatives.
  The customer has expressed extreme satisfaction with both NorthWind teams, particularly noting the quality of the electrical installation work and the process knowledge demonstrated by the programmers and controls technicians.
  Learn more about NorthWind's Solutions the Pet Food Industry or reach out to schedule a walk through of a system.
  By Bryan Reinecke, Senior Project Manager
Source: NorthWind
ANDRITZ Chile Integrates AI for Pet Food Manufacturing
Automation

1+ MIN

04/11/2025

ANDRITZ Chile Integrates AI for Pet Food Manufacturing

This shift is a fact at ANDRITZ Feed & Biofuel—we use technologies such as ACE (Advanced Control Expert), which integrates AI to optimize processes, reduce variability, and lower energy consumption.
  'The premise is clear: advance to more efficient, sustainable, and reliable processes. Thanks to AI, our equipment learns from data record, adjusts critical variables in real time, and makes decisions with no human intervention, ensuring more consistent stability in kibbles while contributing to our global commitment to decarbonization through the motto Growth that Matters,' says Ignacio Oliva, Sales Engineer from the Feed & Biofuel sector at ANDRITZ Chile.
  To illustrate, the executive affirms that their wide and robust portfolio has many developments, e.g., the 'intelligent copilot'—integrated in the HMI (Human Machine Interface)— that assists the operator with accurate insights depending on the recipes and conditions.
  'Technology works as a real-time conversational tool able to answer why pressure increases or which parameter needs adjustment, accessing the technical manual from the operation screen,' he adds.
  According to Oliva, ANDRITZ Chile plans to implement full autonomous process control by 2027-2028. In this way, AI will not only strengthen operational efficiency but also transform the experience of humans in plants, releasing time to do more valuable tasks.

  By ANDRITZ 
Source: All Pet Food Magazine
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