Introduction

ITG Technologies is pleased to announce the successful completion of our partnership with food & Beverage company located in south America. Utilizing our SORBA AI/IIoT platform, we executed a Predictive Maintenance (PdM) and Advanced Process Control (APC) pilot aimed at optimizing customer’s boiler systems and air compressor.

Overview

Objectives

For the customer plant, the primary objectives of the APC pilot were:

1. To optimize five boiler systems by creating a SORBA Digital Twin.

2. To achieve a minimum of 25% improvement in controlling steam pressure rates.

3. To cut fuel consumption costs by up to 10%, while meeting the plant’s production demand.

For the air compressor, the aim was to empower the maintenance team with proactive monitoring capabilities for equipment failures.

Accomplishments

APC Pilot

1. Conducted a thorough discovery of the physical system from P&ID drawings, functional process controls, and available sensors.

2. Reviewed and identified necessary PLC code, I/O, and tags.

3. Configured the SORBA-SDC and ML Platform for real-time edge data collection and APC.

4. Successfully created and trained digital twins for optimizing the five boilers.

5. Established an optimization workflow function block and validated it using simulated data.

PdM Deployment

1. We equipped customer’s maintenance team with the training and knowledge transfer required to develop ML algorithms for proactive monitoring of equipment failures.

2. Deployed SORBA PdM on one air compressor within the utility section of the plant.

Documentation and Training

1. Compiled comprehensive APC pilot documentation and workflow templates to be shared with customer zones globally.

2. Conducted SORBA APC platform training for plant personnel involved in process control.

Project Management

Successfully managed stakeholder objectives, ensuring pilot success within the committed timeframe of 120-180 days from the project kickoff.

Benefits Realized

1. Achieved all defined benchmarks for steam pressure and fuel consumption.

2. Enabled plant personnel to establish best practices for optimizing boiler networks.

3. Positioned customer as a cutting-edge global brewery.

Conclusion

We are thrilled to conclude that our partnership has not only fulfilled but exceeded the intended objectives, confirming SORBA's ability to deliver substantial operational and economic impacts. This successful deployment sets a precedent for customer’s other global zones and adds another valuable partnership to ITG's portfolio.

For more details or future collaborations, feel free to

ITG Technologies: Pioneers in End-to-End Predictive Maintenance & Process Optimization Solutions.

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