Industry 4.0 Increases Productivity by 15%

Case Study Konfitürenmanufaktur Alfred Faller GmbH – Germany

Industry 4.0 increases productivity by 15%

Tradition meets high tech: Bizerba solutions in the jam production of Alfred Faller

The challenge manager at Faller: "The old system glass surfaces are refined, a suitable The Alfred Faller manufactory pro- demanded a lot of time and was prone printing process was found where the duces premium jams traditionally to errors. We wanted to achieve opti- imprint adheres securely and does not stirred by hand in a copper kettle. Else- mal data transparency and a machine become illegible even when the jar is where, manual processes are less wel- utilization of 75 to 80% through net- washed later. When feeding the empty come at Faller. These are, for exam- working and digitization." jars in the production line, a consecu- ple, the documentation of production tive barcode ID is printed on each jar. The printed code is scanned for inspection, the empty jar weighed on a »We are consistently transforming to Industry checkweigher and the result written in 4.0, networked and with transparent data.« a separate database.

Thomas Kessler Automatic ejection in case of an IT-Leiter error After blowing out the jars, they will be filled. A metal detector checks them data or random manual quality gates. Unique ID for each container for foreign bodies and a rejection sys- Due to high competitive pressure and Faller operates one production line for tem ejects contaminated products. increasingly stringent requirements cans and one for jars. The jars have dif- Contamination-free jars are sealed. – keyword HACCP – Faller strives for ferent tare weights which have to be On a second checkweigher, the bar- optimized efficiency and traceability. documented individually per jar for code is scanned again. If the barcode Therefore, the company implements check according to prepack regula- is not readable, the jar is automatically a comprehensive new quality man- tion. A barcode ID is printed on each ejected. If the barcode is readable, agement system. Thomas Kessler, IT jar bottom for this purpose. Since some the database provides the matching

CS_ Konfitürenmanufaktur_Alfred_Faller_GmbH_V01_052021 The customer at a glance Konfitürenmanufaktur Alfred Faller GmbH in Utzenfeld/Black Forest is a third generation fami- ly-owned business. Faller manu- factures according to artisan tra- Food safety through automation: Bizerba Inspection system dition and also processes large quantities of fruit from the neigh- barcode ID with tare weight. The The ID together with the order number, boring regions of Kaiserstuhl and checkweigher receives order num- article number and weight will be Markgräflerland. ber, article, lid weight and nominal fill transferred to the QM system. quantity from the QM system. The indi- • Founded in 1913 vidual tare weight of the jar forms the Further digitization planned • 80+ employees basis for exact checking of the nom- IT manager Thomas Kessler has • 1,600 t of jams per year inal fill quantity according to prepack achieved what he wanted: "Today we regulations. Over or underweight jars know exactly from each single SKU Technical details are ejected. The Bizerba app BRAIN2 (stock keeping unit) what it contains, – Bizerba Hardware: Capture transfers the data to the QM where it is located within the process or 2 x CWEmaxx 1500, system. to whom it was delivered. And if need 1 x CWEmaxx 15000, 3 x iS30, be, targeted recalls can be carried out. 3 x iL Economy 300F/SP, One ID – all data This is an essential concern of retailers." 1 x metal detector For the can production line, a light The next transformation at Faller is – Bizerba Software: sensor activates the scanners on the already being planned: Shipping shall BRAIN2, BRAIN2 Capture, checkweigher. Since cans can turn be optimized. Also here, Bizerba is on Custom PC application around on the belts, four scanners the supplier list as a potential solutions software for system-supported, allow an all-round view on the later- partner. automated tare and gross ally printed codes. Non-readable cans weighing of jars will be ejected. For the readable code the QM system provides the related www.fallerkonfitueren.de order number and article number.

The challenge Solution Result

– New installation of a hardware – Checkweigher for determina- – Productivity increased by 15 % and software solution tion of tare and gross weights

– Optimize traceability – Metal detector and rejection – Increased process reliability systems – Transparency and productivity – Networking with the QM – Less errors system through BRAIN2 and BRAIN2 Capture – Networking with the existing – Integration of printers and – Time saving QM system scanners in order to print and read barcode IDs on jars and cans

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