Food Production · Bakery & Snacks

Continuous Mixer OEE Optimization

Eliminate dosing jams and motor trips by detecting mixer variance 90 seconds before throughput degrades.

+14 pts

OEE Gain

From 68% to 82% on the primary mix line over a 90-day pilot

−62%

Microstops Eliminated

Dosing jams and motor trip events reduced from 18 to 7 per shift

+31%

Dough Consistency Score

SME variance cut by 31%, directly correlated with downstream biscuit weight SD

How Allie Works Here

From signal to action in real time.

Production OptimizationProcess ControlPredictive Maintenance

The Production Optimization agent monitors MIX01.MTR.AMP against a rolling 20-minute baseline segmented by active recipe code. When amperage variance exceeds 1.5 sigma, the Process Control agent queries ingredient dosing flow tags and correlates the deviation to a specific ingredient surge. It triggers a setpoint adjustment on the dosing pump via OPC-UA write, logs the correction in the MES as an auto-adjustment event, and escalates to the line supervisor only if the correction does not stabilize within 90 seconds. In parallel, the Predictive Maintenance agent watches the mixer drive's current signature and dosing pump seal health, flagging bearing degradation or seal wear hours before they would otherwise surface as a microstop, and links each predictive alert to the relevant SOP and prior work-order history surfaced via the Maintenance agent.

Machines & Connectivity

OT-connected, protocol-native.

Reading Bakery Continuous Mixer

Reading Bakery Systems

OPC-UA

Mixes dry and liquid ingredients at controlled shear rates; primary process variable source

Siemens S7-1500 PLC

Siemens

Controls mixer speed setpoints, discharge gate timing, and interlocks

Endress+Hauser Coriolis Flow Meter

Endress+Hauser

Modbus TCP

Measures liquid ingredient mass flow for recipe adherence

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Mixer Motor Amperage	`MIX01.MTR.AMP`	A	42–58	44–52	Tighter
Dough Exit Temperature	`MIX01.TMP.EXIT`	°C	35–44	36–39	Tighter
Specific Mechanical Energy	`MIX01.SME.CALC`	Wh/kg	9.2–14.1	10.5–12.0	Tighter
Ingredient Dosing Deviation	`MIX01.DOSE.ERR`	%	±2.4	±0.8	Tighter

Mixer Motor AmperageTighter

MIX01.MTR.AMP

Baseline: 42–58 A→ 44–52 A

Dough Exit TemperatureTighter

MIX01.TMP.EXIT

Baseline: 35–44 °C→ 36–39 °C

Specific Mechanical EnergyTighter

MIX01.SME.CALC

Baseline: 9.2–14.1 Wh/kg→ 10.5–12.0 Wh/kg

Ingredient Dosing DeviationTighter

MIX01.DOSE.ERR

Baseline: ±2.4 %→ ±0.8 %

In the Field

"a Tier-1 sweet goods manufacturer operating four continuous mix lines in the US Southeast"

Deployed at a Tier-1 sweet goods manufacturer operating four continuous mix lines in the US Southeast. The results above reflect production data from the 60–90 day period following full deployment.

+14 ptsoee gain

−62%microstops eliminated

+31%dough consistency score

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

Book a Discovery Call