Liquids & Drinks · Dairy & Cultured

Aseptic Filling Line OEE

Sustain the aseptic envelope while lifting OEE from 74% to 88% on multi-format dairy filling lines.

+14 pts

OEE Improvement

From 74% to 88% on the primary aseptic carton line over a 10-week pilot, sustained across SKU transitions

−88%

Aseptic Envelope Breaches

Sterilization-tunnel deviation events cut from 2.4 to 0.3 per week through predictive temperature trim

−79%

Seal-Related Quality Holds

Carton seal defect rate from 1.0% to 0.2% via servo wear monitoring on the sealing jaws

How Allie Works Here

From signal to action in real time.

Production OptimizationProcess ControlQuality ControlPredictive Maintenance

The Production Optimization agent classifies every OEE loss by machine, format, and cause within 60 seconds, distinguishing aseptic envelope breaches (which trigger a sterilization re-cycle) from mechanical microstops and changeover ramp losses. The Process Control agent monitors sterilization tunnel exit temperature and adjusts steam injector setpoint via Tetra Pak OPC-UA writes before deviation triggers an envelope breach. The Predictive Maintenance agent tracks sealing-jaw servo torque curves and forming-roller bearing signatures, scheduling component replacement during planned cleans rather than reactively. The Quality Control agent traces seal defect events to specific upstream causes such as cracked sealing strips or off-center carton presentation, with corrective recommendations surfaced to the line lead.

Machines & Connectivity

OT-connected, protocol-native.

Tetra Pak A3/Speed Filler

Tetra Pak

OPC-UA

Aseptic carton filler for UHT milk and cultured products; primary OEE-constrained machine on the line

Elopak Pure-Pak Filler

Elopak

OPC-UA

Gable-top carton filler for ESL dairy products; format-change machine for size and design variants

Allen-Bradley ControlLogix 5580

Rockwell Automation

EtherNet/IP

Line controller integrating filler permissives, sterilization gates, and downstream case-packer signals

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Filler Speed	`DFIL01.SPD.UPM`	units/min	240–320	300–320	Higher
Sterilization Tunnel Exit Temperature Deviation	`DFIL01.STR.DEV`	°C	±4	±1.2	Tighter
Aseptic Envelope Breach Events per Week	`DFIL01.AEB.WK`	events/wk	2.4	0.3	Lower
Carton Seal Defect Rate	`DFIL01.SEAL.DEF`	%	0.6–1.4	0.1–0.3	Lower

Filler SpeedHigher

DFIL01.SPD.UPM

Baseline: 240–320 units/min→ 300–320 units/min

Sterilization Tunnel Exit Temperature DeviationTighter

DFIL01.STR.DEV

Baseline: ±4 °C→ ±1.2 °C

Aseptic Envelope Breach Events per WeekLower

DFIL01.AEB.WK

Baseline: 2.4 events/wk→ 0.3 events/wk

Carton Seal Defect RateLower

DFIL01.SEAL.DEF

Baseline: 0.6–1.4 %→ 0.1–0.3 %

In the Field

"a major Latin American dairy group operating aseptic carton lines on both Tetra Pak and Elopak platforms across multiple plants"

Deployed at a major Latin American dairy group operating aseptic carton lines on both Tetra Pak and Elopak platforms across multiple plants. The results above reflect production data from the 60–90 day period following full deployment.

+14 ptsoee improvement

−88%aseptic envelope breaches

−79%seal-related quality holds

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.

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