Liquids & Drinks · CSD & Juice

Filler Changeover & Recipe Execution

Pre-validate 140+ recipes and eliminate recipe mismatch events entirely through MES-driven pre-staging.

−41%

Changeover Time

From 51-minute average to 25 minutes via pre-staged recipes and parallel task scheduling

−76%

Startup Waste

Startup reject count from 260 units average to 62 units via pre-verified recipe parameters

Zero

Recipe Accuracy Events

No recipe mismatch deviations in 4-month production period, previously 2.3 events per month

How Allie Works Here

From signal to action in real time.

Production PlanningProduction OptimizationProcess Control

The Production Planning agent integrates with the MES work order queue and pushes the next 3 scheduled recipes to the KHS OPC-UA server 20 minutes before each planned changeover, enabling pre-validation of mechanical position parameters. The Process Control agent compares live actuator feedback positions to recipe nominal values after each format adjustment and flags any deviations exceeding tolerance before the line restart is authorized. The Production Optimization agent monitors the startup ramp curve, product count rate from first unit to steady state, and alerts if startup waste will exceed the target before it does.

Machines & Connectivity

OT-connected, protocol-native.

KHS Innopack Kisters SP Shrink Packer

KHS Group

OPC-UA

Multi-format secondary packaging with 140+ stored recipes; format changes require mechanical and recipe adjustments

Omron Sysmac NJ501 PLC

Omron

EtherNet/IP

Controls can/bottle guide rail positions, lane dividers, and label applicator registration

Zebra ZT510 Industrial Printer-Applicator

Zebra Technologies

EtherNet/IP

Case label printing and application with recipe-driven content from MES work order

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Recipe Download Confirmation Time	`PACK02.RCP.CNF`	s	240–480	45–90	Lower
Changeover Duration	`PACK02.CO.DUR`	min	38–65	22–28	Lower
Post-Changeover Startup Rejects	`PACK02.STR.REJ`	units	180–340	40–80	Lower
Label Position Accuracy	`PACK02.LBL.ACC`	mm	±3.2	±0.8	Tighter

Recipe Download Confirmation TimeLower

PACK02.RCP.CNF

Baseline: 240–480 s→ 45–90 s

Changeover DurationLower

PACK02.CO.DUR

Baseline: 38–65 min→ 22–28 min

Post-Changeover Startup RejectsLower

PACK02.STR.REJ

Baseline: 180–340 units→ 40–80 units

Label Position AccuracyTighter

PACK02.LBL.ACC

Baseline: ±3.2 mm→ ±0.8 mm

In the Field

"a major juice co-packer managing over 200 active SKUs across three secondary packaging lines"

Deployed at a major juice co-packer managing over 200 active SKUs across three secondary packaging lines. The results above reflect production data from the 60–90 day period following full deployment.

−41%changeover time

−76%startup waste

Zerorecipe accuracy events

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.

Schedule a Plant Assessment