Digitalization Unlocks Efficiency and Growth in Food Production Plants

When the first cell phone hit the market in 1983, it was a luxury reserved for executives and the social elite. Today, the United Nations reports that cellular subscriptions outnumber the world’s population, a testament to the relentless march of Moore’s Law and the principle of quality‑adjusted pricing: as performance rises, cost falls.

This trend gives smaller enterprises the same technological edge that once belonged only to large corporations. In the food production sector, digital tools—once limited to big‑name plants—are now within reach of manufacturers of every size, offering measurable gains in productivity and operational efficiency.

The Digital Plant

While machinery and robotics have historically driven plant upgrades, the rise of the Industrial Internet of Things (IIoT) has shifted the focus to software, data, and actionable insight. Modern plant managers increasingly rely on digital platforms to monitor equipment health and preempt performance issues.

Consider a typical food‑processing facility that uses a conveyor system to automate part of its line. Over time, components such as the motor experience gradual wear, leading to reduced performance and potential downtime. Predictive maintenance is essential to address these risks before they manifest, but it requires accurate, real‑time performance data.

Instead of deploying costly, brand‑new IIoT solutions, many plants install multi‑functional sensors directly onto motor frames. These sensors capture key metrics—temperature, vibration, and more—sending data to the cloud for analysis and generating actionable reports for plant engineers.

By shifting from reactive to predictive maintenance, plants gain a clearer view of motor health. A simple “stoplight” interface—green, yellow, red—provides an at‑a‑glance assessment of each motor’s status.

Just as smartphones moved from exclusive to ubiquitous, digitalization is no longer the preserve of only the largest food producers. With the right investment, plant managers can integrate advanced digital capabilities at a pace and budget that aligns with their operational goals.

About the Author

Markus Brettschneider is a senior vice president and general manager for global food and beverage applications at ABB.