Discover the world of GEA digital solutions · GEA Cube and GEA Codex support flexible processing...

Discover the world of GEA digital solutions

DECEMBER 2018

Our digital ambition

2GEA digital solutions

Our solutions and products are smart, connected and empowered by standard-setting software, digital

platforms & algorithms …

… enabling us not only to predict and improve the quality of our installed lines but also to support customers in adapting products to changing consumer behavior

and of course, run plants efficiently. Our business model is

leveraged to create customer

value.

We excel in our service-oriented

business model …

… leveraging efficiencies from integrated business and engineering processes to

smart production plants.

Creating value for our customers


We offer advanced data analytics tools for

creating transparency, gaining insights & defining actions at customer plants and

processing lines.

We ensure customer production support

processes are fully digital &

interconnected to minimize manual work steps and failure rate.

We make sure customers have operations

data & informationat their fingertips

(instantly, anywhere, any time), eliminating time wasted searching for

information.

We develop tools for virtual representation

of customer production processes

(e.g. conducting production scenario analyses & virtual

operator trainings).

WORKFORCECONNECTIVITY

AUTOMATED PROCESSES

DATA ANALYTICS

SIMULATIONS

Digital solutions for a multitude of applications

DIGITAL SOLUTIONS

GEA digital solutions 4

During the lifetime of a plant or line, operating conditions and products may change compared to what the plant or line was originally designed for. This can lead to lower than expected production capacities which is expensive to troubleshoot.

That’s why we offer to conduct up-front advanced and detailed 3D simulations of design performance under varying design and operating conditions.

Customer benefits:• Eliminates unplanned plant downtime and

reduces production waste• Opportunity to virtually test ideas directly

under real production conditions without disturbing the running production

Gain insights into production processes via 3D simulationGEA Detailed Process Simulation


Due to the high degree of automation in plants, operators lack hands-on experience. Operator training can lead to downtime and generate production wastage. Operations staff become risk adverse when they lack confidence, especially during the start-up phase or during off-peak hours.

By connecting the original human-machine interface (HMI) to a virtual representation of the programmable logic controller (PLC) and production process, the operator is able to virtually train and manage the production process.

Customer benefits:• Quicker ramp-up for new operators• Ability to train people in extreme situations,

in a safe environment • Reduced downtime• Lower risk of production losses• Increased operator satisfaction through gamification• Higher yield and plant profitability

Train operators on a virtual facsimile of the production processGEA Operator Training Simulation


Production lines consist of complex processes, which are subject to disturbances and fluctuations in raw material quality, the surrounding environment, etc. With current process control measures, we are not always able to handle process disturbances adequately, which can lead to potential business losses.

To better handle process disturbances, GEA OptiPartner is an advanced “autopilot” controller, leading to increased process performance. Being a digital service product, GEA OptiPartner covers the full life cycle of process optimization, e.g. remote services for tuning, software updates, and performance monitoring of the optimizers for continuous improvement.

Customer benefits:• Increased process stability

and operational consistency• Continuous performance optimization

of production line• Increased transparency of

process performance

Increasing production line performanceGEA OptiPartner


Carefully monitoring the spray drying process is key to ensuring the highest quality production of powdered products while also securing the safety of the plant and its operators.

GEA SPRAYEYE® Visual and GEA SPRAYEYE® IR have been designed to continuously monitor the spray drying process to ensure consistent and safe performance during critical phases of the drying process. Sophisticated thermal cameras monitor and provide feedback on process conditions, alerting operators to potential issues.

Customer benefits:• Quick identification of product buildup• Control of spray pattern• Instant checks for leaks• Surveillance of fines return flow• Temperature increase monitored• Quick identification of exact location,

temperature and size of deposit

Continuous visual quality control

GEA SPRAYEYE® Visual & GEA SPRAYEYE® IR


The GEA Monobox and GEA DairyProQ provide professional dairy producers with the greatest advantages available in automated milking. All processes during milking and cleaning are recorded and visualized for the customer so they can reach maximum operational efficiency.

Data logging is used to monitor the system status and to ensure optimal system performance: preventive alarms are generated in case of imminent malfunctions to avoid a deterioration of the productivity of the automated milking system and to prevent unexpected equipment failures.

Customer benefits:• Maximized operational efficiency• Less downtimes• Improved diagnostics and serviceability• Lower maintenance costs

Ideal prospects for milk productionGEA Automated Milking Systems


GEA DairyNet, part of 365FarmNet, is an innovative software solution that connects livestock and crop farming. All indoor and outdoor operations can be conveniently managed from one place.

Different modules like GEA DPconnect Basic and Milking combine GEA milking equipment with state-of-the-art software, providing precise figures and recommendations for all farming needs. Whether customers want to treat a particular animal in the barn or check their crops, they can manage every aspect of their business quickly and efficiently.

Customer benefits:• All operations can be conveniently managed

from one place• Connects livestock, dairy and crop farming• Provides data and recommendations

for all farming needs

Farm management from A to ZGEA DairyNet


With the FarmView web application, GEA offers its customers more insights with an easy online monitoring tool for their automated milking systems. An intelligent alert system and regular analyses of relevant parameters assists farmers in their daily routine and helps them monitor, analyze and optimize processes. GEA FarmView also enables dealerships to provide maximum customer service efficiency –therefore helping to maintain superior system performance.

Customer benefits:• Flexible monitoring – anywhere, any time – via apps• Intelligent alarm system with system alerts via smartphone • Online assistance saves time and money • Less downtime and quick reaction times due to remote access• Improved equipment performance given analysis function• Secure data transmission and daily backup storage

Increasing system performance with online expertiseGEA FarmView


GEA CostFox is a performance measurement tool which is based on overall equipment effectiveness core principles and the real-time display of production parameters. The reporting tool works on PCs and supports the continuous improvement of customers’ production sites.

Customer benefits:• Provides productivity data for

continuous improvement• Monitoring and display of performance

values on the human-machine interface (HMI)• Helps food processors increase profitability

via ongoing performance enhancements

Boosting performance and productivityGEA CostFox


Production lines consist of complex processes, which are subject to disturbances and fluctuations in raw material quality, the surrounding environment, etc. With current process control measures, we are not always able to handle process disturbances adequately, which can lead to potential business losses.

To better handle process disturbances, GEA OptiPartner is an advanced “autopilot” controller, leading to increased process performance. Being a digital service product, GEA OptiPartner covers the full life cycle of process optimization, e.g. remote services for tuning, software updates, and performance monitoring of the optimizers for continuous improvement.

Customer benefits:• Increased process stability

and operational consistency• Continuous performance optimization

of production line• Increased transparency of

process performance

Increasing production line performanceGEA OptiPartner


GEA OxyCheck is the first system worldwide which is able to measure the oxygen content of each modified atmosphere package (MAP), inline, contact free and without destroying the package.

Customer benefits:• In-line quality inspection of MAP• 100% of all produced MAP are checked on oxygen content and

seal integrity • Automated process that promotes food safety and avoids package

and product waste • Automatic discard of packages that do not meet requirements• Collected data gives insight into production performance for

management and adjustments• GEA OxyCheck system and algorithm is scalable and can be used

by other industries

Bringing 100% quality controlled packages to the marketGEA OxyCheck


GEA UptiFox is a web-based tool for food processing and packaging machines with three key functions: tele-monitoring, remote service and preventive maintenance.

Customer benefits:• Provides a quick overview of the technical availability of the line• Service is provided remotely via machine panel and machine

software• Maintenance notifications via e-mail to customers or GEA local

organization• Saves time, mitigates break downs and ultimately helps optimize

uptime• Supports analysis of root causes for poor productivity• Creates notifications regarding errors and availability

Truly in control of packaging processesGEA UptiFox


Our Brewery 4.0 vision combines today’s state-of-the-art brewery solutions with innovative new technologies to facilitate the switch from batch to continuous brewing.

A new philosophy and software tools for supply chain management, lean manufacturing and just-in-time production, which can be used in todays brewing industry as well, will minimize idle stock and allow brewers to produce only what end-users need. Informatic systems exploit big data to optimize plant operations, reduce downtime and predict trends. In addition, the products are 100% traceable.

Customer benefits:• Continuous brewing from wort production, fermentation,

maturation to packaging• Integrated yeast management• Accurate blending and dosing for just-in-time production• Lean manufacturing and inventory controls• Efficient brewing plant maintenance via

intelligent systems and real-time data analysis

A step change towards an exciting futureGEA Brewery 4.0


GEA LYODATATM provides unique marking, clear identification and consistent traceability of pharmaceutical freeze-dried products, making drug counterfeiting practically impossible. The system offers continuous quality inspection, 100% line clearance and precise sampling.

Customer benefits:• 100% traceability of product• Compatible with GEA ALUSTM automatic loading

and unloading system• Unique marking and clear detection of product• Continuous process and product monitoring• 100% line clearance• A reliable anti-counterfeiting system• Promotes patient safety

Continuous traceability of primary packagingGEA LYODATATM


GEA Cube and GEA Codex support flexible processing needs via a complete solutions package for process automation, plant management and data analysis with extensive tools.

Product safety is assured via complete tracking and tracing – from raw ingredients to finished product – ensuring peace of mind and building customer confidence.

Customer benefits:• 100% product traceability • Standardized modules for increased flexibility• Well proven, robust hardware and software platform• Intelligent recipe management• Scalability to meet future manufacturing needs• Plant simulation to test processes before

production begins• Mobile operation for improved plant management• Flexible ERP connectivity

Total transparency in production managementGEA Cube & GEA Codex


Service technicians are often organized in small, specialized groups making effective knowledge sharing difficult. Therefore, GEA has developed an intuitive smartphone application that equips service technicians with artificial intelligence support for failure mode analysis of equipment breakdowns. It ensures consistent handling and the efficient resolution of breakdowns, and closes the feedback loop from front line to product development.

Customer benefits:• Shorter ramp-up time for new service technicians• More efficient root-cause analysis of equipment failures• Faster resolution of equipment failures• Increased uptime of components and plants• Live feedback from field to factory stuff

Solve breakdowns more quickly and accurately GEA Diagnostics


By combining modern conditions-monitoring technologies with GEA’s world-leading industry expertise, we provide customers with maintenance, monitoring, analysis and optimization services that address the different challenges that can arise when customers are on their way to achieving their performance-related goals.

Customer benefits:• Constant transparency: Delivers facts about the current health

status of the equipment• Increased availability: Ensures the equipment is always in good

condition and ready for production• Total productivity: Establishes processes that provide a reliable

production environment• High efficiency: Optimizes production processes in order to

minimize losses

Delivering more insights and better performanceGEA PerformancePlus


For plant inspections, providing support during commissioning and in the event of technical problems, we have developed GEA Remote Eye Wear. Thanks to state-of-the-art technology, it offers customers virtual real-time support from a GEA service technician or helpdesk via remote access.

With its integrated high-resolution camera and reliable microphone, GEA Remote Eye Wear provides a wide range of bidirectional functions. By projecting images onto the screen, repairs, process optimization and inspections can be carried out at the speed of the internet.

Customer benefits:• Quick support without any physical effort• Available for use with all GEA equipment• Simplifies production assistance and visual inspections• Maximizes production time and reduces operational costs• Extends equipment life-time• Ensures staff safety and motivation• Increases quality of service

Virtual technology to improve productivity and reduce downtimeGEA Remote Eye Wear


In the past, component and plant design only came to life in the physical world, sometimes resulting in unexpected problems in terms of maintainability and component accessibility.

With virtual reality, component and plant design come to life and can be fully explored before physical construction. Multi-person collaboration in virtual reality helps in validating design options independent of any physical presence.

Customer benefits:• Component maintainability and accessibility

validated in design phase• Familiarization with plant characteristics prior to construction• Evaluate design options and speed up decision making

via collaboration in virtual reality • Clearly identify critical control points

Experience components and entire plants before they’re ever builtGEA Virtual Reality


In collaboration with MassChallenge* start-up company MachIQ, we can provide a range of digital services including remote assistance, spare parts e-commerce and data analytics for GEA serviced equipment via an open and independent maintenance management tool. Likewise, it is possible to integrate the portal with the majority of ERP systems and therefore provide an end-to-end (from customer to supplier) digital experience.

Customer benefits:• Open platform: Customer access via a single platform to maintain

equipment, irrespective of the original manufacturer • Independent platform provider: Customer decides which data they

want to share with the original equipment manufacturer (OEM)• E-commerce & remote assistance: Ensures streamlined processes

and quick reaction times from GEA Service• Data analytics: The tool provides in-depth equipment- or

maintenance-related data analytics• Spare parts inventory: A fully integrated spare

parts inventory management system helps identify obsolete or missing parts

Maintenance management toolMachIQ Customer Portal

23GEA digital solutions*MassChallenge is a global network of zero-equity startup accelerators (masschallenge.org).

https://masschallenge.org/

gea.com

Discover the world of GEA digital solutions · GEA Cube and GEA Codex support flexible processing...

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