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The perks of power visibility
Technology Category
- Application Infrastructure & Middleware - Data Exchange & Integration
- Analytics & Modeling - Real Time Analytics
- Networks & Connectivity - Network Management & Analysis Software
Applicable Industries
- Food & Beverage
Applicable Functions
- Discrete Manufacturing
- Maintenance
Use Cases
- Predictive Maintenance
- Real-Time Location System (RTLS)
- Edge Computing & Edge Intelligence
Services
- System Integration
- Data Science Services
The Challenge
Nestlé Nescafé, the world’s largest soluble coffee factory, faced a significant challenge with unplanned stoppages disrupting production. In one year, the factory experienced eight unplanned stoppages, which had a significant impact on production efficiency and costs. The factory, located in Toluca, Mexico, produces one million jars of coffee every day, and any disruption in the production process can have a significant financial impact. The factory operates 365 days a year, and any unplanned stoppage can impact the reliability of the processes and affect what makes it to grocery shelves. In 2013, Nestlé invested approximately $125 million to expand this plant, increasing production by 40% and making it the largest soluble coffee facility in the world. At this scale, even modest gains to energy efficiency and service improvements translate to sizable cost savings. Improving the reliability of the facility’s electrical equipment would deliver the productivity, efficiency, and maintenance benefits Nestlé sought.
About The Customer
Nestlé Nescafé is the world’s largest soluble coffee factory, located in Toluca, Mexico. The factory produces one million jars of coffee every day, making it a significant contributor to Nestlé's overall production. One of the most popular products made at this factory is Nescafé Clásico, a staple for people around the globe. The factory operates 365 days a year, making any unplanned stoppage a significant disruption to the production process and potentially impacting the availability of products on grocery shelves. In 2013, Nestlé invested approximately $125 million to expand this plant, increasing production by 40% and making it the largest soluble coffee facility in the world. At this scale, even modest gains to energy efficiency and service improvements translate to sizable cost savings.
The Solution
Nestlé Nescafé turned to Schneider Electric for a solution to their challenge. They implemented Schneider Electric's EcoStruxure Asset Advisor, a solution that allows power systems to be visible and remotely managed 24/7 from any device. The solution was implemented in certain sections of the factory during a pilot phase, with three transformers fitted with PowerLogic Tag Series TH110 wireless temperature sensors, allowing them to communicate with the Asset Advisor service. After a short circuit inside an unmonitored section of the main substation resulted in a 14-hour shutdown, costing Nestlé approximately $588,000, the decision was made to utilize Asset Advisor throughout the Nescafé plant. This gave Nestlé real-time visibility into its electrical equipment, allowing engineers to remotely monitor assets. Prior to Asset Advisor, maintenance was reactive — Nestlé hired specialized service providers as needed. Today, through EcoStruxure, Nestlé has moved to predictive maintenance; connected services anticipate potential failure, which allows teams to resolve issues proactively to avoid downtime.
Operational Impact
Quantitative Benefit
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