Technology providers are constantly removing system components from their portfolio. This also means that food manufacturers have to react with short-term adjustments. However, there is another way: with forward-looking and proactive obsolescence management, plant performance and the state of the art can be maintained for decades without jeopardising production.
In order to cope with the high production pressure in the industry, we need Efficient systems, that are always state of the art. But how can the necessary modernisation work be carried out as quickly and cost-effectively as possible? The key lies in Predictive obsolescence management, as the latest project between Syntegon and Gropper shows. Since 1929, Gropper has stood for forward-looking action and proximity to the customer. What began more than 90 years ago as a cheese dairy is now a successful medium-sized company with more than 900 employees. Although the company name rarely appears on the label, the private label specialist is always present: its dairy products, direct juices, smoothies and water can be found in supermarkets throughout Europe.
Gropper produces in large quantities. Almost 270 million litres of conventional milk and around 81 million litres of organic milk are processed each year. At its main site in Bissingen in northern Swabia, the company produces on seven cup lines, five bottle lines and one gable top carton line. The products are mainly sold in German discounters - an industry with very high cost pressure. Long downtimes are not possible with the volumes required. In addition, the modernisation of systems is only Very short time window in spring or autumn available. To ensure that Gropper products remain a permanent fixture on the refrigerated shelves of discounters and to be able to resume production as quickly as possible, the company relies on efficient processes.
This is also the top priority of Helmut Weissenbach, Project Manager at Syntegon. Modernisation is an integral part of everyday production of its customers in the food industry. It is often not the fault of the system manufacturers themselves that certain parts need to be replaced. They are also dependent on suppliers, for example for components for the control electronics. This is what happened in the most recent case: The machine manufacturer was informed via Schneider Electric (SE), from whom Syntegon purchases the control technology for its filling machines, that components for the control electronics of certain systems will no longer be available from 2024.
Instead of waiting, Weissenbach and his colleagues immediately set off on the Search for a modernisation solution, which takes up as little time and material as possible and thus ensures that customers can continue to reliably supplied with the appropriate control components remain. Gropper also operates one of the affected systems, which Syntegon had recently successfully modernised at a competitor. The experts were able to use the experience gained from this pilot project to implement the modernisation at Gropper even more efficiently.
Claus Mayr, Deputy Head of the Filling and Packaging Technology Project Planning Department at Gropper, welcomes this proactive approach. Both companies have been working together for many years. The machines, requirements and challenges are therefore well known. Accordingly, Mayr also turned to the Modernisation of the affected eight-lane bucket line in the ultra-clean version The modernisation of the first cup filling machine was not only completed faster than planned. In addition to the control technology, the machine's filler was also overhauled within the same time frame. Time and financial savings therefore went hand in hand.
Thanks to the previous pilot project in the milk processing industry, Syntegon Draw on a wealth of experience and optimise processes. The control electronics were replaced and the dosing unit overhauled by experienced experts. The result is impressive: The new control system was installed in just seven days. In fact, the modernisation went so smoothly that Gropper did not need any additional production support from a programmer on the last day of the project. After commissioning, the cup line immediately achieved the usual output rate, so that No efficiency run had to be carried out. The subsequent count reduction test in the test laboratories to determine the microbial count also showed that the microbial reduction functioned perfectly in accordance with the ultra-clean filling requirements.
With this project, Gropper has positioned itself well for the future in more ways than one: The private label specialist now has control technology in stock again, so that components can be supplied as required. replaced quickly and production downtimes kept to a minimum can be realised. The team was also able to pick up some know-how during the modernisation process. The employees also completed a one-day training course so that they can easily replace motors or controllers and carry out motor referencing themselves in future.
The next project planned is the modernisation of another filling line in Bissingen: By 2026, Gropper wants to convert all machines to the new control technology with the active support of Syntegon. This will give the company planning and production security for the coming years. Short-term obsolescence and modernisation are a thing of the past, and the high production volumes can also be optimally met in the future.
