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Automation in the CPG Industry

Plant operations vary greatly within the Consumer Packaged Goods industry. Whether you produce detergents, baby care products, or cosmetics, your business must navigate common challenges associated with rising raw material costs, downtime avoidance, and maximizing overall equipment effectiveness. Malisko can help you navigate by implementing automation technologies into your facilities to deliver solutions to meet your specific needs.

Automation Applications for Consumer Packaged Goods Facilities

Amine and Surfactant Tanks
Anoxic Mixing
Blanketing Systems
Bulk Ingredients Tanks (Tank Farms)
Catalyst & Thin Tanks
Decanter Tanks
De-Ionized Water Systems
Distillation Systems
Drum Charge and Transfer Stations
High-Shear Mixing
Influent Equalization / Neutralization
Ingredient, Catalyst and Solvent Headers
Lift Station Control
Liquid Chemical Blending
Main Batch Tanks
Solids Feeders and Dry Materials Add Stations
Solvent Stills
Vacuum Systems
Weigh Tanks for Pre-Batch

News Release: Malisko Improves Reliability for Pet Food Manufacturer by Adapting and Upgrading the Industrial Automation Control System (IACS) and Production Equipment.

Malisko improves reliability for Pet Food manufacturer by adapting and upgrading the Industrial Automation Control System (IACS) and production equipment.

Case Study: Leading Pet Food Producer Wanted to Increase Operational Efficiency by Upgrading Controls to Critical Retort Basket Handling and Tracking System

A global leading manufacturer of pet foods was faced with increasing operational inefficiencies of their wet pet food processing attributed to their obsolete and unsupportable control system.

Case Study: Global CPG Manufacturer Taps Malisko to Be Master Automation Integrator to Achieve High OEE for new US Production Line

A global consumer products manufacturer made the business case to install a new production / packaging line to increase capacity.

Case Study: Improving Plant-wide Productivity by Creating a Scalable and Uniform Controls Solution for Making Laundry Products

Our client wanted to have an improved batch control and liquid transfer system that could be scalable and applied across their many disparate mixer-based systems within their laundry products manufacturing plant.

Our Approach to CPG Automation

Over 25 years of experience has shown us that no two CPG production plants are the same. With the wide scope of the CPG industry, you need CPG automation experts who have proven experience working within a number of different areas of the CPG industry. Malisko is that expert, with a track-record of proven results and providing strong ROI for our clients. Whether you need a full automation plan designed from scratch, or optimization plans for existing systems, Malisko is here to help. We’ll provide your facility with the best in class CPG automation solutions, catered to your plant’s specific needs and goals. Best of all, when you work with our experts, we’ll provide ample business justification at each step of the process.

Site Assessment

Before we can design your new system and implement automation solutions that save you money and improve efficiency, we have to understand your challenges. To achieve this, we can engage with you to perform a site assessment. We listen to your operators, maintenance staff, engineers and operations personnel to fully understand your process, how your business operates, the problems you want to solve and what success means to you. Most important, we take the time to understand the best ways to collaborate with your in-house engineers throughout the automation process as we become familiar with your facility and the systems that make it run.

Our site assessment follows a tried and true process and is the first step in implementing an automation solution. During each site assessment, we will:

  • Identify Existing Automation Controls
  • Identify Potential Cost-Saving Solutions
  • Identify Opportunities
  • Business Justification
  • Presenting Automation Solutions
Front-End Engineering Design (FEED)

Successful engineering has to align everyday production with the big picture. Each processing unit and work cell must come together with your automation system to form not only an efficient production process but also one that matches your business goals and realities. When we present an automation solution to you, we make sure it matches your budget, your timeline, your current production realities and your goals, all while minimizing risk.

Our Front End Engineering Design (FEED) sets the foundation for a successful project accomplished on time, on budget and in a way that fits your in-house team.

If the needs of your business, plant and production line change over time, our systems come ready to change along with them. And if you need, we’ll even tweak the system design to fit the skill sets of your support team. We believe the best systems change for you. It shouldn’t be the other way around.

Once the FEED is completed, you will receive:

  • Outlined Business Objectives
  • Project Timeline & Budget
Detailed Engineering and Design

In our detailed engineering and design service, we transform the conceptual into the final design. We use all the knowledge we gain from the automation solutions site assessment and Front End Engineering Design (FEED) to minimize your risk, get you running quickly, and align our work with your business realities. Here we will also flush out project risks, planning for them by nailing down a realistic project budget, execution plan and timeline.

Malisko both designs your automation system and implements it. Our detailed engineering and design service picks up right after our FEED services leave off, and our system integration execution picks up right after our detailed engineering and design. We can handle the complete package: specification, design, procurement, development, on-site execution, troubleshooting and support of the control, network, security and MES layers.

During this phase, we can provide you with:

Project Execution

After we’ve completed our thorough automation solutions site assessment, Front End Engineering Design and Detailed Engineering Design, we have the information we need to document, code and integrate your automated system. We keep in mind your business goals. We factor in the strengths and limitations of your team, and we prioritize your most important objectives.

We design your system on a foundation of understanding so that we can rapidly implement it with absolute precision. We program each function in your system and set up an intuitive Human Machine Interface (HMI) and reporting that allows your team to adopt your system efficiently. We outfit your system with the reporting you need to stay on top of your production. Prior to installation, we run your system through several rounds of intensive testing in a simulated environment to make sure it works. Once we have programmed your machines, set up your HMI, created a useful reporting program and tested the functionality and performance of your system, it is time to install your system in your facility. When on-site system installation is complete, our team again extensively tests the operation, performance and functionality of the new system holistically from the field devices through to reporting.

During this phase, we can provide you with:

  • Programming & Logic Development
  • Human Machine Interface (HMI) Development
  • Reporting
  • System Integration Testing & Simulation
  • On-Site Process Commissioning

Computer System Validation (CSV) is a must in FDA-regulated industries. We design and implement your system to deliver consistent, efficient production that also meets CSV for FDA. And we prove it too. If you operate in a regulated industry, we take care of the paperwork related to CSV and reduce your Regulatory risk. We can provide a Validation Master Plan (VMP) and use it to guide our work. We document requirement specs, design specs, functional specs, test plans, installation and operational protocols, trace matrices and summary reports. We execute the protocols as well. We assist with keeping your records up-to-date via change control and help keep your system in compliance. Minimizing risk is ingrained in our company because we are committed to delivering you ROI.

During this phase, we can provide you with:

  • Computer System Validation Documentation
  • Executed Validation Protocols
  • Electronic Records
Post Project Support

If any troubles emerge with your system, we have you covered, whether it is warranty or support under a formal service contract. When you work with Malisko Engineering, you don’t just get a system, you get a whole team to support it. If you have a full maintenance and system support staff on hand, we will provide assistance to fill the cracks. As much as practical, we can help your team be properly equipped to maintain and troubleshoot your process and automation system. If you need full support services, we are available 24/7 to make sure your system works.

During this phase, we can provide you with:

  • Post-Commissioning Technical Support
  • Remote Support

Contact our Trusted Food & Beverage Automation Experts Today

Malisko has decades of experience working with clients in the food and beverage industry. Contact us today to learn more about how we can help optimize your facilities.

Why Hire a Systems Integrator?

Can’t decide between a systems integrator and a general contractor for plant automation? Learn how systems integrators save you money, add value and ensure quality. Download our White Paper to learn more.

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