Transforming Food & Beverage Industry through Greenovative’s Breakthrough Solutions

The client is a renowned food and beverage manufacturer and distributor, operating across the Gulf Cooperation Council (GCC) region.  

The company is known for its high-quality products and strong distribution network, with over 100 distribution centres. 

Its product offerings span across dairy, bakery, and juice categories, catering to the diverse needs of consumers. With a robust presence in the GCC market and a revenue in the billions, the company continues to grow and expand its reach. 

Goal  

The client had set several goals for its operations, focused on delivering top-quality products to customers and streamlining the overall system. With the help of Greenovative, the client aimed to: 

• Maximize productivity with cutting-edge industry 4.0 technologies such as AI and ML.
• Drive towards Net Zero energy consumption across all sites by 2025.
• Adhere to ISO 50001 standards for energy management.
• Optimize energy cost through comprehensive benchmarking across all locations.
• Establish processes in compliance with SFDA regulations.
• Continuous monitoring and improvement of energy management processes to achieve long-term sustainability goals.

Challenges 

The implementation of energy management system across multiple facilities posed significant challenges, some of which were: 

• Coordination and standardization across multiple sites with varying conditions and infrastructure.
• Integrating new hardware and technology with the existing legacy systems.
• Identifying and mitigating the potential risks of downtime and service disruptions during the implementation process.
• Developing a comprehensive plan for data collection, management, and analysis.
• Ensuring seamless communication and collaboration between all stakeholders, including the vendor and internal teams.
• Adequate training and capacity building of internal personnel to efficiently operate and manage the new systems.
• Ensuring data privacy and security in the system.
• Addressing the training and skills development needs of employees to adapt to the new technology.
• Measurement & Verification of energy savings achieved 

Methodology 

The implementation of the advanced energy management system was carried out with a strategic and systematic approach.  

A thorough site survey was conducted to gather vital information and pinpoint key data points.  

This was followed by the aggregation of data and the installation of advanced edge devices to collect real-time data from various sensors placed across 115+ facilities. 

The collected data was encrypted and transmitted to the cloud server, where it was processed by the proprietary energy intelligence platform. This platform, powered by state-of-the-art AI/ML algorithms and analysed the data in real-time to provide insightful recommendations and optimize energy usage.  

 Implementation statistics 

• The implementation involved the installation of cutting-edge technology such as multifunction energy meters, flow sensors, temperature sensors, IoT gateways, and a Microsoft AZURE cloud server to monitor and measure energy consumption and key process parameters. The exact number of each type of sensor installed may vary based on site-specific conditions and requirements as below.
  – Locations: 115+ Across 5 countries in GCC
  – Sensor: 1200
  – Process parameters monitored: 120
  – IoT Edge device: 800 

• The energy intelligence platform processed approximately 525,600 million data points per year, leading to the generation of actionable insights and significant cost savings in energy expenses.