Packaging meat reliably thanks to Smart Services
By using the Smart Services and digital assistance provided by MULTIVAC, "Migros Ostschweiz" in Eastern Switzerland has been able to detect unplanned machine downtime at an early stage and secure its production sustainably.
Fresh meat products are among some of the most sensitive in the food industry. Time-critical sequences and process reliability in production, as well as the reliability of the machines involved, must be coordinated perfectly, since delays or faults have an immediate effect on the entire added value chain. It is therefore even more crucial, that production and packaging processes run consistently, and also function reliably even at high capacity levels.
These demands represent a daily challenge in practice for large food producers. The example from one of the most important meat processors in Eastern Switzerland shows, how critical it is to have a perfectly functioning interaction between production and packaging: The "Migros Ostschweiz" cooperative is one of ten regional cooperatives within the Migros Group, and it is among the largest retail companies in Eastern Switzerland. At the same time it is also one of the leading meat producers in the region, and it sells its fresh meat products via the Migros butchers outlets. Every year around 8.5 million kilograms of meat are processed, and some 24 million packs are produced.
Automated lines from MULTIVAC are used in the company's meat processing and packaging. The packaging process runs without interruption in continuous shift operation, involving thermoforming packaging machines with cross web labellers or conveyor belt labellers. In such an environment any unplanned machine downtime has an immediate effect. If a line breaks down, it stands idle for one to two working days on average, and this has tangible consequences for production planning, delivery capacity and processing costs. In order to detect such risks at an early stage and prevent them if possible, "Migros Ostschweiz" relies on the many years of cooperation with MULTIVAC.
When dependability becomes the strategy
The company has been working with MULTIVAC since 1997, and today it has ten thermoforming packaging machines in use. Sliced products and sausages are packaged in MAP packs, while fresh meat is packaged in MAP, FormShrink or skin packs. In the case of fresh meat, which has to be processed very quickly, a high level of continual line availability is critical. It is for this reason, that the company relies on a major servicing exercise, which is carried out annually by MULTIVAC within the operation: “In the fresh meat business the availability of the lines is crucial for us, since we have to process and package the products immediately. We therefore rely on a preventive maintenance exercise every year out of season, so that the availability of the lines is assured on a continual basis,” says Franz Breitenmoser, Production Manager at Migros Gossau.
Augusto Votta, Senior Director for Sales at MULTIVAC Export AG, adds: “In order to minimise unplanned machine downtime and make service deployments more efficient, we recommend to our customers that they adopt a holistic concept for servicing and machine optimisation. This should also integrate new, data-based approaches as well as the traditional proven ones. Crucial to this is the interaction of different strategies, which complement each other mutually: On the one hand, "Preventive Maintenance" comprises the regular servicing measures, which can be planned and ensure that the machines function reliably and safely in daily operation. This creates the necessary foundation, on which all the other servicing work is built. On the other hand, "Predictive Maintenance" using the analysis of machine data makes it possible to determine, when an unplanned machine breakdown may be threatening, and if there is an actual need for servicing.“
By combining both approaches, it is possible to plan and consolidate machine servicing in a targeted way. This means that unnecessary servicing can be avoided, costs reduced, the lifespan of the machines extended, and the risk of breakdowns reduced. The result is an integrated servicing concept, which can be planned and is data-based, while also being perfectly coordinated with the everyday production of a food company.
When it installed four RX 4.0 thermoforming packaging machines of the new generation, Migros made the decision to also invest in "Predictive Maintenance" using the Smart Services from MULTIVAC. These digital solutions are now used on the four RX 4.0 machines as well as on an existing R 535 thermoforming packaging machine. These data-based digital services, which rely on the analysis of Smart Data and the networking of the machines, were specifically designed for the individual requirements of Migros. The aim is to minimise unplanned machine downtime, make servicing more efficient and easier to plan, while also optimising the available resources – in particular personnel, time and costs. The benefit of this "Predictive Production Management" is that Migros is informed, as soon as a potential problem on the line is looming, and long before it becomes apparent in operation. This means that potential faults can be checked at an early stage and then eliminated.
A concrete example from everyday production shows, how crucial this data-based approach is: A fault in a heating plate was detected at an early stage thanks to the machine data and "Predictive Maintenance" algorithms. There were however no signs of this during the actual packaging process, either in the quality of the pack or the speed of the line. Only the data made it apparent, that a problem was developing in the background: The functioning heaters were compensating for the already defective module – a short-term solution, which could however cause the overloading of the entire heating system over a longer period of time. If another heater had broken down, this would certainly have caused the stoppage of the entire line. The affected heating module was replaced, before it could develop into a fault. The timely intervention prevented a longer production stoppage and the consequent spoilage of large quantities of meat.
Data-based optimisation and Predictive Maintenance
In addition to Smart Services, "Migros Ostschweiz" also relies on MULTIVAC for assistance from digital data, which has the aim of optimising the packaging process, by detecting hidden potential as well as possible breakdowns, reduced machine speeds and increased material wastage. This approach comprises four stages: Analysis, Detecting potential, Optimisation and Successful implementation. Here machine data is captured, bottlenecks identified, and measures developed to increase "Overall Equipment Effectiveness" (OEE). The aim is to increase efficiency sustainably through a combination of data-based analysis and process know-how. In addition to analysis of the technical parameters, it is also possible to give greater transparency to operating and process factors.
Here there is a particular focus on identifying causes that could arise from operating behaviour. For example, it is possible to analyse errors arising from a particular shift: If errors arise less frequently in the early shift than in the late shift, targeted training measures can be adopted for the operators involved. In the case of "Migros Ostschweiz", this assistance from digital data enabled the output to be increased and greater process efficiency to be achieved. Based on the machine data collected, it was possible to identify and implement several measures to optimise the packaging process. This led to a reduction in unplanned machine downtime and an improved OEE, as well as increased line output with the same personnel and time requirement. The analysis of machine data, combined with the practical experience of MULTIVAC's experts in the processing and packaging operations, played a significant role in the outcome.
From data comes reliability
Thanks to this combination of Smart Services, Predictive Maintenance and assistance from digital data, "Migros Ostschweiz" has been able to significantly increase the reliability of its packaging process. “Unplanned machine downtime has been reduced, the OEE improved, and production overall made easier to plan. In our many years of working together with MULTIVAC, the focus has not only been machine availability alone, but also on continual optimisation of the packaging process,” explains Franz Breitenmoser. “Over the 30 years. in which we have worked together, we have always perceived MULTIVAC as a very good partner, who supports us in ensuring the best possible product quality at all times for our customers.“
This added value is underlined by the many concrete examples, of how the timely, data-based replacement of components was able to prevent a potential breakdown. For "Migros Ostschweiz" this means primarily one thing: Greater security in an environment, in which reliability and timing are crucial. Particularly in the production of fresh products, where any interruption has a direct effect on supply, the ability to detect potential risks at an early stage has become a key factor in success. These results show, that the combination of Predictive Maintenance, machine data and an understanding of the process make a sustainable contribution to efficiency and food safety.
28.09.2026
