Driving food manufacturing agility through digital intelligence

Packaged food manufacturers must balance high-volume production with stringent food safety standards and rising raw material costs.

Altizon’s DFX platform unifies your digital operations, connecting disparate production lines and utility systems to provide real-time visibility. From ingredient processing to final packaging, our suite enables you to minimize waste, ensure compliance, and improve performance across the entire factory floor.

Talk to an expert

See case studies

Challenges in food manufacturing industry

Yield loss and Overfill

Inaccurate dosing and filling leads to product giveaway or underweight rejects. Without digital insights into these operations, small variances across high volumes significantly erode margins.

Stringent food safety compliance

Managing HACCP, thermal processing logs, and sanitation (CIP) schedules via paper is slow and error-prone. Transitioning to digital operations is vital to ensure audit- readiness and improve performance.

High-frequency SKU changeovers

Frequent shifts in packaging sizes and recipes create significant downtime. Without digital tracking, identifying the root cause of changeover delays makes it difficult to improve performance.

Utility and thermal intensity

Ovens, fryers, and industrial freezers drive massive energy costs. Failing to monitor SEC and SWC in these operations prevents plants from hitting sustainability and cost-reduction targets.

Altizon DFX: optimizing food production with digital intelligence

Digital quality and food safety

Paperless digital quality checklists.
Critical process and lab parameter analysis in real time
Advanced process analytics to maintain process control limits and improve performance.
Ensure end-to-end traceability from raw material intake through thermal processing to final dispatch.
Automation of digital audit trails to eliminate the "paper scramble" and ensure food safety.

Impact:

Production performance

Real-time tracking of batches, work orders, and SKUs to synchronize production plans with operations.
Granular OEE and loss analysis across mixing, cooking, filling, and packaging lines
Identification of bottlenecks and unplanned losses across varying shifts and product types.
Anomaly detection via real-time monitoring of critical process parameters to prevent batch failures.
Mass balancing from raw material to output, to identify and eliminate sources of yield loss.

Impact:

Utilities optimization

Real-time monitoring of electrical energy, steam, compressed air, and chilled water across operations
Granular tracking of SEC and SWC at the process and department level to improve performance and sustainability.
Automated maintenance scheduling and alerts based on periodic, time-based, or runtime-based usage.
Identification of utility waste in energy-intensive stages like thermal processing and industrial freezing.
Correlation of utility consumption with specific batches and SKUs for accurate cost-per-case analysis.
Improvement: 3–5% reduction in energy and water consumption. Sustainability dashboards for water reuse, effluent, and waste

Impact:

Enterprise visibility

Centralized digital operations cockpit for real-time KPI comparison across plants
Standardized performance benchmarking and transparency for contract partners.
High-level executive scorecards for SEC, SWC, and OEE trends across the enterprise.
Instant digital audit trails for government, and environmental compliance.
Data-driven trend analysis and forecasting to identify long-term opportunities to improve performance.

Impact:

The Altizon advantage

Unified asset connectivity

Directly integrates data from disparate processing equipment, like industrial ovens and mixers with high-speed packaging lines to create a single digital record of all operations.

Food industry KPIs

Standardizes the tracking of SEC, SWC, mass balance, and giveaway (overfill) to improve performance using industry-specific templates instead of custom code.

Digital compliance

Enforces real-time validation for HACCP and quality parameters at the source, replacing manual logs to ensure accurate, audit-ready data without the "paper scramble.

Enterprise scaling

Synchronizes digital operations and benchmarks across internal plants and external co-packers to provide a single, audited version of truth for the entire supply chain.

Proven improvements across production lines

10–15%

Higher throughput

Maximize asset utilization and eliminate downtime to drive higher output from processing and packaging operations.

20–30%

Fewer quality deviations

Minimize rejects and rework through real-time digital visibility and tighter control over safety parameters.

2–3%

Lower utility costs

Reduce SEC and SWC by optimizing energy and water usage across thermal and sanitation cycles.

30%

Faster audit readiness

Digitize logs to automate HACCP reporting and accelerate root-cause analysis (RCA) via digital operations.

Altizon deployment roadmap

Pilot (6 weeks)

1 plant, 4 lines. quality and productivity digitization

Scale (10-12 weeks)

Scale up to the whole plant. Digitize energy and other utilities

Enterprise (20+ weeks)

Multi-plant rollout with centralized cockpit and standardized KPIs

Case study snapshot

Varun Beverages: Standardizing performance across…

Altizon’s Digital Factory Platform helped Varun Beverages connect multi-OEM bottling lines and utilities into a single, vendor-neutral digital…

Suhana Spices: Digital batch intelligence…

Altizon’s Digital Factory Platform helped Suhana Spices transform manual and siloed batch tracking into a connected, real-time system…

Bring clarity and control to packaged food operations at scale

Request a demo