Category: Equipment

In an era dominated by digital transformation, the packaging and processing industries increasingly rely on big data to streamline operations and enhance efficiency. Central to this revolution is the concept of the “data lake”—a vast, dynamic repository that stores and secures colossal amounts of raw data. PMMI’s white paper, Transforming Packaging and Processing Operations, offers a deep dive into the challenges and opportunities associated with data lakes, revealing how industry leaders leverage this resource to gain a competitive edge.

Understanding the Data Lake

  A data lake serves as a central point where businesses can store unstructured data across various sources until needed. One of the unique features of a data lake–and this distinguishes them from data warehouses–is that they are not schema-in. This means they can take in raw data in its native format without changing any of the data attributes from the source. They only apply schema to the data on the actionable side of the data lake once it has been processed for analytics, making it schema-out. Data warehouses, on the other hand, are schema-in, meaning the data must be structured before coming in.

  Data lakes are helping manufacturers solve concrete problems. With the schema-out structure of data lakes, manufacturers organize what information they need when they need it. This flexibility makes it an invaluable tool for machine learning, analytics, and real-time reporting, helping companies to react swiftly to market changes and internal demands. On the other hand, manufacturers must define their data needs with a schema-in structure before using it. And in most cases, they only end up using a fraction of the data.

  The packaging and processing industry is increasingly seeing the potential value of data as an asset. It is being used to measure and enhance business performance and operations, with applications including:

•             Measuring performance and downtime

•             Developing and tracking KPIs

•             Driving operational improvements

•             Performance opportunities

•             Analyzing equipment

•             Processing performance vs. expectations

•             Tracking quality and production metrics

•             Analyzing business operations

•             Driving, planning, safety, BOMs, specs, and operations improvements.

  For example, a quality problem—whether it is beverage contamination or a delivery that doesn’t meet specifications—can mean a dreaded slog through uncontextualized (or even paper) data to find out what happened. Moving to a data lake turns this process into a much simpler query that can be done in minutes. Proactively creating traceability reports means that manufacturers can quickly identify the underlying issue and pinpoint just the affected units, keeping products on the shelves and ultimately protecting consumers and the bottom line.

  Finally, predictive maintenance is often considered the pinnacle of data-driven manufacturing. According to another report by PMMI, Trends in Remote Monitoring, the ability to use predictive maintenance was seen as either somewhat or very important by 83% of end-users. Reduced machine downtime is a major factor in end-users specifically investing in predictive and preventative maintenance, with 92% of end-users citing machine downtime as a very or somewhat important factor. Data is the foundation and requires a combination of people, process, and technology expertise. Without enough data and the right data architecture, it will remain elusive.

  Data lakes are the foundation to process and analyze immense amounts of sensor data in real time and then visualize it to enable pattern recognition. This opens the door to testing and training machine learning models on historical sensor data to identify the precursors to machine failure. As manufacturers and their technology partners fine-tune these models, they become increasingly adept at predicting machine failure far enough in advance to perform necessary maintenance to prevent failure.

  However, the Transforming Packaging and Processing Operations white paper shows that while data lakes are widely acknowledged for their potential, many companies in the packaging and processing sectors are not fully tapping into this potential. End-users and OEMs alike admit that there is significant room for improvement in how they utilize data to enhance operational efficiencies and drive business growth.

Challenges in Data Management

  One of the primary challenges in managing a data lake is ensuring the quality and consistency of the collected data. PMMI’s findings indicate that data management practices vary widely, from manual data entry to sophisticated AI-driven analytics platforms. This inconsistency can lead to data reliability and usefulness issues, potentially turning a data lake into a “data swamp.”

  Security is another critical concern. As companies move more of their operations to the cloud, they must protect data against breaches and theft. According to the PMMI white paper, data governance and security challenges emphasize the need for robust strategies to manage and protect the vast amounts of data collected and stored in data lakes. This includes concerns about interoperability and sharing data across different platforms and stakeholders while ensuring data security and privacy.

  One end-user participant in PMMI’s research pointed to the importance of storing data in the cloud so that it can be shared across organizations and noted, “the more data you have, the more value you’ll create at the data lake” and “the more people who have access to the data, the more that value can actually be realized.”

  However, data security and confidentiality concerns can prevent data from being shared and fully leveraged. These are often the most common threats within IT teams in factories and can lead to tension between IT and OT teams. The white paper suggests that action is needed to bring IT and OT leaders together and to involve IT specialists more in discussions about data analytics. Although the technology to leverage data offers “tremendous economic benefits,” very real risks can be “profoundly expensive to the organizations if any of these security vulnerabilities get exploited.”

Leveraging AI and Advanced Analytics

  Artificial Intelligence (AI) and machine learning are playing increasingly critical roles in navigating the complex data landscapes of the packaging and processing sectors. The rise of artificial intelligence and advanced analytics has transformed the potential of data lakes. These technologies allow companies to predict trends, automate decision-making processes, and optimize operations in ways previously unimaginable. For instance, as previously noted, AI-driven predictive maintenance can anticipate equipment failures before they occur, minimizing downtime and maintenance costs.

  The integration of AI extends beyond maintenance. It’s also transforming operational processes by enabling the analysis of vast data sets to identify inefficiencies and optimize production lines. AI’s potential to offer predictive insights can lead to significant improvements in both productivity and operational reliability.

  The Transforming Packaging and Processing Operations white paper underscores the varying degrees of AI integration across the industry, with some companies at the forefront of innovation and others just beginning to explore the possibilities. The common thread, however, is a clear recognition of the need to invest in these technologies to stay competitive.

Collaborative Efforts and Industry Standardization

  PMMI’s white paper stresses the importance of collaboration and standardization to maximize the benefits of data lakes. By sharing data and analytics tools, companies can gain insights that would be unattainable in isolation. Standardizing data formats and analytics processes can also facilitate a more seamless integration of new technologies across the industry.

  The PMMI white paper highlighted several collaborative initiatives, such as the Vision 2030 series and the OpX Leadership Network, which are focused on developing industry guidelines and best practices. These efforts are essential in fostering a more integrated and efficient data management and utilization approach.

Future Directions and PACK EXPO Southeast

  Looking forward, the report suggests that embracing data-driven strategies will be crucial for the packaging and processing industries. PACK EXPO Southeast (March 10-12, 2025; Georgia World Congress Center, Atlanta) offers numerous resources, such as Innovation Stage presentations and networking opportunities, to aid in this transition. These gatherings allow industry leaders to share best practices, explore new technologies, and form partnerships that can help them navigate the complexities of data management.

  The three-day event comes on the heels of a successful PACK EXPO International, the largest packaging and processing trade show this year. PMMI forecasts a convergence of 7,000 attendees to Atlanta from consumer-packaged goods and life sciences companies based in the Southeast to witness innovation in action, learn about the latest industry trends and topics, and network for brand and professional growth. PACK EXPO Southeast will feature 400 exhibitors displaying the latest solutions and technologies for 40+ vertical markets over 100,000 net square feet of exhibit space, making it a perfectly sized show where attendees can explore many solutions yet have a personalized experience and meaningful interactions to address their specific needs.

  As the packaging and processing industries continue to evolve, the role of data lakes will become increasingly central. By addressing the challenges of data management, harnessing the power of AI, and fostering industry-wide collaboration, companies can unlock the full potential of their data to drive innovation and efficiency. The insights from PMMI’s report and the resources provided at PACK EXPO Southeast are invaluable tools in this ongoing journey, helping businesses stay afloat in the vast data lake and thrive in these turbulent digital waters.

  Dive into the innovation epicenter and discover answers to your packaging and processing challenges at PACK EXPO Southeast. Taking place in one of the U.S.’s most vibrant manufacturing hubs comes the new PACK EXPO Southeast (March 10-12, 2025; Georgia World Congress Center, Atlanta). Discover the future of packaging and processing at the most comprehensive show in the region offering crossover solutions for any of today’s biggest manufacturing needs to 40+ vertical markets. Brands will find the Atlanta location, a manufacturing hub of the region, convenient and easy to access for teams to attend, assess the latest technologies, learn from leading industry experts, and make valuable connections to meet current or upcoming projects. For more information and to register, visit packexposoutheast.com.

By: Alyssa L. Ochs

Efficiently managing wastewater helps breweries and distilleries reduce operational costs and promote environmental sustainability. The management process may involve reducing water usage by fixing leaks, using high-efficiency equipment and optimizing cleaning processes. It may also involve monitoring the quality of wastewater to identify issues early on and understanding what’s in the wastewater to adjust treatment methods accordingly.

  Breweries and distilleries can handle wastewater using various treatment options. To get a better sense of the options available, we connected with companies working in this industry and producers who have found wastewater treatment systems that work well for them.

Where Wastewater Comes From

  Craft beverage producers use a lot of water in their processes, and much of that water becomes wastewater. Wastewater production comes from various cleaning tasks, including washing bottles, kegs, utensils and building surfaces.

Wastewater comes from wort production because making wort requires water as an ingredient to standardize the alcohol content. Washing and sterilizing vessels, refrigeration and container applications also produce wastewater in a beverage production facility.

Wastewater Treatment Options

  One treatment option for wastewater is ultrafiltration, which uses a membrane filtration process to remove microorganisms and particles from water. Some facilities use filtration to pretreat water before reverse osmosis.

  Reverse osmosis is a purification process that removes tiny molecules in water and is typically more effective than other methods. However, it can potentially cause bacteria contamination, and the production rate can be slow.

  Ultrafiltration is a treatment option to remove bacteria, viruses and other microorganisms from water. However, it is not powerful enough to remove dissolved solids, metals or chemicals.

  It is also possible to use a bioreactor in the wastewater treatment process that supports a biologically active environment where bacteria and protozoa can grow. This type of chamber can be aerobic to remove organic matter and oxidize ammonia to nitrate or anaerobic, which just removes organic matter. An anoxic bioreactor removes nitrogen from nitrates to nitrogen gas.

What’s Working, What’s Available

  Tyler Glaze is the COO of Shorts Brewing in Elk Rapids, Michigan and told Beverage Master Magazine that his brewery uses an aerobic membrane bioreactor (MBR) to treat wastewater. Shorts Brewing is a mom-and-pop operation, yet one of the largest craft breweries in the state. It prioritizes natural resource protection, outdoor recreation, equity and other community development initiatives.

  Glaze said that his brewery does not use wastewater in the brewing process because there isn’t a cost-benefit to doing so at the moment.

Yet he said that historically, Shorts’ most significant wastewater challenge was the volume of biochemical oxygen demand (BOD), phosphorus and total suspended solids (TSS). This is because Shorts’ aerobic MBR system and side-streaming efforts in the brewhouse and the cellar control BOD, phosphorous and TSS exceptionally well.

  “Our BOD to drain is reduced from around 700 to 1,000 pounds of BOD per day to less than one pound of BOD per day to the municipality,” he said. “We have similar reductions in the volume of TSS and phosphorous as well.”

  However, he said the brewery’s biggest challenge currently is the volume of solids separated from the wastewater treatment plant.  “Our aerobic treatment system creates solids as a byproduct of treatment,” Glaze said. “Reducing the volume of the solids through separation and drying would be our next step to reduce the costs of hauling the solids.”

We also connected with Copper Bottom Craft Distillery in Holly Hill, Florida, to discuss wastewater. Copper Bottom is a small-batch distillery that produces handcrafted, award-winning spirits from raw sugar cane without artificial colors, flavors or sugars added. It offers tours, a tasting room and a membership-based Rum Club.

  Jenni Craig, Copper Bottom’s CMO, told Beverage Master, “We don’t use anything to treat wastewater. We treat our product and production water through a reverse osmosis unit. We use this RO water to proof our spirits.” Craig also shared, “We use 25 percent of our stillage from the previous run into the next cook.” To date, Copper Bottom has not encountered any significant challenges with its wastewater.

  One company working in this space is Cambrian Innovation, based in Watertown, Massachusetts. Cambrian’s mission is to make distributed water reuse simple, sustainable and cost-effective. It helps businesses across various sectors (including beer, spirits and wine) transform their wastewater into a valuable resource while generating clean energy and clean water with industry-leading solutions. This leader in sustainable resource management specializes in transforming environmental liabilities into assets while helping businesses save money through efficient processes and environmentally responsible practices.

  Matt Silver, CEO of Cambrian, told Beverage Master that his very first customers were in the craft beer industry. He is currently working on projects with numerous craft beverage customers today. Cambrian’s Water-Energy Purchase Agreement (WEPA) allows beverage manufacturers to recycle high-strength wastewater as a service.

“Cambrian’s core focus is helping customers recover clean water, clean energy and even carbon dioxide from their waste streams,” Silver said. “Our goal is to eliminate the challenge of managing these waste streams and the cost associated with that, as well as the cost of using those commodities and utilities. It’s really a win-win.”

Silver explained, “We have a range of proprietary technologies and solutions that we install onsite that take polluted water and generate drinking-quality water and biogas that can be used for heat and electricity. What that does is cut the customers’ waste generation, reduces their carbon footprint and decreases their overall water use.”

Silver said craft beverage producers interested in improving their wastewater management should reach out to Cambrian to have a phone conversation or visit their website. From that point, Cambrian will ask for details about the customer’s facility, evaluate the opportunity, provide an estimate and present a term sheet to sign before developing a final design. Cambrian’s services are best geared toward medium- to large-size breweries that produce more than 30,000 barrels per year.

Another company you should familiarize yourself with when you’re developing a wastewater solution is American Hose & Supply. This company is a leading hydraulic and industrial hose supplier that ships to all U.S. states and internationally.

  Based in Tulsa, Oklahoma, American Hose & Supply serves many different industries, including breweries. Its product line includes various sizes and types of hydraulic hoses and rugged hoses for industrial applications. It can custom-build hoses at any length for your needs and according to your desired pressure rating and end-fitting specifications. You can also contact American Hose & Supply for pressure washers, gauges, tubing, valves, clamps, barbs, fittings and couplers to handle wastewater.

Choosing Your Wastewater Solution

  Silver from Cambrian Innovation emphasized the need for beverage makers to continuously consider their wastewater management goals throughout the process of researching options.

“Are they looking for compliance, or are they looking to reduce the volume of water they use?” Silver asked. “That will dictate the quality of the water they need. Also, think about whether they want to own and operate their own system or pay for performance on a per-gallon basis while they focus on their business.”

  Glaze from Shorts Brewing urges craft beverage producers to remember that you cannot control what you don’t measure. If you don’t work hard to get an accurate understanding of your waste stream, you won’t be able to design an appropriate system to handle it. He recommends doing your research or hiring a team to help you determine the best approach to handling your waste stream.

“There is no one-size-fits-all solution to brewery waste management because every municipality has different constraints,” Glaze said. “You might be surprised what you are able to send to a municipal waste system and what you are not.”

  He also explained that there is a quick and easy way to determine if your local municipal wastewater treatment system is functioning well or needs improvement.

  “Typically, if a system is working well, you won’t ever hear from your wastewater treatment facility, especially as you are starting up a brewery,” Glaze said. “If the municipal wastewater treatment system isn’t able to effectively handle waste, they will start surveying industrial users like breweries and food producers.”

  He recommends using the EPA’s Water Pollutant Loading Tool to locate your local system and look up the detailed facility report for that local treatment system.

  “If you notice a trend that shows they are seeing increased loading or violations in the quarters where you are producing the most beer, then you should definitely start the process of planning improvements to your waste stream,” said Glaze. “It’s best to be proactive and avoid this approach, but most people won’t act until they are required to. Use this information to explain to stakeholders at your business that the issue might require more urgency.”

  Finally, Glaze advises producers to work with their municipalities to develop solutions.  “The people who work at the waste plants are incredibly knowledgeable and typically have experience with all kinds of different wastewater systems,” said Glaze. “They have big brains and most of the time would love to chat about their job with you over a beer. You can learn a ton from them, and they can help guide you toward solutions to reduce the most impactful constituents in your waste stream.”