Mars: Enhanced Pet Food Production with AVEVA Automation Solutions

From its Verden facility in northern Germany, Mars Pet Food supplies products across Europe. This site includes a research and development division and utilizes AVEVA software for automated production. The process involves packaging, sterilization, and packing various pet food types. Complex demands require a robust IT infrastructure and batch management to create recipes.

Multi-pack production—combining four different products—necessitates simultaneous batch tracking, achievable only through automation. Mars is also expanding with two new product lines.

Integrated Management Approach

Food safety regulations apply equally to pet food. Mars enforces even stricter internal standards by monitoring every production stage, from raw material to shelf-ready product. Two highly automated lines are continuously monitored. The system must identify completed pallets, record defects, and minimize safety margins. A key upgrade involved integrating sterilization data, previously matched manually. Now, data is directly linked to product tracking with real-time visualization. The software solution required adaptable reporting, system compatibility, transparency, scalability, and support for reverse genealogy—tracing ingredients forward and backward. AVEVA software met all criteria.

Implementation Process

All production events had to be identified and classified, accounting for material consumption and parameters. Mars collaborated with equipment manufacturers to define specifications and launched implementation with support from G&O Automatisierungsgesellschaft mbH, a certified AVEVA integrator and longtime Mars partner. G&O brought extensive experience with AVEVA InTouch HMI, AVEVA System Platform, and more.

Software Configuration and Adaptation

Due to time limits, a standard interface between processing and shipping wasn't feasible. AVEVA System Platform’s flexibility allowed for EOM (Equipment Operations Module) containers to unify data. In processing, the open structure enabled connection to a third-party MES using the container model. Because the batch system couldn’t provide real-time data during dosing, auxiliary objects in the database handled adjustments post-batch. These objects format data for seamless system integration and can be replaced later with direct connections.

Sterilization data integration used AVEVA Historian, which already captured the information. G&O enhanced it by including sterilization start and end events in SQL tables, enabling accurate matching for up to 2436 packages—now key for reporting.

Packaging Area Tracking

Due to weak linkage between transport and cardboard packaging, unit-based tracking wasn't feasible. Instead, larger transport units were tracked virtually using FIFO logic and corrective algorithms within AVEVA System Platform to ensure accuracy.

Benefits Across Operations

AVEVA’s solutions have delivered significant advantages. Mars now operates a seamless process management system with integrated tools. "Using open system technologies, Mars gains a comprehensive, scalable solution adaptable to future needs," says G&O’s Managing Director, Günter Osswald. AVEVA software combines customization with built-in reporting tools, facilitating issue identification and resolution. Sterilization data, for instance, is now part of performance evaluations.

Customer Benefits of AVEVA Solutions in the Food and Beverage Industry:

1. Operational Efficiency – Streamlined processes reduce downtime and boost productivity.
2. Quality Control – End-to-end monitoring ensures product integrity and regulatory compliance.
3. Scalability – Flexible platforms support future expansion and adaptation.
4. Cost Reduction – Efficient resource use and waste reduction lower operational costs.
5. Sustainability – Improved energy use and reduced environmental impact.
6. Real-Time Insights – Data analytics enhance decision-making and process optimization.
7. System Integration – Seamless connections with existing equipment and systems ensure smooth operations.