Cutting-edge technology to stay ahead.
Thousands of parameters throughout production are continuously monitored. It ensures constant control, on-the-fly adjustments and ongoing improvement. But this wealth of data is also used to identify patterns, detect anomalies and make accurate predictions. No time and no data is wasted. All the hassle has been stripped away from production thanks to the seamless digital integration and synchronised control of both people and machines. A remarkable story that fills everyone with pride.
Growth comes with challenges
With the addition of their fourth production line in 2016, a clear need emerged for a reliable system for data monitoring and reporting. There was no efficient way to track production parameters or detect deviations in time. As a result, it became difficult to intervene quickly when issues arose, increasing the risk of delays, downtime, and production losses. The team opted for Ikologik’s data monitoring system.
Follow the data
First experience was gained by monitoring the critical factors of the water treatment system, just outside of production. But the production processes quickly followed. What began with around a hundred tags rapidly exceeded a thousand. Today, more than 10,000 tags are being monitored. 90 tons of fries in one hour ... this is no small business.
The platform delivers real time and historical insights. It sends alerts when deviations occur. Dashboards bring continuous insight and reports are generated automatically. The goal is clear: maximum efficiency, minimal downtime.
MES rollout
The initial focus when introducing MES (Manufacturing Execution System) was on the control of the packaging lines. This allowed for a controlled start, targeting immediate operational impact. The system now manages both packaging and production lines. The core ideas are simple: improve operator comfort, eliminate repetitive work, minimise error-risk and integrate quality control. It's not just a tool for control, MES enablers smarter, more efficient processing.
The scalable solution supports Ecofrost’s ongoing growth. The integration of a dedicated flakes line into the MES has recently been completed and preparations are in progress to start up the new site in France, construction in full swing as we speak, with full automation from day one.
Golden fries, silver data
Projects are in progress to support certain processes with suggestive instructions using data in powerful machine learning algorithms. The projects themselves remain confidential for now, but they reflect the broader evolution of software within the industrial landscape. Software, not only as a tool to increase process efficiency, but also to assist decision making.
About Ecofrost
A vibrant Belgian company pushing the boundaries in high quality frozen potato products. This includes French fries, frozen specialties, and dry flakes. Founded in 2003 by industry veterans combining three generations of deep rooted expertise and experience in potatoes and vegetables, Ecofrost now delivers to over 150 countries worldwide, joining the ranks of the industry leaders.
Fueled by innovation and a passion for excellence, Ecofrost meets customer needs through smart, automated production that places energy efficiency and sustainability at its core. Whether under private labels or their own brand, their products serve a diverse range of markets including retail, foodservice, industry and quick service.
At the heart of Ecofrost lies a culture built on trust, agility, teamwork and an unwavering commitment to quality and customer satisfaction. This dedication sets the company apart as a true trailblazer not only in the frozen potato industry but as a leading example for the food industry. They may not blow the loudest trumpets, but their achievements are truly phenomenal.