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GEA set up production of Nestlé's Ready-to-drink Coffee line in Japan remotely
10 Mar 2022
GEA has remotely put into operation a ready-to-drink coffee production line in Shimada, Japan, for Nestlé, the world's largest food company. Due to the pandemic, the commissioning, the most critical phase, was done remotely. This opened up new, more sustainable ways of collaboration between globally dispersed project teams.
Start of production in Nestlé’s Shimada Factory supplied by GEA: The Japanese team's take on the project work during the pandemic: Physical work can be done faster and more sustainably with digital support. Copyright: Nestlé
- Successful remote commissioning of a plant under pandemic restrictions
- Digital networking increases effectiveness and sustainability of work
GEA has remotely put into operation a ready-to-drink coffee production line in Shimada, Japan, for Nestlé, the world's largest food company. Due to the pandemic, the commissioning, the most critical phase, was done remotely. This opened up new, more sustainable ways of collaboration between globally dispersed project teams.
”We have already completed a few projects for Nestlé in Japan. Getting the entire production completely up and running virtually and on schedule was where our partnership really came into its own. We're proud of this joint effort, which has proven its worth in the six months since production began“, says Takayuki Miyazaki, Managing Director of GEA in Japan. “The extreme conditions we faced due to the COVID-19 restrictions forced us to be exceedingly flexible and enabled us to leverage digitization opportunities more effectively. Ultimately, we are glad we had this experience, which exposed us to a new way of working on projects: We are becoming more agile and adaptable.”
COVID-19 alters the course of the project implementation
To protect the workforce and avoid jeopardizing the project, Nestlé and GEA moved the work to the digital sphere and changed process routines: Much of the equipment was pre-installed at GEA’s plants instead of on-site. In fact, the UHT (ultra-heat temperature) treatment system was transported from Germany to Japan in one piece after extensive factory acceptance testing in the workshop. Using digital tools like remote service desktops along with digital control rooms allowed GEA's commissioning experts from Germany, Pakistan and Singapore to guide the team in Japan remotely as it did the actual hands-on work. Thus GEA simulated and optimized operations in a virtual environment, making sure the commissioning went smoothly for Nestlé.
NOTE TO EDITORS
Process technology for Nestlé production plant in Japan
The plant in Shimada, situated at the east of the country, produces various coffee products for leading international brands. Nestlé is increasing its capacities by expanding production to boost its market leadership in the RTD coffee beverage segment. Accordingly, GEA developed, built, and installed the entire process technology for the production of ready-to-drink (RTD) coffee – from raw material intake and mixing to the aseptic treatment, including the cleaning-in-place (CIP) unit.
RTD coffee is a promising growth market
Asia Pacific is by far the largest market for RTD coffee . It accounted for 80 percent of global sales volume in 2020. At the forefront is Japan, whose population drinks more than half of the RTD coffee traded globally.
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About GEA
GEA is one of the world’s largest suppliers of systems and components to the food, beverage and pharmaceutical industries. The international technology group, founded in 1881, focuses on machinery and plants, as well as advanced process technology, components and comprehensive services.
