Galbusera’s AI-driven Cracker Production Line

Galbusera, a leading manufacturer in the food industry, sought to digitally transform its production processes. The company needed a scalable and integrated solution to:

• Centralize data collection from production lines for real-time monitoring.
• Enhance efficiency by reducing waste and optimizing machine performance.
• Enable predictive maintenance to minimize unplanned downtime.
• Improve product quality while maintaining high industry standards.
• Ensure seamless integration with existing ERP and MES systems following ISA-95 standards.
• Implement AI-driven analytics to support continuous process improvements.

To achieve these goals, Galbusera required a future-proof Industrial IoT (IIoT) solution that would collect, analyze, and leverage production data. 

SECO implemented a Digital Factory Solution powered by the IoT Software Framework Clea, optimizing Galbusera’s production in three phases:

• Proof of Concept – Tested data ingestion from a single PLC via SECO Gateways and Clea Astarte.
• Pilot Project – Expanded to the cracker line, integrating dashboards, waste tracking, and real-time monitoring.
• Mass Deployment – Scaled across multiple sites, adding predictive analytics, AI-driven maintenance, and energy monitoring.

This is how it works:

• SECO Gateways collect PLC data.
• Clea Astarte orchestrates secure data transmission.
• Clea Edgehog & Clea Portal enable remote fleet management.
• Google Cloud Platform provides highly scalable cloud-computing resources.
• AI-powered analytics optimize maintenance and production.
• Looker dashboards provide real-time KPI insights. 

With SECO’s Clea-powered IoT ecosystem, Galbusera has stepped into the future of manufacturing—where Industry 5.0 meets sustainability, intelligence, and efficiency at every level.

• Faster event response time – With real-time machine status updates and automated notifications, Galbusera can take immediate action to prevent bottlenecks.
• Reduction in waste – AI-powered monitoring detects early signs of defects, reducing product loss and optimizing raw material use.
• Increase in OEE – Enhanced predictive maintenance and process optimizations improve machine uptime and overall efficiency.
• Seamless ERP & MES integration – The solution aligns with ISA-95 standards, ensuring data consistency and a fully automated workflow.
• Energy savings – Factory-wide energy consumption tracking optimizes resource usage, reducing operational costs and environmental impact.