A large global food manufacturer implemented Rockwell’s FactoryTalk® Analytics™ PavilionX™ Model Predictive Control (MPC) technology to improve whey permeate product consistency, reduce operational losses, and advance sustainability goals at its U.S. production facility. MPC solutions use advanced analytics models to compute the best control moves to improve performance within given constraints. MPC software helps manufacturers achieve precision by reducing product variability and increasing yield, while enhancing profitability.
A global leader in taste and nutrition, this manufacturer’s portfolio includes food, beverage, biotechnology and health. Their sustainability strategy aims to create healthier diets while minimizing environmental impact, and they have cross-functional teams in place to optimize manufacturing through process technology excellence.
- Approximately 145 hours of annual production was lost at its U.S. production facility due to spray dryer blockages triggering additional clean-in-place (CIP) cycles
- Significant product variability in moisture and density required frequent operator intervention
- Operations experienced highly variable energy usage across seasons and throughput levels
- Continual safety monitoring during dryer operation necessitated high operator involvement
- FactoryTalk® Analytics™ PavilionX™ Model Predictive Control (MPC)
- Integration with existing plant control systems
- Prescriptive models for dryer and evaporator performance
- Eliminated 145 hours of lost production time per year
- Improved product quality with consistent target conditions and reduced shift-to-shift variability
- Increased dryer throughput by as much as 21% by avoiding bottlenecks and seasonal constraints
- Enhanced operator productivity and safety with less time spent monitoring dryer safety conditions
- Rapid ROI was delivered in under six months, far exceeding the original projection of two years
Challenge
Product variability and lost production hours required a technology solution to stabilize operations
A global food manufacturer’s facility struggled with inconsistent dryer and evaporator performance driven by seasonal temperature and humidity swings. High dryer blockages, frequent clean‑in‑place events, and nearly a week of downtime annually reduced available capacity, limiting output during dry winter months and causing drying instability during humid summers. These conditions resulted in lost production hours, product variability, and an inability to reliably maximize whey powder output without a more robust process control solution.
Solution
ROI achieved in under six months with Model Predictive Control software
The manufacturer implemented FactoryTalk® Analytics™ PavilionX™ MPC across its evaporators and spray dryers to stabilize operations and improve forecasting and control.
The MPC platform functioned as a “cruise control” layer on top of existing automation, using predictive models to continuously adjust setpoints for optimal performance. It offered the following capabilities:
- Real-time optimization of moisture, density, and other critical quality and process variables parameters
- Adaptive responses to seasonal conditions and upstream/downstream constraints
- Automated stabilization of dryer conditions to maintain safe operating ranges
- Integration with existing equipment to modernize legacy assets without major capital investment
The new solution incorporated feedback from operators from all involved shifts to make sure that the HMI displays were efficient and effective, with easy-to-use MPC control screens.
“Rockwell’s model predictive control brings all process variables together to predict the most efficient path forward. By continuously optimizing energy, throughput, and stability, MPC helps our customers operate more economically while reducing waste, downtime, and environmental impact.”
Scott Jost - Director of Industrial Data Science for Kalypso, a Rockwell Automation business
Result
Increased throughput, improved capacity, and stabilized operations to eliminate 145 hours of lost production annually
By implementing model predictive control (MPC) to continually optimize dryer operating parameters, the manufacturer significantly improved spray dryer performance and reliability. The solution significantly reduced unplanned downtime and improved dryer efficiency by as much as 21%, while delivering more consistent product quality through tighter control of moisture and density. The improvements in product quality also supported the manufacturer's sustainability goals by reducing rework and minimizing energy consumption.
The MPC system also eased the burden on operations teams by maintaining stable, safe operating conditions with improved production consistency between shifts. Operators spent less time monitoring and intervening in the process, allowing greater focus on higher‑value tasks and improving confidence across shifts. The results translated quickly to the bottom line, with the project achieving a six‑month return on investment—far exceeding initial expectations.
Published May 14, 2026
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