Fromarsac, a Savencia dairy plant near Périgueux, France, had to turn milk whose composition changes with the seasons into cheese that consumers expect to taste the same every time. By digitizing its industrial operations with OIAnalytics, the plant reduced process variability, gained productivity and improved the score its consumer panel gives its products.
Fromarsac is a dairy processing plant located in Marsac-sur-l'Isle, on the outskirts of Périgueux in the Dordogne region of France. A subsidiary of the Savencia Fromage & Dairy group, the site makes cheese specialties sold in supermarkets, including St Môret and Tartare.
The plant produces the equivalent of 14,000 tonnes of cheese specialties a year. It employs 320 people, 220 of them at the production site, and sources nearly 70 million liters of milk annually.
Milk processing runs in several stages. The milk is first standardized: the cream is separated from the skimmed milk, and the blend is then restandardized. Natural ingredients are added to this cheese base before it is packed into tubs and trays.
The fat content of the collected milk varies with the seasons, because the cows' diet changes throughout the year. Yet consumers expect a standardized, compliant product that always offers the same taste and texture.
Fromarsac's goal was therefore to gain tighter control over product quality and reduce its variability.
“On one side, we have milk that is variable and comes in variably, and on the other, consumers who want a standardized, compliant product that always tastes the same. To control this variability, digitalization gave us answers.” (translated from French) — Sébastien Rosier, Operational Excellence Manager, Fromarsac
Before the digitalization initiative was launched, process parameter readings and analyses were entirely manual. They took a great deal of time and gave no real-time view of production.
Since 2020, Fromarsac has been pursuing its digitalization journey with Optimistik and its OIAnalytics solution. The site digitized all of its process parameters: flow rates, pressures, temperatures, line speeds, laboratory analyses and more.
This data flows straight to the operators. They use tablets that display dashboards and real-time control charts. Each operator tracks their parameters on screen, receives alerts when deviations appear, and adjusts the line at the right moment.
“The operators have tablets, so they get dashboards and control charts in real time. […] Above all, it helps them avoid over-adjustments or unnecessary adjustments.” (translated from French) — Didier Vigier, Process Manager, Fromarsac
Beyond day-to-day operations, the data history gives management an overall view of products and processes. It provides the basis for analysis work to understand process variability and to optimize processes. It also informs the thinking that precedes strategic decisions.
“It lets us make strategic decisions and get a truly global view, with plenty of perspective on our products.” (translated from French) — Didier Vigier, Process Manager
Having started with a first project focused on product quality, the initiative then expanded to further use cases: energy management, material yield and maintenance.
Digitalization has significantly reduced parameter variability and helped improve other aspects of industrial performance. The benefits show up on several levels:
“This digitalization has allowed us to modernize our image and be more attractive to younger generations. And that is essential for any industry.” (translated from French) — Didier Vigier
At Fromarsac, process data has become a shared management tool, from the line operator to plant management. It makes it possible to deliver consistent cheese from a raw material that is anything but consistent.
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