Integrated automation delivers record-speed factory launch for global snack food manufacturer

Project summary

Sector: Feed, Food & Beverage
Customer: International snack manufacturer
Location: Asia-Pacific
Project type: Greenfield manufacturing facility
Expertise: Industrial Automation |Control Systems | Systems Integration | Electrical Engineering | Control Panel Design & Manufacture | Installation & Commissioning

Key facts:

• Record-speed factory launch supported by on-time automation delivery
• End-to-end process integration from potato intake to seasoning
• Multiple OEM systems brought together into one coordinated production line
• Complete automation solution from design and panel manufacture to commissioning
• 10+ process and quality KPIs achieved first time ahead of production launch
• 25,000+ tonnes of annual production capacity at the new facility

The challenge: Integrating complex production systems for a record-speed factory launch

The international snack manufacturer was investing in a new greenfield factory to expand its production capacity in the region. The facility needed to be operational within an ambitious launch schedule, while meeting the stringent product quality and process performance standards expected across the manufacturer’s international brands.

The challenge extended beyond controlling individual machines. Specialist equipment from multiple OEMs, spanning potato intake and slicing through to frying and seasoning, needed to operate as one integrated production line. Some equipment packages had their own control systems, while others required new controls to be developed. All needed to work together reliably, with production data captured to support performance monitoring and continuous improvement.

The accelerated delivery programme added further complexity. Controls integration and commissioning typically take place towards the end of a greenfield factory build, leaving limited scope to recover delays. Any setbacks in equipment delivery or mechanical and electrical installation could reduce the time available to test, commission and verify the line’s performance before commercial production began.

The solution: Delivering integrated automation for production performance and quality assurance

The manufacturer appointed Actemium Automation Peterborough, part of Actemium UK, building on a longstanding international relationship and more than 40 years of specialist experience in crisp and snack manufacturing.

Actemium took responsibility for the complete process integration, creating a unified control solution tailored to the production line’s operational and quality specifications.

Working from the manufacturer’s requirements and information provided by the equipment suppliers, the team developed the functional and control system design before progressing software development and control panel manufacture in parallel. Software was simulated alongside panel build, while control panels, system interfaces and equipment functions were verified before shipment. This allowed potential issues to be identified and resolved before installation, reducing commissioning risk and helping protect delivery schedule.

Once the equipment was connected on-site, Actemium supervised and verified the electrical installation before completing site I/O, safety and functional checks. The line then progressed through dry commissioning, testing the equipment and integrated controls without product, followed by wet commissioning with the production services required to operate the process.

During the live product trials, the team assessed more than ten processes and product-quality KPIs, including temperature verification and tests to confirm how the process responded to changing conditions. This provided evidence that the integrated line could achieve the required performance and product quality before progressing to saleable production.

Commissioning also took place while some elements of construction continued across the wider facility, requiring close coordination with local contractors to maintain safe working conditions.

To manage the additional risks of international delivery, Actemium shipped critical spares and backup engineering equipment to site, while supervising local electrical installation to ensure cabling was correctly installed and labelled. Local personnel were also trained to support the production line following handover.

The results: On-time launch and verified production performance

Actemium delivered the project on time and within budget, helping the manufacturer achieve its planned factory launch with the required process performance and product quality.

The integrated approach delivered the following key benefits:

·       Integrated and reliable production: A unified control solution brought equipment from multiple OEMs together, reducing interface risks and enabling coordinated operation across the production line.

·       Protected production schedule: Early testing and structured commissioning minimised the risk of delays, supporting an on-time factory launch.

·       Verified product quality: Live production trials and KPI assessments confirmed that the line met the required process and quality standards before commercial production.

·       Improved visibility and operational efficiency: Production data capture (digitalisation) enabled better performance monitoring, faster identification of inefficiencies and more informed decisions to optimise production processes.

·       Local operational capability: Training equipped on-site personnel with the knowledge to operate and support the production line following handover.

Snack automation expertise, delivered internationally

Actemium Automation Peterborough, part of Actemium UK, combines more than four decades of industrial automation solutions expertise with in-house engineering and manufacturing capability, including extensive experience across snack foods and food & beverage manufacturing. From consultancy and control system design to software development and digitalisation, panel manufacture, installation, commissioning and lifecycle support, the business can take responsibility across the complete automation project lifecycle, helping manufacturers improve productivity, reliability and product consistency.

As part of Actemium UK and the wider VINCI Energies network, customers also benefit from global engineering expertise, specialist industry knowledge and international project delivery capability, backed by long-term support.