Summary of the Impact:
A global, 130-year-old food and beverage manufacturer deployed ThroughPut’s AI in food manufacturing platform – a powerful Supply Chain Decision Intelligence solution – to eliminate unplanned machine outages and unlock major operational gains.
- Recovered $0.5M in weekly productivity losses
- Increased output by 5% through smarter machine utilization
- Reduced unplanned downtime across work shifts
- Enabled faster, data-driven CAPEX decisions
- Boosted workforce productivity with real-time insights
Who Is This Global Food Manufacturer?
This iconic food and beverage brand operates across 9 countries and exports to over 50 markets worldwide. With thousands of SKUs and large-scale operations, managing asset health and factory output across shifts was a major challenge especially without end-to-end visibility.
Despite their legacy and global footprint, the client turned to AI in food manufacturing to solve their growing problems with downtime, productivity losses, and capital planning inefficiencies.
Why AI in Food Manufacturing Was the Right Solution?
Unplanned outages were costing the business millions annually in lost output and inefficiencies. AI in food manufacturing delivered the visibility and intelligence they needed to take back control — from predictive maintenance to smarter CAPEX decisions.
What Challenges Did This Manufacturer Face Before AI?
1. Why Was Machine Downtime Costing Millions?
Unplanned outages weren’t just an inconvenience—they were bleeding productivity every week. Without real-time machine insights, capacity planning was inconsistent, reactive, and expensive.
2. How Did Lack of Visibility Impact CAPEX Tracking?
The client lacked a clear view of actual machine performance and lifecycle, making it hard to validate capital investments or upgrades. With no accurate, data-driven CAPEX framework, decisions were often delayed or misinformed.
3. What Was the Impact on Productivity?
Machine breakdowns led to frequent disruptions across multiple shifts. Worker idle time increased, and output fell behind schedule. The business needed an intelligent solution to align machine performance with workforce productivity and production planning.
How Did ThroughPut AI Solve These Operational Challenges?
A. How Did AI Predict Downtime Before It Happened?
ThroughPut’s platform supply chain intelligence software leveraged historical and live machine performance data to predict potential equipment failures. The system provided near-term and long-term visibility into machine health reducing surprises and preventing outages before they happened.
B. How Did AI Improve Capacity Utilization?
ThrougPut’s supply chain intelligence software delivered SKU-level analysis and machine-wise performance insights to identify where in-house fabrication made the most operational sense. It mapped machine performance against SKU profitability, enabling smarter asset allocation and maximizing throughput.
C. How Did AI Optimize Productivity and CAPEX?
Using real-time data and root cause analytics, ThroughPut helped the client isolate recurring issues from one-off failures. This allowed faster resolution, better planning, and confident CAPEX spending—all while cutting costs from bottlenecks, waste, and inefficiencies.
This is where AI in food manufacturing truly delivered value – by empowering plant leaders to make proactive decisions based on real-time operational data.
What Were the Tangible Results of AI in Food Manufacturing?
| KPI | Result |
| Productivity Savings | $0.5M per week |
| Output Increase | 5% improvement |
| CAPEX Planning | Real-time validation |
| Downtime Reduction | Across multiple shifts |
| Bottleneck Visibility | From plant floor to SKU level |
Why Does This Case Study Matter to Food Manufacturers?
If you’re running a large-scale food processing operation, unpredictable outages and inefficient CAPEX decisions could be silently draining millions from your bottom line.
ThroughPut’s AI in food manufacturing platform helps:
- Forecast machine downtime before it disrupts production
- Optimize capacity planning with data-backed asset insights
- Prioritize profitable SKUs with real-time performance mapping
- Enable smarter, faster CAPEX decisions
- Boost productivity without increasing headcount or cost
What Makes ThroughPut AI Different?
Rapid ROI in Under 90 Days
Start seeing real savings and productivity boosts without long implementation cycles.
Seamless Tech Integration
Works with your existing ERP, MES, WMS, SCADA, PLCs – no need to rip and replace.
Built for Manufacturing
From machine-level health to SKU profitability, it’s purpose-built for process-heavy industries.
AI that Thinks Like an Ops Manager
ThrougPut’s supply chain intelligence software goes beyond BI dashboards. It recommends actions based on domain knowledge and real-time data patterns.
Ready to Stop Losing Millions to Downtime?
ThroughPut AI helped this global food manufacturer eliminate chaos and recover $0.5M+ in lost productivity every week. Imagine what it can do for your operations.
