The FactoryOps software’s adaptability and predictive capabilities ensure continual improvement over time. Credit: rafapress via Shutterstock.

Berry Global has said it leverages real-time energy monitoring systems in the pursuit of heightened operational efficiency and reduced environmental impact.

This approach not only trims electricity bills but contributes to minimising greenhouse gas emissions, aligning with the company’s commitment to environmental, social, and governance standards. 

Strategic collaboration with energy management innovators

Berry partners with energy management solutions providers, including Guidewheel, Factbird, SensorFact, and SiteWatch. Guidewheel’s FactoryOps software has emerged as a beacon for manufacturers, providing real-time visibility into operational landscapes.

Lauren Dunford, Guidewheel’s CEO, commended Berry’s dedication to sustainability and operational excellence, citing substantial savings across energy, production, and maintenance.

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“It’s an honour to work with Berry Global and see the innovative, impactful ways the company is using Guidewheel to achieve huge operational savings across energy, production, and maintenance – plus even more energy and cost savings through data-driven facility improvements.”

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Guidewheel’s approach to real-time monitoring

Guidewheel’s real-time FactoryOps software starts with attaching sensors to power sources, delivering comprehensive runtimes, cycle times, and energy data. This information, tracked second by second and transmitted to the cloud, empowers Berry to make informed decisions promptly. 

The software’s adaptability and predictive capabilities ensure continual improvement over time.

Berry’s achievements

Berry said its Fremont, Indiana plant, in the US, exemplified the success of Guidewheel’s real-time energy management software. Over a year, Berry claimed that the plant achieved a 10% improvement in operational efficiency through strategic interventions:

  • Smart energy consumption: Berry monitors electricity usage, adjusting power consumption during peak and off-peak hours.
  • Equipment downtime prevention: Automatic shutdown of machines inactive for four or more hours prevents unnecessary energy consumption.
  • Investment in efficiency: Assessment of equipment efficiency guides strategic investments in newer, more efficient machinery.

For instance, Guidewheel’s software revealed inefficiencies in the plant’s cooling system, installed in the 1980s. By replacing this outdated system, Berry anticipated an annual cost saving of approximately $500,000, demonstrating how sustainable practices can be economically viable. 

Dennis Carroll, Berry’s production manager, and Rod Chupp, Berry’s Fremont plant manager, emphasised the positive cultural shift instigated by Guidewheel’s monitoring. 

“The monitoring Guidewheel provides is helping create a culture of accountability at our plant and motivating team members to continue doing better. The electricity, and therefore cost, savings also allow us to grow and create more jobs.”