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Efficiency and Predictability on the Production Line with IoT

Suzano, a global leader in cellulose and paper, sought to reduce unplanned downtime and improve productivity at its Imperatriz (MA) unit. The lack of real-time visibility of equipment made it difficult to make agile decisions.

In partnership with Zurich, PackIOT implemented real-time analysis software coupled with industrial equipment.

The plug-and-play cloud solution enabled:

  • Automated production monitoring

  • Early alerts to prevent failures

  • Clear data for shift transitions

The collaboration between Suzano, Zurich, and PackIOT generated benefits beyond expectations, such as:

  • Reduction of downtime with actionable insights

  • Greater operational efficiency and deadline compliance

  • Improved quality of life for operators, in line with Industry 4.0

“PackIOT's data was fundamental to optimizing our maintenance and production.”

William dos Santos, Maintenance Coordinator at Suzano

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VIVIX is one of the most modern flat glass factories in the world. Producing around 900 tons of float glass per day at its 90,000-square-meter facility, the company has achieved a unique position as the only glass manufacturer in Brazil with its own solar power plant to supply energy to the glass production factory and its own raw material processing plant.

How PackIOT and HighByte ajudaram a VIVIX revolutionize its glass production with intelligent data and high performance

Challenges:

  • Merging, normalizing, standardizing, and contextualizing operational data to improve asset maintenance forecasting, scheduling, and execution.
  • Overcoming challenges related to scalability, data integration, and data product development within Mendix, the company’s application development platform.
  • Balancing cost efficiency and performance by restructuring its data architecture for future growth.

Approach:

  • Deploying the HighByte Intelligence Hub in the corporate data center to curate, orchestrate, and model data from OPC servers, SQL servers, and other industrial sources at the edge before publishing payloads to the AWS ecosystem.
    ▪ Build a highly scalable Industrial Data Fabric architecture, using Intelligence Hub as the DataOps layer and Amazon S3 as the centralized data repository in the cloud.
  • Host the Intelligence Hub in the AWS cloud to optimize integrations and transformations between various cloud-based services, including Amazon Bedrock, Snowflake, and business intelligence applications such as Mendix.
  • Leverage Amazon Bedrock and Mendix to develop GenAI agents for maintenance teams.

Benefits:

 

✔ Reduced operating costs through industrial data integration and maintenance forecasting.

✔ Fewer unplanned downtimes and longer asset lifespans, ensuring continuous production.

✔ Scalable architecture with HighByte Intelligence Hub and AWS, implemented by PackIOT.

✔ Collaboration between teams and systems, accelerating data-driven decision making.

✔ Low-code solution that simplified application development and integrations.

 

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“With HighByte Intelligence Hub and PackIOT support, we have built a digital infrastructure that enables operational efficiency and agile decision-making to produce high-quality glass. The low-code approach was essential.” Aristóteles Terceiro Neto, Industrial Transformation Manager at VIVIX

Aristóteles Terceiro Neto, Industrial Transformation Manager at VIVIX

C-Pack transformed its production with PackIOT

Eficiência operacional real, com dashboards inteligentes e tomada de decisão baseada em dados e integração rápida com o chão de fábrica.

With PackIOT, C-Pack achieved real operational efficiency, with smart dashboards, data-driven decision making and rapid integration with the factory floor.

C-Pack is a leader in Latin America in the production of extruded plastic tubes for the cosmetics, pharmaceutical, food, and industrial sectors, with one of the most modern production facilities in the region.

 

Before PackIOT, C-Pack faced manual data collection processes on the factory floor, with operators spending a lot of time recording information in production logs. This resulted in slower decision-making and difficulty in obtaining reliable real-time data.

How PackIOT Increased C-Pack's Efficiency – Less Paper, More Production

PackIOT implemented its IoT and real-time production analysis solution, eliminating the use of paper. With automated data collection, operators now have instant access to production information on computers and tablets, monitoring production volume, waste, and downtime.

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Real-Time Decisions with PackIOT

Results of thedigital transformation

The partnership with PackIOT allowed C-Pack to:

  • Significantly increase the speed and fluidity of operations.

  • Gain agility in the factory, with decisions being made in real time based on solid and reliable data.

  • Free up the technical team to focus more on analysis and the search for new solutions, rather than data collection.

  • Improve operational efficiency and production visibility.

“After PackIOT, everything started to work much faster and more smoothly. We brought agility to the factory with real-time decisions based on solid data. Making decisions with this type of data is much easier.”

Augusto Oliveira, Industrial Director at C-Pack.

Success stories from Clients

REAL CASES. REAL SAVINGS.

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