Siemens and Sachsenmilch Achieve 24/7 Dairy Production with AI-Powered Predictive Maintenance

AI-Supported Predictive Maintenance: Siemens and Sachsenmilch Innovate in Dairy Production

Siemens is helping Sachsenmilch Leppersdorf GmbH, one of Europe’s most advanced milk processing plants, implement an AI-driven predictive maintenance system. Their solution, Senseye Predictive Maintenance, supports Sachsenmilch in maintaining continuous operation throughout the year while adhering to strict quality standards.

Sachsenmilch processes 4.7 million liters of fresh milk daily, producing a wide range of dairy products including milk, butter, yogurt, cheese, baby food derivatives, and even bioethanol. The plant’s nearly fully automated setup requires equipment to run around the clock with minimal downtime to meet production demands.

Data-Driven Insights from Interconnected Machines

The production facility features interconnected machines that generate large volumes of operational data, making it an ideal candidate for Siemens’ Senseye Predictive Maintenance pilot. This AI solution analyzes data such as temperature, vibration levels, and frequencies to detect early signs of equipment issues. By predicting failures before they happen, maintenance can be scheduled proactively, avoiding costly production stoppages.

Implementing the solution involved integrating existing plant data with new vibration sensors and the Siplus CMS 1200 measurement system. Siemens provided technical and project management support throughout, enabling Sachsenmilch’s maintenance team to take over the system after training.

Roland Ziepel, Technical Manager and project lead at Sachsenmilch, highlighted the balanced expertise Siemens brought to the table: "Siemens has know-how on both the technological and technical sides as well as in project management."

Reducing Unplanned Downtime Pays Off

The pilot project has already delivered tangible results. Early detection of a failing pump allowed Sachsenmilch to avoid major repair costs and production delays, saving a significant amount in what Ziepel described as "the low six figures."

Margherita Adragna, CEO of Customer Services at Siemens Digital Industries, noted, "Senseye Predictive Maintenance supports efficiency and competitiveness by integrating preventive maintenance strategies into existing workflows. Its ongoing development is helping transform maintenance operations."

Next Steps: Integration and Automation

Building on this success, Sachsenmilch plans to connect Senseye Predictive Maintenance with their SAP Plant Maintenance System. This integration aims to automate the transfer of maintenance alerts, improving planning and response times.

Additionally, data-driven recommendations from the Maintenance Copilot Senseye will assist maintenance teams in making informed decisions. Siemens continues to support these efforts to help customers maintain long-term operational success through innovative maintenance approaches.

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