Melitta drives sustainable growth with automation

The Melitta Group owes its existence to Melitta Bentz. Her invention of the coffee filter revolutionized the enjoyment of coffee in 1908. Since then, the company has achieved unique success with many groundbreaking innovations. Today, the company employs about 6,000 people worldwide.

Sven Neuhaus, Chief Officer of Operations & Development at Melitta Europe Coffee Preparation, states:
“As a family business with over 115 years of tradition, we believe that a company only has a ‘license to operate’ when it contributes to making people’s lives better. Sustainable development is integral to all our business activities.”

Improving every day

The decision to replace Melitta’s previous automation system with Valmet DNA Distributed Control System (DCS) highlights the company’s commitment to sustainability.

Valmet DNA helps Melitta achieve its sustainability targets by using controls to stabilize operations. The DCS reduces process disturbances, like sheet breaks, which lead to wasted raw materials, chemicals, water and energy.

Eduard Pertsch, Head of Technical Service at Melitta Europe Coffee Preparation and Martin Grundmann, Area Sales Manager at Valmet. 

Tools for trending, monitoring, and operating enable teams to collaborate better and guide the process towards optimized raw material, water and energy consumption.

Eduard Pertsch, Head of Technical Service at Melitta Europe Coffee Preparation, explains, “An all-in-one system allows operations to be monitored and analyzed from one operating place. System-wise, we now have more options for technical and organizational networking. The increased transparency, technical networking, and intelligent analysis systems are paving the way for improved collaboration between teams.”

“The enhanced data exchange capabilities have contributed to better product quality and process efficiency. Now, we can monitor the processes across different stages of paper production which improves internal communication and collaboration. Our ability to analyze paper quality has increased significantly,” Pertsch says.

One system with an effortless user experience

The DCS upgrade included a modern web-based Valmet DNAe User Interface. It makes information available to all users according to their specific roles.

Eduard Pertsch highlights the benefits of having the full automation package in the same user interface: “When analyses, operating concepts and visualizations are consistent, it’s faster to operate a system. Our operators particularly value the many possibilities for trend analysis and the simple operation and adjustability. The team also appreciates the drag-and-drop functionality.”

Troubleshooting and process control are easier in a single system.

“The main benefit for maintenance is that all systems can be managed from a single point and with the same maintenance tools. Error analysis is not limited to technicians; operators can also perform the analysis to a certain extent as it is understandable and traceable,” Peperkorn says.

The new DCS has also made system integrations easier. “We’re currently installing a new winder, and thanks to Valmet’s system, integrating this new equipment into our production process has been significantly easier,” Pertsch notes.

Transitioning from a different system to Valmet DNA

Transitioning from a previous control system to Valmet DNA required teamwork. Melitta uses Valmet DNA in its plant in Brazil. The local team provided reassurance that the project was in good hands.

“A tight timeframe can create pressure. But positive feedback from our colleagues who had previously worked with Valmet helped reduce project tension,” Neuhaus says.

 “Our previous system had reached the end of its lifecycle, and no longer met our standards for efficiency, quality, and environmental impact. In addition, challenges in the availability of spare parts, services and training made it clear that a change was necessary,” Neuhaus explains.

Eduard Pertsch advises companies considering a similar upgrade: “Take the time to thoroughly prepare and test the system before implementation. It’s also crucial to involve your operators. Service staff should be intensively trained by Valmet before the implementation phase. If possible, set up a training station with a predefined training program.”

The collaboration continues

Melitta’s tradition of innovation and commitment to sustainability continues to guide its growth. The partnership with Valmet has strengthened this foundation, combining advanced technology with a service agreement with 24/7 support.

“Having continuous access to Valmet’s services helps us minimize downtime and ensures that production is secure,” concludes Neuhaus.