Projects Zwanenberg HighFive case

Zwanenberg HighFive case

Food waste is a persistent challenge in the food industry. A brand-new AI solution, developed as part of the European innovation program HighFive in collaboration with RBK Group and partners, supports operators with real-time recommendations. The result: less waste, with the added benefits of more efficient production and maintained quality.

Future-proof development

Less waste in the production process

Companies are always looking for smart production processes. In practice, however, it’s difficult for them to set aside time for a critical analysis of their existing processes. “A company has to produce. After all, without production, there’s nothing to sell. That makes it hard to find room for optimization,” says Moché Chamla, HighFive project manager at RBK Group. Thanks to his many years of experience in the industry, he understands better than anyone the challenges associated with implementing an ERP/MES system in food companies. According to him, however, the return on investment is significant when companies do invest in process optimization.

“By automating and optimizing processes, you can produce more while maintaining the desired quality standards. At the same time, you reduce waste, rework, and give-away. This results in significant savings on production costs.”

What's your challenge?

High-Five RBK Zwanenberg

HIGHFIVE Program

As part of the HighFive program, 33 companies are collaborating to help European food companies—from meat to fish processing and from produce to snacks—produce more sustainably. The project focuses on accurately recording process data. A software algorithm analyzes and interprets this data and advises operators on how to prevent waste and monitor quality.

Specific recommendations

A concrete example comes from the production of fresh meat products. Products such as roast beef often have to be produced and delivered on the same day. Raw materials are purchased weeks in advance, and the schedule is set. On the day itself, everything has to come together. “An ERP/MES system must facilitate this perfectly. Our solution enables purchasing, planning, and production to be coordinated more efficiently. That’s essential, especially in times of labor shortages and high quality standards.” The AI application also offers opportunities in the production of dry sausages. A pilot project is currently underway at the Zwanenberg Food Group facility in Vlagtwedde. There, the algorithm is being tested to reduce waste in this artisanal process.

“During the drying process, the sausage dough loses weight. Operators therefore routinely fill the casings with slightly more dough to ensure they remain above the specified quality threshold. Suppose you need 100 grams of dough, but you fill 102 grams just to be safe. If the final product ends up weighing 52 grams, you’ve wasted 2 grams. On an annual basis, that adds up to significant losses,” explains Moché. “The algorithm links historical data (such as processing information on raw materials) to real-time data, including moisture content, fat content, salt, and pH value. Based on this, the software provides specific recommendations. This way, operators know exactly how much dough is needed to avoid waste without compromising quality.”

Start small

Small steps that help you

The strength of the AI solution lies in its ability to translate data into actionable insights. Whereas systems traditionally focus primarily on recording data, this new approach directly assists operators in making decisions. This not only makes work more efficient but also helps preserve knowledge. In an industry where experienced employees are becoming increasingly scarce, this is a significant advantage. Moché: “An ERP/MES system collects enormous amounts of data. The algorithm ensures that historical and current data are converted into clear recommendations. In this way, we support operators and ensure that decisions are based on facts.”

According to Moché, the first step should definitely not be too big. “It’s important to start small. Begin by tackling a single product group or production line. This makes it clear what benefits can be achieved and builds trust.” For manufacturers looking to implement AI, partnering with the right provider is crucial. RBK Group not only provides the software but also offers consulting and support. “We go so far that customers often say we’re part of their company. That’s exactly our approach: we like to think along with them. Together on the path to a sustainable future, with smart solutions. You lead, AI delivers!”