Tetra Pak rolls out Factory Os to enhance efficiency in sustainable food packaging

SWITZERLAND – Tetra Pak has introduced its Automation and Digitalization portfolio, known as Tetra Pak Factory OS, targeting food and beverage manufacturers with tools for smarter production lines. 

This collection of technologies integrates data from various factory systems into a single real-time dashboard, allowing operators to track performance across equipment of any age or origin.

In a statement, Adolfo Otero, President of Tetra Pak Product Solutions, said, “Factory OS connects the dots in production, giving teams the visibility needed to cut waste and energy use right away.” 

The platform draws on open standards to link machines, sensors and software, providing insights into material flow, quality checks and equipment health. 

Producers can access these through a consistent interface that works from shop floors to control centers.

The setup includes apps for monitoring output in real time, helping to spot issues early and adjust processes on the fly. 

Tetra Pak developed the system alongside Accenture, with input from partners like Siemens, Rockwell Automation and Inductive Automation. 

This network ensures the tools expand easily as factories grow or upgrade.

According to company details, the portfolio standardizes data handling, which cuts down on manual errors and downtime. 

Food and beverage firms stand to gain from lower energy bills and smoother operations, directly supporting goals for greener manufacturing. 

One early focus area involves optimizing carton filling lines, where precise control over utilities like water and steam leads to measurable savings.

This launch builds on Tetra Pak’s recent push into eco-friendly materials. Earlier this year, the firm debuted a paper-based cap for its cartons, containing 87 percent renewable fibers. 

Aldo Fontana, Global Product Manager at Tetra Pak, noted during a summer briefing, “Switching to more paper in caps means less plastic overall, easing the load on recycling streams.” 

The design fits existing filling machines without changes, helping brands phase in sustainable options faster.

In related developments, major players are testing AI-driven waste tracking to close loops in packaging recovery. 

Unilever, Amcor and Asahi Group Holdings started a pilot last month with Greyparrot’s Deepnest platform. 

The system deploys AI cameras in sorting facilities to trace individual packages, logging what gets recycled versus discarded. 

A Greyparrot spokesperson explained that the trial reveals exact recovery rates for specific formats, enabling brands to tweak designs based on hard data.

In October, Dubai-based Al Ghurair Foods partnered with a local automation firm to install digital twins for its beverage lines, mirroring Factory OS capabilities. 

The project, valued at US$2.5 million, aims to trim water use by 15% through predictive analytics, as outlined in a company release. 

This move comes amid rising demand for traceable supply chains in the Gulf, where beverage exports hit US$1.2 billion last year.

Tetra Pak’s Factory OS arrives at a time when industry data shows digital upgrades can slash production emissions by up to 20%. 

With built-in scalability, the tools prepare plants for future AI integrations, keeping pace with evolving regulations on packaging sustainability. 

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