14 September 2015

Process Improvements with Innova at AquaChile

Innova has improved process performance and given better control of production.

AquaChile’s investment in Innova Software Solutions has improved their process performance and given them better control of production from receiving to dispatch.

AquaChile is the largest salmon processing company in Puerto Montt, Chile. It employs more than 5,500 workers in Chile, Costa Rica, Panama, and the United States. The company’s niche in the market is the production and processing of salmon (Coho, Atlantic), sea trout, and tilapia. Its products are sent to every continent around the world, with more than 230 customers in 30 countries.

With Innova, we can optimize our production performance – in fact we have now reduced by 30% the time it takes for registrations, analysis, and generating process information reports.

- Felipe Espinosa, Plant Manager at AquaChile in Cardonal
 

AquaChile and Marel have been working together since Marel established a subsidiary in Chile in 2004, opening a local office in Puerto Montt. AquaChile was quick to recognize Marel’s expertise in the fish processing world, and leadership in food processing more generally.

“The quality of Marel equipment is indisputable,” says Felipe Espinosa, Plant Manager at AquaChile in Cardonal. But in order to optimize their processing equipment, AquaChile also needed the best in intelligent production control. They needed to collect the process data in real time and centralize the information, in order to improve their process performance and gain better control of production from receiving to dispatch.

After considering competing software solutions, AquaChile quickly came to the conclusion that Marel’s Innova software is the best choice, and invested in Innova modules covering a range of functions: from administration and order management, to process and quality control, and all the way through to packing and dispatch.

The Innova system at AquaChile improves control of the process, ensuring information is constantly available online at each point of production. Better control ultimately means higher yield and better quality.

“We can be confident with Innova that we have full traceability at any point in the system, we can detect any problems, and we know where to make improvements on the process line immediately,” explains Baldemir Rivera, IT Process Manager at AquaChile.

After defining the requirements and establishing the system parameters, Marel worked with AquaChile to install the Innova system at two different plants, starting with Cardonal and then at the Calbuco plant. The installation was completed over a single weekend, ensuring minimum disruption of processing operations. Next, the company plans to install Innova for one of its packing lines at its plant in Chiloé, Chile.

“After just two months we could see the value of the software,” says Espinosa. “The Innova solution gives us timely and credible information that adds value to our process.”

The company needed to optimize performance, maintain high quality, and ensure traceability and food safety across their entire operation – this has all been achieved thanks to their collaboration with Marel.

“Thanks to Marel, we have saved labor costs, we have all the information available online, and we can better plan our process. With Innova, we can optimize our production performance – in fact we have now reduced by 30% the time it takes for registrations, analysis, and generating process information reports,” explains Espinosa.

The most important benefits of the Innova system for AquaChile include the centralization, accessibility, and reliability of information; the integration with all parallel systems; and the unification of various developments and applications into a single production system.

Throughout the installation phase and on an ongoing basis, Innova support makes it easy for AquaChile to ask questions and get advice about how to use the system, as well as access updates and new versions of Innova.

“Innova is a reliable and efficient system that give us the flexibility to be ourselves, as administrators, creating new tools that facilitate our daily work and organize our data,” says Rivera.


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