​​​​​Brazilian dairy producer increases Production Time Utilisation by 26% in nine months and eliminates unsterility cases 

Focusing on Preventive Maintenance has reduced breakdown frequency, downtime and operational costs 

​A dairy producer in Brazil needed to reduce breakdown frequency and improve equipment uptime, so it targeted increases in Production Time Utilisation (PTU) and Line Machine Mechanical Efficiency (LMME). It also aimed to reduce operational costs, including maintenance costs, utilities, packaging material waste, labour costs and freight for urgent spare parts deliveries. Moreover, it wanted to eliminate an average of three unsterility cases per year.​​​​​ 

​A Tetra Pak® Plant Care agreement combining Tetra Pak® Maintenance Services offerings with an employee recognition programme 

An analysis of operations found that existing maintenance procedures were insufficient, leading to equipment breakdowns. The solution was a Tetra Pak® Plant Care agreement – a long-term maintenance agreement that included several Tetra Pak® Maintenance Services offerings, with the emphasis on Preventive Maintenance. An employee recognition programme was also introduced to enhance productivity.

Results achieved

  • Production Time Utilisation (PTU) increase: 66% to 92%

  • Line Machine Mechanical Efficiency (LMME) increase: 75% to 97%

  • Annual unsterility cases: zero

  • Packaging material waste decrease: 3.0% to 0.6%

  • Results sustained, with annual operational cost reduction of18%