Downeast Cider

Downeast Cider, a craft hard cider producer, was managing production operations through manual tracking processes that created significant blind spots across its brewing and packaging lines. In food and beverage manufacturing, traceability is both a regulatory requirement and an operational necessity — without it, producers cannot accurately account for raw ingredient consumption, work-in-progress, or finished goods movement. Relying on manual records made it difficult to reconcile inventory at each production stage, leading to bloated safety stock, misallocated materials, and inflated cost of goods. The compounding effect was eroding margins in an already cost-sensitive craft beverage segment.

Downeast Cider implemented a Manufacturing Execution System (MES) through Rockwell Automation's Plex platform, which includes purpose-built capabilities for food and beverage producers. The deployment connected production tracking, inventory management, and traceability into a single unified system, replacing spreadsheets and manual recording with real-time data capture at each stage of the production process — from raw ingredient receipt through fermentation, packaging, and finished goods. Plex MES for Food & Beverage provided end-to-end lot traceability, enabling the team to track every batch with precision. The system integrated inventory visibility with production workflows, allowing accurate consumption recording and tighter material planning without requiring excess buffer stock to compensate for uncertainty.

The MES implementation delivered measurable financial impact across two key cost areas:

• 10% reduction in inventory costs — tighter traceability eliminated the need for excess safety stock maintained to offset manual tracking uncertainty
• 17% reduction in COGS — real-time production data enabled better yield management and reduced material waste across the beverage manufacturing process

Beyond the headline numbers, the shift from manual to system-driven traceability gave operations teams reliable, auditable records at every production stage — supporting both internal decision-making and food safety compliance requirements inherent to regulated beverage manufacturing.

• MES traceability directly addresses inventory overstock caused by manual uncertainty — quantified savings appear in both working capital and COGS simultaneously.
• Craft and mid-market beverage producers should prioritize food and beverage-specific MES platforms over generic manufacturing software, as batch traceability and lot management requirements differ significantly from discrete manufacturing.
• The path to lower COGS in beverage manufacturing often runs through data quality, not process redesign — accurate consumption tracking exposes waste that manual systems routinely obscure.
• Connecting inventory management to live production data is the mechanism; traceability compliance becomes a byproduct rather than a separate initiative.