Probiotical S.p.A.

Probiotical was experiencing exponential demand growth with supplement-stick volumes rising from 1.5 million to 10 million per year, requiring rapid manufacturing scale-up. The company had minimal holistic visibility into operations, making it difficult to integrate new packaging lines while maintaining efficiency.

ThingWorx IIoT solution, part of FactoryTalk InnovationSuite, was implemented to provide real-time and historical production data visibility. The platform connected IT and OT landscapes and was extended to existing facilities beyond the initial new-plant scope.

Machine availability increased by 15-20% and OEE reached near-optimum value. Energy consumption and packaging waste were both reduced. The platform enabled data-driven decision-making to support the company's rapid scaling.

• IIoT platforms can deliver 15-20% machine availability improvement in life sciences manufacturing through better operational visibility
• Deploying IIoT on existing assets before new plant construction captures quick wins and informs future investments
• OEE near-optimum is achievable when real-time production data replaces manual observation