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Clif Bar

Clif Bar charts its path toward self-sufficient operations

When Clif Bar, the well-known energy bar maker, began producing its own products in 2014, it turned to AVEVA MES System, MES Quality Solution, MES Operations, AVEVA Historian and other AVEVA solutions to support its strategic initiatives. The company needed to launch a new facility in Twin Falls by replicating the operational architecture of its Indianapolis site, build a data-driven culture and guarantee product quality despite having no prior in-house manufacturing experience. AVEVA solutions integrate seamlessly with a wide variety of OEM hardware and existing assets, enable Clif Bar to measure and validate its commitment to its 5 Aspirations, and chart a clear path toward self-sustaining, sustainable operations that support the company's future growth.

Objectives

  • Launch a new facility in Twin Falls using the same operational architecture as its brownfield facility in Indianapolis.
  • Establish a data-driven culture to better understand opportunities for continuous improvement.
  • Select an MES system that integrates seamlessly with a variety of existing OEM hardware and assets.
  • Measure and validate Clif Bar's commitment to its 5 Aspirations.

Solutions

  • AVEVA MES
  • AVEVA Historian

Results

  • Clif Bar went from manufacturing 0 to 75% of its own bars in one year.
  • Despite an 8% chance of success, Clif Bar has taken control of the operations of new and industrial sites without compromising product quality or performance.
  • The continued use of Historian data allows Clif Bar to take advantage of predictive analytics.

FAQ

How does AVEVA MES standardize multi-site food production?
AVEVA MES deploys a common platform that models recipes, processes and quality indicators across all the production sites of a food manufacturer like Clif Bar. This standardization ensures that every product has the same characteristics regardless of the plant, while making it easier to roll out new recipes. Teams benefit from a unified view of performance and can compare sites to identify best practices.
Why is MES traceability critical in the food industry?
The food industry is subject to strict traceability requirements, particularly for food safety and allergen management. AVEVA MES automatically records every production step: raw material batches, process parameters and quality checks. In the event of a product recall, the scope of impact is identified in minutes rather than days. It is an essential standard for any manufacturer wishing to export or supply major retailers.
How does AVEVA System Platform unify food production processes?
AVEVA System Platform serves as a unified technical foundation that integrates the mixing, baking, packaging and palletizing equipment of a food plant. The object-oriented platform makes it possible to model each production line and replicate configurations on new sites. Combined with InTouch HMI and Historian, it provides real-time industrial supervision and complete data historization, which are essential for managing performance and guaranteeing quality.
What operational benefits does an MES bring to a food producer?
An AVEVA MES improves material yield, reduces production losses and speeds up changeovers thanks to automated recipe management. Paper records give way to reliable electronic traceability. Industrial performance indicators (OEE, yield, quality) are calculated in real time, allowing managers to quickly identify bottlenecks and take targeted corrective action on the lines or teams concerned.
How does AVEVA support the transition to sustainable food production?
AVEVA provides food manufacturers with the measurement and optimization tools essential to sustainable production: energy consumption monitoring, waste reduction, packaging optimization and traceability of responsible sourcing. Industrial supervision and MES make it possible to precisely quantify the environmental footprint of each product and launch quantified action plans, in line with CSR commitments and growing consumer expectations.