GEA introduces digital support for food packaging changeovers

GEA has launched Changeover Assist, a new software solution designed to standardise product and format changeovers on food processing and packaging machines. The system provides recipe-based guidance directly through the SmartControl human-machine interface, helping operators complete changeovers more consistently and efficiently.

The software is initially available for GEA PowerPak thermoformers and the GEA MaxiFormer drum former, with a phased rollout planned for additional machines, including the GEA OptiSlicer.

Changeovers create production challenges

Product and format changeovers are among the most demanding stages of industrial food production. Growing product variety, seasonal labour and employee turnover can increase the complexity of these operations and make it more difficult to maintain consistent procedures.

Errors such as using incorrect packaging materials or skipping individual changeover steps can lead to material and food waste, rework, quality deviations and production interruptions. Changeover Assist is designed to reduce these risks by providing operators with standardised instructions for each specific changeover.

Recipe-based guidance improves consistency

The software provides recipe-based operator guidance through the SmartControl HMI. Instructions are tailored to the selected product or packaging format and can be presented in multiple languages.

Each step of the changeover process is documented as it is completed, improving transparency and traceability. The system can also incorporate additional information to help operators understand the required procedures and complete them correctly.

Reducing waste and production interruptions

By helping operators follow the correct sequence during a changeover, GEA expects the software to reduce operating errors and the associated waste of packaging materials and food products. More consistent procedures can also help minimise production interruptions and improve overall equipment availability.

The technology can be particularly useful in production environments where operators have different levels of experience. Making machine and process knowledge available directly through the equipment can reduce reliance on individual expertise and help new employees become familiar with complex procedures more quickly.

Digitalisation supports machine operators

Changeover Assist is connected to GEA's InsightPartner solution, allowing customers to centrally manage and update changeover instructions. This provides manufacturers with a digital knowledge base that can be maintained as production requirements and procedures evolve.

The approach forms part of GEA's wider digitalisation strategy for food processing and packaging. Instead of focusing exclusively on physical automation, the company is also using software to support operators, standardise processes and make production knowledge more accessible.

More flexibility requires better digital tools

Food manufacturers are increasingly required to produce a wider variety of products and packaging formats while maintaining high levels of productivity. This makes fast and reliable changeovers increasingly important for packaging operations.

Digital assistance can help bridge the gap between highly flexible machinery and the practical knowledge required to operate it. By providing instructions at the point of operation, manufacturers can make complex procedures easier to follow while maintaining consistent production standards.

Software becomes part of packaging automation

GEA's Changeover Assist illustrates how software is becoming an increasingly important component of modern packaging machinery. Connected systems can complement mechanical automation by improving operator guidance, process documentation and production reliability.

As food packaging lines become more flexible and manufacturers face increasing pressure to reduce waste and downtime, digital changeover solutions could play a growing role in improving the efficiency of packaging operations.