Process monitoring in the Melitta roastery control center: Where tradition and technology go hand in hand
At Melitta, tradition and technology go hand in hand. While the brand has stood for high-quality coffee for generations, a new roastery control center in Bremen ensures that these high quality standards are reliably maintained even in a highly automated production environment. Together with JST, the project team developed a modern production control center that combines digital process monitoring with the expertise of Melitta’s master roasters.
All processes are monitored in the new roastery control center, from the receipt of green coffee beans to supplying the packaging lines. It forms the heart of coffee production at the Bremen site. However, the roastmasters’ work does not end at the control room screens: In addition to overseeing the production processes, they regularly check coffee quality directly on the production floor.
Digital monitoring and direct quality control
This interaction between digital process monitoring in the control room and direct quality checks at the production facilities ensures that every batch meets the specified requirements. “We are always pleased when people do not see themselves merely as Operators, but once again as master roasters,” explains Max Lorenz, describing the special role of his colleagues.
The journey toward the new roastery control center began with a challenge that will sound familiar to many control room operators and administrators. Over the years, more and more displays, input devices and systems had accumulated. Almost every monitor had its own mouse-and-keyboard setup. Maintaining an overview became increasingly difficult, and the working environment no longer met the ergonomic requirements of a modern production control room.
The search for a holistic control room concept
Together with its employees, Melitta developed initial ideas for redesigning the workspace. It quickly became clear, however, that simply installing new desks or reducing the number of monitors would not solve the problem. What was needed was a comprehensive concept that would combine situational awareness, ergonomics and modern workflows.
The decisive turning point came with a visit to the JST control room simulator. Starting from very general requirements such as “fewer screens” and “less peripheral equipment,” a concrete vision for the future control room gradually took shape. At the same time, it became clear that modern control room technology does not have to be more complicated. The system proved intuitive to use and was quickly accepted even by experienced team members.
“Operation was almost self-explanatory”
Today, employees benefit from significantly better situational awareness and more flexible workflows. The combination of a central DisplayWall and innovative KVM technology based on JST MultiStreaming® enables information to be called up as needed, processes to be assessed collaboratively and disruptions to be analysed more quickly. Integrated JST CommandPads® allow employees to conveniently control all required systems.
One shared view instead of monitor clutter
The new control room reduces complexity, creates a shared operational picture and supports the Operators in their daily work. “Today we have far more possibilities. And operating the system was almost self-explanatory,” says Max Lorenz, describing the experience after commissioning. According to feedback from the control room team, the ergonomic workstations are particularly appreciated. Height-adjustable Stratos X11® control room consoles are complemented by OPAL X11® ceiling sails, which not only improve room acoustics but also provide a natural lighting atmosphere through integrated HCL (Human Centric Lighting).
Future development already considered
Future requirements were also taken into account during the planning phase. Additional functions and extensions can be integrated step by step. As a result, the new roastery control center not only provides better conditions for current operations, but also serves as the foundation for the site’s continued development.
In this way, the new roastery control center brings together two worlds that are inseparably linked at Melitta: the experience and passion of the master roasters, and modern control room technology that makes people’s work easier and ensures the consistent quality of Melitta coffee products – from the first bean to the finished coffee.
Our references today (selection)
A
B
C
E
H
I
M
N
P
R
S
- s.Oliver, Rottendorf
- SachsenEnergie, Dresden
- SAG, Berlin
- SAG, Nürnberg / Nürnberg Messe
- Salzgitter Flachstahl
- Senvion SE, Osterrönfeld
- SGL Carbon Group, Bonn
- SIEMENS
- SIEMENS, Wegberg
- Spenner, Erwitte
- Städtische Werke Magdeburg
- Stadtwerke Gießen
- Stadtwerke Ratingen
- Stadtwerke Schwerin, Kraftwerk Süd
- Stadtwerke Steinburg GmbH, Itzehoe
- Stadtwerke Wolfenbüttel
- Starlim Sterner, Marchtrenk
- STORAG ETZEL, Friedeburg
- Straßenverkehrsamt Frankfurt am Main
V
W
Unsere Referenzen (Archive)
