FlowLine CESAR

    FlowLine CESAR

    OEE Intelligence

    CESAR FLOWLINE SYSTEMS - FZCO

    OEE Measurement for Beverage Filling

    OEE Measurement &
    Tracking for Filling Lines

    Precise OEE measurement for beverage filling lines with the CESAR OEE Box. Plug & Play, manufacturer-independent, no intervention in machine controls. Capture availability, performance and quality in real time – ROI in under 6 months.

    Two Paths. One Goal.

    How You Can Use CESAR

    Whether commissioning a new line or in continuous production – CESAR delivers the precise data you need at every stage.

    Project Phase

    FAT Support & Commissioning Supervision

    Manufacturer-independent supervision during acceptance of new filling lines – with objective performance measurement through CESAR from first test run to final handover.

    • Objective performance measurement independent of OEM
    • Factory Acceptance Test (FAT) with real CESAR data
    • Capture of all stops, micro-stops and changeover times from day 1
    • Comparison of target vs. actual performance across all machines
    • Early detection of performance deviations
    • Handover protocol with documented OEE metrics
    Request Acceptance Support
    Continuous Operation

    Continuous OEE Monitoring

    Permanent deployment of CESAR in ongoing production for continuous transparency, data-driven optimization and sustainable efficiency gains across all sites.

    • 24/7 real-time OEE capture at line, plant and corporate level
    • Automated shift reports & stop analysis
    • Energy & consumption metrics in real time
    • Company-wide benchmarking across all sites
    • Role-based dashboards from operator to management
    • Continuous optimization through data-driven decisions
    Request Monitoring
    Live Tracking

    The OEE BOX Along the Line

    Station

    Filler

    Speed
    Live
    Micro-stops
    Live
    Fill level
    Live
    FlowLine OEE BOX
    Transmitting
    FL
    Station

    Labeler

    Material shortage
    Live
    Rejects
    Live
    Setup time
    Live
    FlowLine OEE BOX
    Transmitting
    FL
    Station

    Packer

    Backlog
    Live
    Cycle time
    Live
    Format change
    Live
    FlowLine OEE BOX
    Transmitting
    FL
    FlowLine LogoFlowLine
    FlowLine LogoFlowLine

    FlowLine Consulting

    Engineering & Consulting

    We are former engineers and project managers from global leaders in the beverage industry. For years, we witnessed firsthand how bottlers worldwide lose valuable time, energy, and resources daily due to inefficient processes and a lack of data transparency.

    Our goal was uncompromising: We wanted to develop a solution that brings real, measurable efficiency to the shop floor – without the complexity of traditional large-scale IT projects. This led to the creation of FlowLine Consulting for strategic optimization and CESAR, our revolutionary hardware solution that finally makes machine data usable.

    Our Origin

    By Bottlers.
    For Bottlers.

    15+
    Years Industry Experience
    100%
    Focus on Beverage Industry
    CESAR
    Proprietary Hardware
    FlowLine OEE BOX Detail

    The FlowLine OEE BOX

    The core of our solution. A robust, industrial-grade IoT gateway that captures, processes, and visualizes machine data in real-time. Developed according to the highest German engineering standards.

    • Plug & Play installation on existing plants
    • Real-time recording of machine and process data
    • Robust design for harsh industrial environments
    • Secure data transmission and edge computing capabilities
    Challenges

    Hidden Losses in Every Shift

    Without real-time data, all levels of your company suffer from the same systemic problems.

    Operators

    Manual Effort & Stress

    • Handwritten stop logs at end of shift
    • Reactive actions instead of early warnings
    • High documentation effort reduces focus
    Shift Management

    Lack of Overview

    • No real-time view of all lines
    • Decisions based on gut feeling
    • Time lost through manual data preparation
    Management

    Missing Fact Base

    • No objective benchmarking of sites
    • Hidden cost drivers remain undetected
    • Difficult investment planning without data
    Cost of Inaction(approx. 15€ per minute)

    What unrecognized micro-stops are costing you right now

    Lost revenue today:
    4.319,33 €
    The Difference

    CESAR vs. VS Traditional MES

    Why more and more bottlers are turning their backs on classic IT projects and relying on Plug & Play.

    FlowLine CESAR

    Classic MES

    Implementation Time
    48 hours
    6-12 months
    IT Resources
    None required
    High IT effort
    Production Stop
    Not required
    Multi-day downtime
    Cost Structure
    Clear ROI < 6 months
    High Capex, hidden costs
    Hardware Intervention
    100% Non-Invasive (Edge)
    PLC reprogramming required

    Seamless Integration

    Our hardware can be effortlessly integrated into any existing production environment.

    Comprehensive Software Features

    Our solution offers you deep insights into your production – from real-time monitoring to cross-site analyses.

    Historical Analysis

    Deep insights into past line performance.

    • Advanced reports
    • Reasons for scrap
    • First Faults Analysis

    Real-time Monitoring

    Machine and line status in live view for immediate reactions.

    • KPIs for machines and lines
    • Time stealers & error detection
    • Analysis of causes for downtimes

    Enterprise Reporting

    Tailor-made reports for all levels of your company.

    • Customized reports
    • Company-level reports
    • Cross-site analyses
    Energy Management

    Energy Measurement incl. Visualization

    Keep track of your consumption data. Identify savings potential through detailed analyses and sustainably reduce your operating costs.

    Power Consumption

    Detailed recording and analysis of electrical energy at machine and line level.

    Air Flow Measurement

    Monitoring of compressed air consumption to detect leaks and inefficiencies.

    Live Energy Monitor
    Connected
    Current Load
    142.5 kW
    +2.4%
    Daily Consumption
    3,450 kWh
    -5.1%
    CO₂ Emissions
    1.2 t
    -1.2%
    Multi-Site Enterprise Architecture

    From the Bottling Line to the Global Corporate Dashboard

    Full control across all hierarchy levels of your company. Granular role permissions and company-wide comparison of all OEE and energy metrics.

    Multi-Site Enterprise Architecture

    From the Bottling Line to the Global Corporate Dashboard

    Full control across all hierarchy levels of your company. Granular role permissions and company-wide comparison of all OEE and energy metrics.

    LEVEL 3 · KONZERN- & EXECUTIVE-EBENE

    Globales Konzern-Dashboard

    Multi-Plant KPIsOEE & Energy Benchmarking Executive Board
    LEVEL 2Live OEE
    Werk / Standort A

    Werksleitung & QM Overview

    Linie 1
    Glas-Mehrweg
    Linie 2
    PET-Linie
    LEVEL 2Live OEE
    Werk / Standort B

    Werksleitung & QM Overview

    Linie 3
    Dosenlinie
    Linie 4
    Keg-Abfüllung
    LEVEL 2+ n Werke
    Weitere Standorte (n)

    Skalierbar über alle Standorte

    Linie N1
    Abfüllung 5
    Linie N2
    Abfüllung 6
    LEVEL 0 / 1 · LEVEL SHOPFLOOR & SENSORIK (NON-INVASIVE CESAR OEE BOX HARDWARE)

    Sensoren erfassen Füllstände, Lichtschranken & Energieverbrauch an jeder Maschine – ohne Eingriff in die SPS.

    Ebene wählen:
    Standort:
    CESAR Live OS/Global Executive Dashboard (12 Werke)
    Live Sync (100ms)
    Zugriff: C-Level / Group Operations
    Konzern-OEE Global
    82.6%
    +3.2% vs. Vorjahr
    Aktive Standorte
    12 Werke
    42 Abfülllinien vernetzt
    Jahresausstoß Total
    4.8 Mrd. Fl.
    100% CESAR-Erfasst
    CO₂-Einsparung (YTD)
    -1,420 t
    Durch Energiemanagement
    Standort-Benchmarking (Top Werke)Automatisches Best-Practice Ranking
    #1🇩🇪 Werk München
    88.4%
    #2🇩🇪 Werk Hamburg
    85.1%
    #3🇺🇸 Plant Atlanta
    82.6%
    #4🇯🇵 Tokyo Facility
    89.2%
    Top-Ebene

    Level 3: Global Corporate & Executive Level

    Level 3

    Company-wide benchmark across national and international sites. Best practice identification, strategic CO₂ and OEE evaluation.

    Group OEE
    82.6%
    Active Plants
    12 Sites
    Annual Output
    4.8B Bottles
    Executive Board, C-Level, Group Operations, Sustainability Officers
    Cross-plant ranking & best practices
    Centralized CO₂ & energy monitoring
    Granular Role-Based Access Control (SSO / RBAC)
    ↓
    Mittlere Ebene

    Level 2: Plant & Facility Level

    Level 2

    Aggregated overview of all bottling lines in a factory. Shift comparisons, hall utilization, and energy peak load management.

    Plant OEE
    84.2%
    Active Lines
    6 / 6 Lines
    Daily Output
    1.42M Units
    Plant Managers, Production Directors, Energy Managers
    Shift & line benchmarking
    Peak power load warning system
    Facility-wide reporting & shift handover
    ↓
    Basis-Ebene

    Level 1: Machine & Line Level

    Level 1

    Detailed view for shopfloor staff: Live OEE, micro-stops, loss reasons, and exact energy consumption per minute.

    Line OEE
    88.4%
    Current Speed
    48,200 bph
    Power Load
    142 kW
    Shift Supervisors, Operators, Maintenance Techs
    Real-time stop reason logging
    Live alerts for micro-stops
    Direct operator input via shopfloor terminal

    Secure Role-Based Access Control (RBAC)

    Every employee sees exactly the data relevant to their role – from terminal operators to HQ executives.

    Request OEE Measurement

    Your Advantages with Flowline

    Benefit from measurable results and a significant increase in your production efficiency.

    Cost Efficiency

    Cost drivers for production downtimes are identified and continuously reduced.

    Time Savings

    Optimize time expenditure thanks to fast and comprehensive processing of all data.

    Global Availability

    Use Flowline 24/7 – regardless of location and your chosen device.

    Increase OEE

    Get an overview of machine data as well as KPIs and create the basis to increase your Overall Equipment Effectiveness (OEE).

    Transparency

    Advanced Analytics records and logs all relevant status and process data of your production line.

    Overview

    The system translates the multitude of complex plant information into meaningful key figures and enables the derivation of well-founded actions.

    CESAR · OEE Intelligence

    Industry Benchmark Configurator

    Example Data

    Real capacity and efficiency values of industrial beverage filling lines – by line type and size class.

    1Company Class
    2Line Type
    3Size Class
    Nominal Capacity
    60.000
    Units/h
    Actual Output (OEE)
    50.400
    Units/h
    Total OEE
    84%
    Availability × Performance × Quality
    Capacity Loss
    9.600
    Units/h lost

    OEE Breakdown

    Availability91%
    Performance93%
    Quality99%
    Total OEE84%
    Typical Machine Components
    Hochleistungsfüller (Monoblock)
    Doppelend-Reinigungsmaschine
    Abschrauber / Verschließer
    Vollgut-Inspektion
    Hochleistungs-Etikettierer
    Roboter-Palettierer

    Reference Details

    Reference TypeInternationale Großbrauerei, Norddeutschland
    Investment Volume45 Mio. €
    Commissioning (Ref.)2025
    Daily Output (OEE)1.209.600 Units/h / day
    OEE ClassGood (75–84%)
    CESAR Potential+2.880 Units/h (est. +30%)

    CESAR enables exact OEE measurement on this line

    Retrofit-ready · No IT integration required · Live dashboard from day 1

    Inquire Now

    System Architecture Secure Real-Time Data Flow

    From the machine to the dashboard – see how the FlowLine OEE BOX collects, processes, and visualizes your production data.

    Shopfloor

    Your Bottling Line

    • PLC & Controllers
    • Additional Sensors
    • Machine Signals

    Edge Processing

    FlowLine OEE BOX

    • Local Data Buffering
    • Protocol Translation
    • TLS 1.3 Encryption

    Cloud & Dashboard

    CESAR Platform

    • Real-Time Analytics
    • Historical Reports
    • ERP Integration

    Interfaces & Compatibility

    The FlowLine OEE BOX speaks the language of your machines. Seamless integration thanks to broad protocol support.

    OPC UA

    The Industry Standard

    HTTP

    Cloud-Ready

    SQL

    Database Export

    Roadmap

    Upcoming Releases

    We are continuously developing CESAR. Here is a preview of upcoming features.

    REST-API Interface

    Seamless integration into your existing systems and dashboards via our modern REST-API. Full access to live data and historical analysis.

    AI-Powered Predictive Maintenance

    A module that detects patterns in micro-stops and predicts machine failures (e.g., at the filler or labeler) before they happen.

    Automated Shift Reports

    Push notifications that automatically summarize the most important KPIs and top loss reasons for management and shift leaders after every shift.

    Energy & OEE Correlation

    A direct link between the energy monitor and downtime to show exactly what idle time costs in Euros and CO₂.

    Enterprise Grade

    IT Security & Compliance

    We protect your most valuable asset. Our architecture is 'Secure by Design' and meets the strictest industrial IT guidelines.

    Data Security

    Your production data remains protected. We guarantee purely passive read access (read-only) with no impact on your machine control.

    • Isolated networks
    • No control intervention
    • GDPR compliant

    Encryption

    State-of-the-art cryptographic methods secure all data traffic from the edge box to the cloud dashboard.

    • End-to-End TLS 1.3
    • Certificate-based
    • Secure VPN tunnels

    Edge Computing

    Pre-processing directly at the line. Only relevant, aggregated data leaves the plant network.

    • Local data buffering
    • Bandwidth optimized
    • Fail-safe (Offline mode)

    Holistic Optimization

    We accompany you from the initial analysis to successful implementation and continuous improvement.

    OEE Analysis

    Identification of losses, bottlenecks, and untapped potential in your production lines.

    Process Consulting

    Development of tailored strategies to reduce setup times and waste.

    Hardware Integration

    Seamless integration of the FlowLine OEE BOX into your existing infrastructure for real-time data.

    Installation & Training

    Plug-in. Power-on. Produce.

    CESAR is ready to use in 48 hours – without production stops, without IT projects.

    Our experts handle the entire hardware installation directly at your filling line. Sensors are precisely positioned, calibrated, and integrated into the CESAR system – tailored to your line, your machines, your shift structure.

    After commissioning, we specifically train your operators, shift supervisors, and management on the CESAR platform. No generic training materials – but training on your real live data, with your real stop reasons and KPIs.

    What you receive:

    • On-site installation by certified FlowLine technicians
    • System configuration & calibration to your line
    • Operator training (Shopfloor level)
    • Management briefing (KPI interpretation & reporting)
    • Acceptance protocol & Go-Live confirmation

    What you receive:

    • Structured line analysis based on real CESAR data
    • Identification of the top 3 loss causes per machine
    • Prioritized action plan with ROI estimation
    • Workshop with shift management & plant management
    • Optional: ongoing performance monitoring (Quarterly Review)
    Optimization Consulting

    Data is the beginning.
    Results are the goal.

    We analyze your OEE data and show you exactly where your line is losing money – and how to get it back.

    Many manufacturers know they are wasting potential. But they don't know where, how much – and what it costs them daily. This is exactly where FlowLine optimization consulting comes in.

    Our consultants work directly with your CESAR data: They identify the biggest sources of loss along the line, prioritize measures based on impact and feasibility – and support your team during concrete implementation.

    The result is not a PowerPoint presentation. It is a measurable increase in OEE.

    Acceptance Support

    Certainty for New Plants.

    Manufacturer-independent acceptance support by our globally experienced experts.

    Don't rely solely on the manufacturer's data when accepting your new beverage filling line. With our external, manufacturer-independent system, we measure the actual performance under real conditions.

    Our experts have years of worldwide experience in optimizing beverage filling plants. We ensure that your new line delivers the contractually guaranteed OEE from day one and uncover hidden bottlenecks before final acceptance.

    What you receive:

    • Manufacturer-independent performance measurement
    • Objective proof of the guaranteed OEE
    • Identification of bottlenecks before final acceptance
    • Worldwide expertise in the beverage industry
    • Detailed, reliable acceptance protocol
    Path to Success

    In 4 steps to maximum OEE

    A proven, seamless process from initial analysis to measurable results.

    1

    Potential Analysis

    We analyze your plant and identify the biggest levers for more efficiency.

    2

    Plug & Play Installation

    Installation of the FlowLine OEE BOX in under 48 hours - without production stop.

    3

    Training & Go-Live

    Training of your team on real live data and official start of monitoring.

    4

    OEE Improvement

    Continuous optimization and measurable increase of your overall equipment effectiveness.

    OEE Calculator & ROI Analysis

    Calculate your current OEE and simulate how much you can save through a targeted increase in plant availability.

    1 Current OEE Parameters

    80%
    90%
    98%

    2 Simulate Savings Potential

    +5%

    Expected percentage increase in Overall Equipment Effectiveness

    Current OEE

    70.6%

    Industry average. Potential available.

    Possible Savings / Year

    1.800.000 €

    Additional contribution margin through 5% OEE increase (12.000.000 additional bottles).

    Ø Amortization (ROI)

    < 6 months

    The investment in the FlowLine OEE BOX usually pays off in a few months.

    Frequently Asked Questions

    Everything you need to know about OEE measurement and implementing the CESAR OEE Box.

    Non-Binding Consultation

    Ready for the
    next step?

    Secure your free potential analysis. Our engineering experts will show you based on your line data how to sustainably boost OEE with FlowLine CESAR.

    Ready in 48h

    Fast installation without production stops or complex IT projects

    100% Non-Invasive

    Secure edge data capture without touching your machine control

    Measurable Results

    Concrete identification of your Top-3 losses & ROI < 6 months

    Guaranteed Response

    A FlowLine plant specialist will get back to you within 24 hours

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