German Engineering

    Maximize Your
    Production Efficiency

    Flowline Consulting combines deep industry expertise with the advanced FlowLine OEE BOX for measurable results in your manufacturing.

    Live Tracking

    The OEE BOX Along the Line

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    Filler

    Speed
    Live
    Micro-stops
    Live
    Fill level
    Live
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    Station

    Labeler

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

    Packer

    Backlog
    Live
    Cycle time
    Live
    Format change
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    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

    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%
    COâ‚‚ Emissions
    1.2 t
    -1.2%

    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.

    1
    Company Class

    2
    Line Type

    3
    Size 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 COâ‚‚.

    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 implementing the FlowLine OEE BOX.

    Ready for the
    next step?

    Contact us for a non-binding initial consultation. We will show you how you can sustainably increase your OEE with FlowLine.

    Send Message

    Fill out the form and our team will get back to you immediately.