Solutions by industry / Food & beverage
Pistachio roasting on target humidity, 4× ROI in one year
Ireco, a leading pistachio producer, uses AI closed-loop automation to reach the target humidity in every batch with less energy, now on three roasters.
The challenge
The right humidity, with the least energy
In roasting, the priority is to reach the target humidity in the end product, use the least energy to get there, and keep quality consistent.
The difficulty is that the raw product never arrives the same, and the energy needed to reach the right roast varies with it:
The plan, in two steps
- Real-time set-point recommendation. A model calculates the optimal value of three set points from the raw material's characteristics, accounting for humidity lost during roasting and packing.
- Data-driven automation. After a period of open-loop recommendations for testing and fine-tuning, the model moves to AI closed-loop control of the roasting conditions.
Our approach
From one roaster's data to three roasters in closed loop
Wizata and Ireco's local experts worked side by side, with measurable ROI as the target from day one.
A digital twin of the roaster
The Wizata platform, hosted in Ireco's own Azure tenant, ingests data from the roaster sensors, the raw material and the end product, organised in a digital twin built around the roaster.
Real-time set points
Process data is transformed and put in context. Machine-learning models from the platform produce real-time recommendations, with dashboards for each stakeholder.
Closed loop, then replicated
Once validated in open loop, the model runs in closed loop and has been replicated to two more roasters.
The outcome
More output, less energy, stable quality
The rise in annual production value quadrupled the initial investment in one year.
3% less energy
Lower operating costs, in line with Ireco's commitment to sustainable production.
Higher output
A consistent process and the right humidity raised annual production value.
Real-time response
Contextualised data lets the team react to incidents before quality drifts.
One model, every roaster
Models are maintained centrally, so a change reaches all roasters at once.
Built on the Wizata platform
Explore the platform →Next step
Hit your target on every batch
You don't have to do it alone. Talk to one of our engineers, or spend one or two days with our team on your own data.