MANUFACTURING · FOOD & BEVERAGE · DAIRY

AI Automation for Dairy.

Harmony digitizes paper intake sheets and CIP logs, streams pasteurizers and fillers live, schedules around silo levels and code dates, and puts AI on yield and traceability. One AI-native operating system over everything: your floor, your machines, and the software you already run. No rip-and-replace.

Start with a pilot ROI Calculators & Tools

THE PROCESS

First a digital transformation. Then an AI transformation.

FIG. 01 · THE TWO ARCS

ARC 1 · DIGITAL

ARC 2 · AI

Data engineering is the work.AI is what it unlocks.

THE PHASED ROLLOUT

Three phases of a digital and AI transformation.

PHASE 01

PHASE 1

Lay the Data Foundation · Digitization

Every pen-and-paper record digitized at the station, every software system connected, and all of the data unified into one live layer. The digital transformation starts here.

PHASE 02

PHASE 2

Production & Operations Scale

Factory operations turn proactive: live sensors and machine data, the AI scheduling board, predictive maintenance before failure.

PHASE 03

PHASE 3

AI-Native Operations

Agents across the floor and the back office act on the live layer: quality signals, reports, copilots. Humans approve.

AI USE CASES

Twelve ways the AI layer earns its keep.

Index · 11 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Intake sheets, pasteurizer charts, CIP logs, and cooler temperature checks live on clipboards, keyed into Excel a day later or filed in binders and never read.

Harmony AI Solution. Captured once at intake and at the line on tablets. AI flags out-of-range entries the moment they are written, and the record exists the same shift it happened.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Divert temps live on a chart recorder, separator flow on the HMI, fill counts on a tally sheet. Nobody sees them together, and nobody sees them live.

Harmony AI Solution. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, any brand, via OPC UA or whatever the machine speaks.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Light fills, bad seals, and missing codes are found at palletizing or at the customer, after a full run carries the same problem into the cooler.

Harmony AI Solution. Fill weights from the checkweighers, seal integrity results, and coder events feed ML as product exits the line.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "Which silos fed that vat?" or "What did CIP record before the failed swab?" means binders, batch sheets, and three phone calls.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, pasteurization records, CIP logs, and live machine data. Natural language in, cited answer out.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Runs sequenced by hand every morning around silo levels, code dates, allergen order, and CIP windows, in a spreadsheet only one person understands.

Harmony AI Solution. AI production scheduling models those same constraints and proposes the sequence. The plan proposes, the planner approves, and stays in charge.

U6

Yield Optimization

Use case 06 · YIELD + SOLIDS BALANCE

Problem. Component solids are reconciled at month-end. The loss is real, but the run, the vat, and the shift behind it are long gone.

Harmony AI Solution. Fat and solids tracked live from the tanker to the filled package. Loss shows by run and by vat the same day, with a cause attached, not a month-end variance.

U7

Back-Office AI Automations

Use case 07 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. Chart rolls, initials, and binders. Audit prep means days of pulling paper and hoping every roll was filed.

Harmony AI Solution. Full-scope AI agents run the workflows across financial, sales, procurement, and logistics: deductions and AR worked automatically, POs parsed from the inbox, and reports written before the morning meeting.

Scope. Financials, sales, procurement, and logistics automations, in the same platform.

U8

RFID + Serial Genealogy

Use case 08 · LOT TRACEABILITY

Problem. A mock recall means batch sheets, intake logs, and a day on the phone to prove where a lot went and what fed it.

Harmony AI Solution. Silo to vat to fill run to customer, one-up and one-back, answered in seconds with the records to show for it.

U9

Short-Code Demand

Use case 09 · SHORT-CODE DEMAND

Problem. Short-coded product is discovered in the cooler after it is too late to sell at full price, then dumped or discounted.

Harmony AI Solution. ML forecasts short-code risk by SKU and customer from live inventory age and demand, so product moves while it still has life on the code.

U10

Inventory + Shortage Intelligence

Use case 10 · INVENTORY

Problem. Ingredient, culture, and packaging counts drift from reality, and the shortage is discovered when the run is already staged.

Harmony AI Solution. An AI-maintained true-stock layer for ingredients, cultures, and packaging. Material readiness checked before a run releases, count drift flagged before it stops a line.

U11

AI Workflow Automation

Use case 11 · CIP VERIFICATION

Problem. The CIP skid logs its cycles, someone checks them by hand when there is time, and a shorted cycle is found at the failed swab or the audit.

Harmony AI Solution. Every CIP cycle verified automatically against its time, temperature, flow, and conductivity spec.

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YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

SAPInfor CloudSuite F&BApteanIgnitionAVEVA/WonderwareCIP automationCustom appsLocal servers

MACHINES

GEA separators + pasteurizersTetra Pak separators + pasteurizersEvergreen fillersElopak fillersVideojet date codersDomino date codersMettler-Toledo checkweighersCIP skids

You might run any of these. Or none of them. Harmony is software and hardware agnostic, and we connect live machine data from any PLC brand and any software or custom app.

AI AGENTS

Agents that watch, flag, and act. Humans decide.

CIP Verifier

Code-Date Watch

Pasteurizer Chart Writer

Silo-to-Vat Tracer

Fill Weight Watch

Solids Balance Agent

PO Inbox Parser

AR + Collections Copilot

Morning Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every dairy floor, and why they happen.

The ERP, SCADA, and the lab never connect

The ERP does not talk to Ignition or Wonderware, the CIP automation logs to its own historian, and the lab keeps results in its own files.

Intake sheets and CIP logs live on paper

Intake sheets, pasteurizer chart rolls, CIP logs, and cooler temperature checks are filled in by hand on clipboards.

The shelf-life clock starts at fill

Every unit leaves the filler with a code date, and every day it sits in cold storage is a day of sellable life gone.

Fat and solids are reconciled at month-end

Component solids come in on the tanker and leave in the package, but the balance between them is only closed at month-end.

The back office runs on manual work

POs are typed in from emails, invoices keyed into the ERP, deductions and AR worked from spreadsheets, and reports built by hand before the morning meeting.

THE PILOT

$15–20K. 4–6 weeks. One painful problem.

We pick one specific pain point, send engineers to live in your factory for 4–6 weeks, and solve it. One-time payment, working software by week 3, and no obligation to go further. If you do, you choose the modules that you like.

FIRST CALLSECOND CALLCHOOSE PILOTDATA ACCESS FROM ITON-SITEBUILDTESTROIREVIEW

Start with a pilot →Book a Demo →

QUESTIONS, ANSWERED

Do you replace our ERP or our SCADA?

Additive by default. The AI layer sits on top of what you already run, SAP, Infor, Aptean, Ignition, Wonderware, the CIP automation, and when a system deserves to be replaced, we replace it. Sometimes we're the layer on top of your MES. Sometimes we are the MES.

Can you get live data off our GEA and Tetra Pak lines, and our Evergreen and Elopak fillers?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks, plus checkweighers, coders, and CIP skids, streamed into the AI layer in real time. Software and hardware agnostic.

Will digital pasteurization records stand up in an audit?

The records are generated from live pasteurizer data: time, temperature, flow, and divert events, complete and source-linked, with nothing retyped. We build them alongside your existing charts first, and your QA team reviews them with your regulator before any paper retires. Baseline first, then measure.

How does the AI get our data?

Read-only connections, scheduled exports, or on-prem. Security is reviewed together in scoping. Read-only pilots. Every agent proposes. A person approves.

Do you work remotely?

No. We always start a pilot in person and on-site, with forward-deployed engineers on your floor. Very rarely do we do anything remotely.

What does it cost after the pilot?

A per-plant annual platform: unlimited seats, no user fees, hardware at cost. The pilot itself is $15-20K over 4-6 weeks against one painful problem, with working software by week 3.

Harmony AI puts intake, pasteurization, CIP, and the cold chain on one live layer, so the plant proves itself while it runs.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Bakery & Snacks →Meat & Poultry →Beverage & Bottling →Dairy →