At a glance

• 6 — Production Lines Connected
• 5 — Iconic Brands Covered
• Since 1892 — Legacy of Excellence

About Britannia Industries Limited

Britannia Industries Limited is one of India's oldest and most trusted food companies, founded in 1892 in Kolkata. A flagship company of the Wadia Group, Britannia is a market leader in biscuits, bread, cakes, and dairy products, with a portfolio spanning iconic brands like Good Day, Tiger, NutriChoice, Milk Bikis, and Marie Gold. The company operates multiple manufacturing facilities across India and exports to over 80 countries.

Headquarters: Bangalore, India · Industry: Food Manufacturing / FMCG · Size: Enterprise (13,000+ employees)

Introduction

This case study shares how Britannia, one of India's largest food manufacturers, partnered with Itanta Analytics to improve its day-to-day operations through digital transformation. The company was facing common manufacturing challenges such as manual data logging, limited real-time visibility, and delays in identifying production issues.

With Itanta's no-code platform, Britannia was able to gain better visibility into operations, automate alerts, and bring key performance data into one place. This helped teams on the ground react faster and gave managers reliable information to track performance. The project showed how a simple, step-by-step approach to digital adoption can make a big difference in how a factory runs.

Operational Challenges

• Manual Data Logging: Operators were recording critical production parameters manually which was inefficient and prone to errors. Also leads to data inconsistences.
• Workload Imbalance: Engineers were spending hours manually compiling reports for compliance and weekly reviews, leading to inefficient reporting cycles and over-reliance on technical experts.
• No Real-Time Visibility: Data was collected at the end of the shift or day and analyzed manually due to which anomalies were detected late and couldn't pinpoint issues.
• Siloed Systems: Without integration between systems, data remained siloed across processes. This made it difficult to correlate key metrics and each new line or facility required fresh configurations from scratch due to the lack of a unified data architecture.
• No Centralized Alerts: Alerts for production issues were either entirely manual or didn't exist. This delayed root cause identification and created communication gaps between departments.

Highlights

• 6 production lines connected into a unified monitoring ecosystem
• Real-time production monitoring with live OEE calculations and tonnage tracking
• Mobile app alerts for critical deviations in MIHS, packing, molding, and baking
• Automated data flow from SCADA replacing manual data entry entirely
• Auto-generated compliance and performance reports freeing up engineering time
• Formula Builder with automated deviation calculations (Set vs Actual values)

Background

Britannia Industries Limited stands as one of the most established and reputable food enterprises in India, with a history stretching back to 1892. The company aimed to enhance its manufacturing processes. In line with a steadfast dedication to operational excellence, Britannia has welcomed digital innovation to boost productivity, guarantee compliance with food safety regulations, and optimize production effectiveness. The objective was to reduce manual data input and improve machine oversight.

• Good Day
• Tiger
• NutriChoice
• Milk Bikis
• Marie Gold

The launch of a Smart Factory approach was designed to deliver immediate visibility and centralized notifications, decreasing machinery downtime and quality inconsistencies throughout production facilities. This optimization endeavor encompassed production lines associated with some of India's most iconic food brands, recognized for their extensive consumer appeal and leadership across categories.

Laying the Digital Foundation

System Overview

To address these pressing challenges, rather than relying on fragmented tools and manual processes, the solution called for a more integrated, scalable, and intelligent system. This led to the implementation of a robust architecture designed to streamline data flow, enable real-time monitoring, and support informed decision-making across operations.

• Smart Factory Integration: Itanta Analytics platform connects Britannia's 6 production lines (Mixing, Molder, Baking, Oven, CMS and Packing) with MIHS (Minor Ingredient Handling System) into a unified monitoring ecosystem.
• Real-time Production Monitoring: Live tracking of line efficiency, OEE calculations, production tonnage, downtime analysis, and ingredient deviation monitoring across all manufacturing processes.

Key Components

The architecture integrates data collection, processing, visualization, and mobile alerting into a seamless pipeline.

• Data Collection: Data was collected from Kepware OPC DA server integrated with ABB DCS.
• Itanta's Platform: DS Manager processes data using industry-standard OPC protocols, while Dashboard Builder creates real-time dashboards showing molder/cutter speeds, baking times, roller speeds (RPM), and flour-cream ratios.
• Mobile Alert System: The Itanta Mobile App was developed for critical deviations in MIHS, packing machine performance, molding issues, and baking parameters.
• Formula Builder and UNS: Automated deviation calculations (Set vs Actual values), package machine tracking with start/end times, and comprehensive downtime statistics.

Itanta's Solutions

• SCADA integration + auto logging: Automated Data Flow from SCADA to Itanta via DS Manager. Manual data entry was fully replaced with real-time automated logging improving data accuracy.
• Unified data layer via DS Manager: All equipment and process data from SCADA to packaging lines, was consolidated into a single platform, to ensure end-to-end traceability across the plant.
• Dashboards with live data feeds: Line supervisors and operations teams gained live visibility into production KPIs enabling quicker diagnosis of anomalies and data-driven decisions during shifts.
• Mobile app alerts: Automated alerts allowed teams to act on issues instantly, such as equipment faults. Reduces unplanned downtime and improves first-response times.
• Auto-generated reports & visual dashboards: Engineers no longer had to compile reports manually. Routine compliance and performance reports were automated, freeing up time for higher-value work.

Britannia's Dashboards

• 1. Mixing Dashboard Overview:
• 2. Packing Overview Dashboard:

Conclusion

By tapping into Itanta Analytics' powerful out-of-the-box platform, Britannia Industries kickstarted its journey toward becoming a truly connected Smart Factory—without writing a single line of code.

• Shifted from manual logs to real-time data and insights
• Used built-in SCADA integration, dashboards, and deviation tracking
• Enabled faster response with Itanta Mobile App alerts and live metrics
• Empowered teams to monitor performance and reduce downtime

Most importantly, this transformation wasn't built from scratch—it was achieved by simply unlocking the full potential of Itanta's existing platform.

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