A new model of manufacturing: digital and efficient
From modular production management to quality control with AI, up to end-to-end traceability: Lavazza makes its industrial processes more flexible, efficient, and sustainable.
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THE CHALLENGE
Digitization to reduce costs and ensure quality and traceability
To respond to the needs of an increasingly dynamic and turbulent market, Lavazza is evolving its industrial digitalization journey by introducing increasingly flexible and intelligent tools, focused on optimizing production processes and quality control. At the same time, the company has focused on end-to-end traceability as a strategic lever to meet new regulations regarding sustainability and certification of the origin of raw materials. The collaboration with Hermes Reply has shaped an integrated manufacturing platform capable of collecting, standardizing, and enhancing production data, creating the conditions for the adoption of intelligent technologies throughout the entire industrial supply chain.
THE STRATEGY
A central platform to enable data-driven manufacturing
To address these challenges, Lavazza has defined an industrial strategy based on the creation of a central platform for manufacturing that revolves around a new conception of MES, capable of connecting heterogeneous systems and machinery, collecting process data, and enabling intelligent logic to support production efficiency and quality control.
MODULAR MES PLATFORM
New platform for production management
The first step involved the creation of a new MES platform for managing packaging lines.
Completely modular and based on a microservices architecture, the platform is designed to flexibly adapt to the needs of different plants and scale quickly according to requirements.
The interface has been simplified and optimized for every operational touchpoint, such as line terminals and control portals.
Centralizing data in a single core system allows for the application of specific optimization logics for each facility.
The solution is already active in three facilities.
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PALLET ANOMALY DETECTION
AI and Computer Vision for automatic quality control
In a second step, Lavazza introduced an anomaly detection system to support the palletization process:
The solution, based on Computer Vision and ML, checks the palletization layer by layer and identifies positioning or composition errors that can be difficult to detect once the pallet is completed. This prevents wrapping issues and reduces risks during handling and transport.
For training the algorithm, synthetic data was also used, accelerating the fine-tuning of the models.
The system, already operational in a first bay at one of the plants, has achieved high accuracy and the Group is extending its adoption to other palletization bays.
END-TO-END TRACEABILITY
A centralized system for product traceability
Another important piece is represented by a solution for the complete traceability of the product, made available from the beginning of 2025:
The platform collects and manages all data regarding the transformation of the product, from the origin of the raw materials to the packaging used.
It allows for precise monitoring of the produced batches and a quick response to regulatory needs or market requests.
The system has been released for all the Group's plants.
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THE RESULTS
Flexibility, control, and quality: the advantages of the new production model
Thanks to the collaboration with Hermes Reply, Lavazza has laid the foundations for an intelligent and scalable production ecosystem. The developed platforms now allow for unified management of factory data, automation of critical controls, and the introduction of AI to support quality, efficiency, and sustainability. A concrete transformation towards a more advanced, controlled, and resilient production model.
Founded in Turin in 1895, Lavazza is an Italian coffee company owned by the Lavazza family for four generations. Today, the Group is one of the leading players in the global coffee industry, with revenues of over €3.3 billion and a portfolio of leading brands in their respective markets, including Lavazza, Carte Noire, Merrild, and Kicking Horse.
The Group operates across all business segments and is present in 140 markets, with 9 production plants in 5 countries. Its global presence is the result of a growth journey spanning 130 years, and the more than 30 billion cups of Lavazza coffee produced each year are a testament to a remarkable success story, driven by the commitment to continue offering the best possible coffee in every form, with careful attention to every stage of the value chain, from the selection of raw materials to the final cup.
Hermes Reply specializes in architectural and technological solutions, Application Maintenance services for the Automotive & Manufacturing sector, and management consulting services. By combining an in-depth knowledge of production processes, Industry 4.0 technologies, delivery capabilities, and strategic vision, Hermes Reply supports its clients in the digital transformation journey to facilitate the adoption of digital enablers and achieve short-term and long-term results.