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Preserving the power of nature
In the catering and hospitality sectors, it is no longer just what ends up on the table that matters. How it gets there and the conditions under which it was produced are also becoming increasingly important. Today, guests, hosts and buyers are taking a closer look: at origin, production and the question of what responsibility brands and suppliers assume throughout the entire value chain. There is a demand for partners who firmly embed responsibility within their corporate strategy.
As a product that is, by its very nature, entirely natural, Gerolsteiner mineral water is entirely dependent on an intact environment. To preserve this, the mineral water company combines its responsibility for water resources, the environment and the climate with technological innovation. Throughout its entire value chain, the company relies on solutions that equally enhance efficiency, environmental and climate protection, and productivity.
Digital and data-driven solutions, for example, give rise to a production approach that systematically integrates environmental responsibility, sustainable water use and economic efficiency. These digital innovations help to use resources more efficiently, make processes more resilient and, at the same time, strengthen environmental and climate protection. In this interview, Ulrich Rust, Managing Director of Technology & Logistics at Gerolsteiner Brunnen GmbH & Co. KG, explains how Gerolsteiner is driving forward digitalisation and sustainability hand in hand.
From a natural product to sustainable production
Mr Rust, why are innovation, sustainability and digitalisation inextricably linked at Gerolsteiner?
Ulrich Rust: Because, in practice, they all contribute to the same goal: to provide a natural product in a responsible and sustainable manner. For us, sustainability means more than just individual environmental measures. It extends from the protection of water as a resource and its source, through the entire value chain, to production, logistics and energy supply.
Digital innovations are a key driver for advancing environmental and economic goals in tandem. Data-driven forecasts, networked systems and intelligent process control help us to use resources more effectively, stabilise processes and make better-informed decisions.
What role does your data-driven factory play in this transformation process?
Ulrich Rust: A key one. Digital applications only realise their full potential when data is not held in isolation within individual departments, but is systematically consolidated and translated into decisions. This is precisely why we have developed a Data Intelligence Platform that acts as a single source of truth, consolidating all relevant company data. It provides the infrastructural foundation for faster analyses, more reliable forecasts and more precise production planning, utilising AI tools, amongst other things.
Where are the benefits of digital applications particularly evident?
Ulrich Rust: One key use case is sales and returnable packaging forecasting. Even before the first bottle is filled, the quality of the planning determines how effectively production capacities, material flows and logistics work together. For sales planning, we use an AI-supported forecasting system that takes into account, amongst other things, holiday periods, temperatures, seasonal fluctuations and promotional activity. Over a period of six to eight weeks, the application achieves a forecasting accuracy of up to 90 per cent. This provides planning certainty: we can plan production volumes more precisely, avoid last-minute reorders and reduce overproduction. This is complemented by an intelligent empties forecast. After all, even the best sales planning only works if there is clarity regarding expected returns and available bottle stocks.
Using our data platform, we also automatically monitor key parameters of our returnable container systems, such as return rates, dwell times in-store and the proportion of defective or third-party bottles. This makes the circulation of returnable containers more transparent, simplifies the planning of the returnable container pool, and has enabled us to significantly reduce unplanned procurement processes. This conserves raw materials, relieves pressure on storage capacity and strengthens control throughout the supply chain.
Are there other stages in the production chain that benefit from digital applications?
Ulrich Rust: Of course – take quality control in the reusable bottle system, for example. There, we have further developed what is known as ‘sniffer’ technology, which detects contaminants in reusable bottles and sorts them out if necessary. The sensor data is now processed on our platform to identify anomalies at an early stage. This is important because, otherwise, the system – which is deliberately designed to be very sensitive – could end up rejecting bottles that are actually usable. Our innovation is expected to reduce the error rate in quality control by around 30 per cent and ensures that suitable returnable bottles complete as many cycles as possible.
Furthermore, sensors are used in the bottle cleaning process within the returnable bottle system to continuously measure parameters such as temperature, pressure and conductivity. The systems automatically analyse the data via the platform and adjust the cleaning parameters accordingly. This ensures that hygiene requirements are met, whilst at the same time, in the interests of the environment, we use only as much energy, heat and cleaning agent as is necessary.
How is sustainable change evident in other parts of the site?
Ulrich Rust: Among other things, we are currently transforming the energy infrastructure at our production site. Our aim is to organise our energy supply and use of resources in such a way that they become sustainable and resilient. A key component of this is our own biomass combined heat and power plant. Together with solar power and green electricity, it will play a pivotal role in our future energy supply. The project is expected to reduce CO₂ emissions by around 7,000 tonnes and lessen our reliance on fossil fuels. It therefore contributes directly to our sustainability strategy and helps to secure the 1.5-degree target for Scope 1 and 2 emissions in the long term – a target we have already achieved ahead of schedule at this site by 2024. Such transformation processes are not merely a technological challenge, but always an organisational one as well. They can only succeed with a leadership team that works collaboratively, purposefully and with a strong commitment to excellence in order to continuously improve processes.
About Ulrich Rust
Ulrich Rust has been Managing Director of Technology & Logistics at Gerolsteiner Brunnen GmbH & Co. KG since June 2007. Since then, he has implemented numerous groundbreaking innovations within his department, including the introduction of personalised packaging, the construction of a compact warehouse with 18,500 storage spaces and the development of a comprehensive sustainability strategy. An engineering graduate, he has worked in the drinks industry since 1992 and has held various positions with responsibility for areas including quality, technology, technical controlling, the environment and engineering. He has also held senior roles as plant manager and Managing Director of Technology.
Conclusion:
Anyone who offers a natural product has a special responsibility. For more than 130 years, Gerolsteiner has combined nature, quality and values, and continues to build on this commitment consistently, with an eye to the future. This results in an approach that sustainably combines ecological and economic practices – from a responsible Dealing with the Water as a resource via data-driven production processes right up to a sustainable energy supply.
At the same time, it becomes clear that, that sustainable transformation will only succeed if Business in the long term Thinking and innovation consistently into their Implement the strategy. Creating digital solutions at the same time the basis, resources to use them more efficiently, to make processes more resilient policy-making and environmental and climate protection targets to provide measurable support.
Contact:
Gerolsteiner Brunnen GmbH & Co. KG
Tel.: +49 6591 14–0
Email: info@gerolsteiner.de
Finally, we would like to extend our sincere thanks to Ulrich Rust, Managing Director of Technology & Logistics at Gerolsteiner Brunnen GmbH & Co. KG, for the informative discussion and the fascinating insights into how Gerolsteiner successfully combines sustainability, innovation and digitalisation, thereby setting the pace for a sustainable food and drink industry.
Kind regards, Sandra
