Industry 4.0 Advanced Process Control – Rendering (Stage 1 Evaluation at Brooklyn)

The project set out to see whether an Industry 4.0 Advanced Process Control (APC) system - called CORE - could make rendering operations at JBS Brooklyn more stable and efficient. Rendering is naturally inconsistent because raw materials, equipment condition, and operator decisions vary from day to day. The team wanted to know if a machine‑learning control system could reduce this variability and deliver measurable economic benefits. Early testing showed some encouraging results, such as steadier combustion temperatures, higher decanter feed rates, and smoother burner performance.

However, these improvements did not last. Independent reviews found ongoing mechanical problems - such as failing air‑dampers, overloaded decanters, unstable torque, and inconsistent feed moisture - that disrupted the system. Because of this instability, the APC system could not perform as intended, and sustained improvements were not achieved. 

Nevertheless, the project produced important insights: stable equipment, validated sensors, predictable feedstock, and consistent controller use are prerequisites.