Innovations and Future Trends in Automation : An Exclusive Interview with Shanmuga Prasad R of BGR Neo

 Shweta Kumari from Food Infotech speaks to Shanmuga Prasad R, DGM – Sales & Application, Robotics Division at BGR Neo in an exclusive interview, where he shares insights into the company’s innovative strides in automation technology.

 Mr. Prasad underscores BGR Neo’s commitment to revolutionizing the food and beverage industry with cutting-edge automation solutions, highlighting recent advancements like automated sugar debagging and truck loading systems. He also discusses the challenges of integrating automation into traditional processes and the company’s strategies for addressing these issues.  

 For a more in-depth understanding of BGR Neo’s contributions to automation technology and their future plans for growth and innovation, let’s delve deeper into the interview and explore their latest initiatives. 

1. BGR Neo has been a leader in robotics and automation solutions, driving innovation across industries. Could you share the journey of the company, and how its core philosophy has shaped its client-centric approach and cutting-edge advancements?

Founding and Background: BGR NEO LIMITED was established in 2018, leveraging the rich engineering heritage of its parent company, BGR Group, which has over 25 years of experience in delivering value-driven engineering solutions​.

Initial Focus: Initially, BGR NEO focused on industrial automation and turnkey solutions, catering to industries like automotive, aerospace, fmcg, general and electronics. Their early success was driven by their expertise in robotic welding, drilling, and assembly line automation.​

Expansion of Industry Reach: Over time, BGR NEO expanded its footprint into sectors like pharmaceuticals, food & beverages, and general engineering. The company’s solutions became increasingly modular and customized, allowing them to meet diverse client needs across multiple verticals​.

Strategic Vision and Leadership: The leadership of Swarnamugi Raghupathy, appointed in 2018, has been pivotal. Her vision for integrating technological innovation with a client-centric approach helped BGR NEO achieve a reputation for reliability and excellence in the automation space​.

Recent Developments: By 2023, BGR NEO became recognized for offering turnkey end-to-end automation solutions. Their innovations now include advanced applications like robotic vision inspection, palletizing, and depalletizing, which are critical for modern industrial environments​.

Future Goals: BGR NEO envisions becoming a global leader in automation, aiming to build long-term partnerships and ensure customer delight by delivering solutions that are both cost-effective and highly innovative. Their mission reflects a commitment to continuous improvement and technological leadership in the automation sector​.

 2. Can you share some of the most significant innovations BGR Neo has introduced in recent years?

 BGR NEO has consistently pushed the boundaries of innovation in robotics and automation, achieving notable advancements in recent years. Here are some of their most significant innovations:

 

1. Automated Sugar Debagging System for Coca-Cola:
   • One of BGR NEO’s standout innovations is their automated sugar debagging system developed for the Coca-Cola consumer segment. This previously manual process, which required five to six workers for handling, was completely automated. The new system can process 200 bags per hour, significantly reducing manual labor and the likelihood of errors. This solution not only enhanced throughput but also contributed to greater operational efficiency​.
2. Truck Loading Automation System:
   • BGR NEO’s truck loading automation system is another major innovation. It addressed the issue of lengthy truck waiting times, which previously took up to two hours. With the new automated system, the waiting time has been reduced to just 2-3 minutes, drastically improving operational speed. This innovation not only boosts efficiency but also leads to substantial savings for clients by optimizing logistics and reducing downtime​.

3. Your solutions emphasize efficiency and hygiene—key factors in the food sector. What unique technologies or methods have you introduced to achieve these goals? 

BGR NEO LIMITED has introduced several innovative technologies and methods that are designed to meet the dual challenges of efficiency and hygiene, particularly in the food sector. These innovations focus on automation systems that reduce human contact, ensure higher precision, and enhance safety.

Key Technologies and Methods:

1. Robotic Automation for Hygienic Processes:
   • BGR NEO’s robotic automation solutions help minimize human intervention, which is crucial for maintaining hygiene standards. Their systems are designed with easy-to-clean surfaces and are equipped with sanitary features that comply with food safety regulations. This is particularly important in processes like packaging, sorting, and debagging where cleanliness is paramount​.

 Vision Inspection Systems:

1. • To ensure high product quality and hygiene, BGR NEO employs vision inspection technology. These systems can detect defects or contaminants in the production line, preventing subpar products from reaching the consumer. This ensures compliance with industry standards for food safety while enhancing operational efficiency​.

 

1. Automated Handling and Sorting:
   • In food processing and packaging, automated handling systems significantly improve both speed and hygiene. These systems reduce the need for manual handling, ensuring that products are less likely to be contaminated during handling. For instance, their automated sugar debagging system for Coca-Cola helps improve throughput while minimizing manual labor, which is a key concern in food safety​.
2. End-to-End Food Processing Solutions:
   • BGR NEO offers turnkey solutions for food manufacturing that streamline processes such as ingredient handling, product assembly, and packaging. By automating the entire process from start to finish, the company can improve both efficiency and hygiene, making food production safer and more cost-effective​.

 

BGR NEO’s unique approach combines cutting-edge robotics with a focus on maintaining sanitary environments, making it a trusted partner for food companies looking to improve both operational performance and food safety.

4. Vision inspection, palletizing, and assembly line automation are some of your highlighted offerings. Could you explain how these contribute to enhancing productivity and maintaining product quality in the food sector?

 

BGR NEO’s offerings in vision inspection, palletizing, and assembly line automation significantly contribute to enhancing productivity and maintaining product quality, especially in the food sector. Here’s how each of these technologies plays a vital role:

1. Vision Inspection:

• Quality Control: Vision inspection systems are critical for maintaining product quality in food production. These systems use high-resolution cameras and advanced image processing software to detect defects, contamination, or inconsistencies in products on the production line. This reduces the chance of human error and ensures that only products that meet safety and quality standards make it to packaging. For example, vision systems can check for damaged packaging or foreign objects in food products, thereby preventing product recalls and ensuring food safety​.

 

• Efficiency: Vision inspection automates quality checks at high speeds, allowing for continuous monitoring of the production process. This drastically improves throughput without compromising on accuracy or product safety​.

 

2. Palletizing:

• Enhanced Efficiency and Ergonomics: In the food sector, automated palletizing systems are used to stack products (such as boxes, cans, or cartons) onto pallets in an organized manner. These systems replace manual labor and significantly reduce the risk of musculoskeletal injuries among workers, while increasing operational speed. The automation of this process can reduce load times and improve the flow of goods in the warehouse​. 

• Consistency in Output: Automated palletizing ensures that goods are placed in a consistent and optimized manner, maximizing pallet space and reducing damage during transportation. This contributes to cost savings by optimizing space and improving logistics​. 

3. Assembly Line Automation:

• Streamlined Production: BGR NEO’s assembly line automation solutions help streamline complex food production processes, such as sorting, packaging, and labeling. By automating repetitive tasks, such as filling, capping, or wrapping, production speed is increased while minimizing the risk of contamination or human error.
• Precision and Hygiene: Automated assembly lines are equipped with sanitary designs, reducing human contact with the product. This is crucial in food processing, where hygiene is paramount to meet health and safety standards. The precision of automation also ensures uniformity in product size, packaging, and labeling, which is essential for maintaining brand consistency and quality control​.

 

In summary, BGR NEO’s vision inspection, palletizing, and assembly line automation solutions contribute significantly to the food sector by:

• Enhancing productivity through faster, error-free processes.
• Ensuring high product quality with consistent checks and reduced human intervention.
• Maintaining hygiene and safety, crucial factors in food production.

 

5. What challenges do you face when integrating automation in the food industry, and how do you address them?

 Integrating automation into the food industry can present several challenges, but BGR NEO has developed strategies to effectively address them. These challenges include:

1. Maintaining Hygiene Standards:

• Challenge: The food industry is subject to stringent hygiene and safety regulations. Automation systems must meet these standards to prevent contamination, which is especially critical in food processing, packaging, and handling.
• Solution: BGR NEO designs its automation systems with sanitary engineering principles to ensure that all surfaces in contact with food products are easy to clean and resistant to contamination. This includes using food-grade materials, ensuring that robots and machines are easily disassembled for cleaning, and ensuring that the automation process minimizes direct human contact with food​. 

2. Adaptability to Diverse Food Products:

• Challenge: The food sector includes a wide variety of products, each with its own unique handling requirements, such as temperature sensitivity, size, shape, and fragility.
• Solution: BGR NEO’s modular and flexible automation solutions allow for easy customization to suit different food types. For example, their vision inspection systems are adaptable to different product types, and their robotic handling systems can be fine-tuned for different food packaging or sorting needs​.

The company often works closely with clients to understand the specific needs of their production lines and develop tailored automation systems.

3. Integration with Existing Systems:

• Challenge: Integrating new automation systems with existing production lines or legacy equipment can be complex, requiring careful planning to ensure seamless operation.
• Solution: BGR NEO employs a systematic integration approach, ensuring that their automation systems are compatible with existing infrastructure. This includes working with clients to upgrade their current systems without disrupting ongoing operations, utilizing scalable solutions that can evolve as the business grows​. 

4. Cost Considerations:

• Challenge: The initial cost of implementing automation systems can be a barrier for many food companies, particularly smaller businesses or those with tight margins.
• Solution: BGR NEO focuses on creating cost-effective automation solutions that provide long-term ROI through improved efficiency, reduced labor costs, and better product quality. The company often provides detailed cost-benefit analyses to help clients understand how automation can lead to savings over time​. 

5. Employee Training and Change Management:

• Challenge: Introducing automation may face resistance from employees who fear job loss or have difficulty adapting to new systems.
• Solution: BGR NEO emphasizes employee training to ensure that staff members can operate and maintain automated systems efficiently. By involving employees early in the process and explaining the benefits, they can ease the transition and encourage buy-in​. 

By addressing these challenges through innovative solutions, flexible designs, and close collaboration with clients, BGR NEO has positioned itself as a trusted partner in the food industry automation space, helping businesses improve productivity while adhering to the industry’s hygiene and quality standards.

6. Could you provide examples of how automation has improved quality control? 

BGR NEO has leveraged automation to significantly enhance quality control, particularly in the food sector, through several key innovations. One standout example is the automated sugar debagging system developed for Coca-Cola, which replaced a manual process that previously required four workers per shift. This automation allows for a throughput of 200 bags per hour, ensuring consistency, accuracy, and a reduction in human error, ultimately improving product quality and operational efficiency. This solution is a prime illustration of how automation can enhance productivity while maintaining stringent quality control standards in food production​.

In addition to the sugar debagging system, BGR NEO has implemented vision inspection systems that detect defects and inconsistencies on the production line. These systems ensure that only products that meet safety and quality standards reach packaging, preventing potential contamination and reducing waste. Furthermore, robotic palletizing and assembly line automation also contribute to improved quality control by ensuring consistent handling and reducing human error in processes like sorting, packing, and labeling, all of which are critical for maintaining product integrity in food manufacturing​.

Together, these automated solutions help food manufacturers maintain high-quality standards while boosting efficiency, ensuring both safety and consumer satisfaction. Here are a few ways automation has helped:

1. Precision and Accuracy in Inspections:

• Example: Vision inspection systems, which use high-definition cameras and advanced software algorithms, allow for real-time quality checks on production lines. These systems can detect defects, foreign objects, and inconsistencies (such as incorrect labeling, damaged packaging, or under-filled containers) that human inspectors might miss. This ensures that only high-quality products make it to packaging, reducing waste and improving customer satisfaction.
• Impact: Automation provides more precise and consistent inspections than manual methods, leading to better adherence to quality standards, particularly important in food manufacturing, where product defects can directly impact consumer health and brand reputation​.

2. Reduced Human Error:

• Example: Automated systems such as robotic palletizing and assembly line handling reduce the risk of manual errors that can lead to product mix-ups, contamination, or uneven distribution. For example, in food packaging, robots can place items into cartons with uniformity, ensuring that each package contains the correct quantity and configuration of products.
• Impact: By eliminating human error, automation ensures a higher degree of product consistency across batches, making it easier to meet regulatory requirements and consumer expectations​.

3. Enhanced Traceability and Monitoring:

• Example: With automation, data logging becomes seamless. Systems track every action—such as product handling, inspection, and packaging—making it easier to identify any defects or batches that don’t meet quality standards. This data can then be used for continuous improvement of processes, ensuring that quality control isn’t just a one-time check but an ongoing system of refinement.
• Impact: The traceability enabled by automation is particularly useful in food safety because it allows for swift identification and correction of any issues before products are distributed, thereby improving product reliability.

4. Consistency in Production Standards:

• Example: Automated systems ensure that every product is manufactured to the same high standard, whether it’s in packaging, labeling, or processing. For example, an automated sugar debagging system for Coca-Cola ensures that every bag is processed with the same level of precision, eliminating variability caused by human labor.
• Impact: Consistent production results in uniform quality for every product, which is essential for maintaining brand integrity and customer trust​.

5. Real-Time Adjustments:

• Example: Advanced robotic systems and vision inspection can make real-time adjustments if defects are detected. For instance, if an issue such as a misshaped product or incorrectly packaged item is detected, the system can immediately alert operators to make changes or halt the process until the problem is corrected.
• Impact: These real-time corrective actions ensure that quality control is dynamic, proactive, and prevents defective products from reaching consumers​.In summary, automation enhances quality control by enabling precise inspections, reducing human error, offering traceability, ensuring consistency, and providing the ability to make real-time adjustments. This not only improves product quality but also enhances efficiency, reduces waste, and ultimately leads to better consumer satisfaction. 

7. How does BGR Neo ensure scalability and adaptability of its solutions to meet diverse client needs?

BGR NEO ensures the scalability and adaptability of its automation solutions by designing modular and flexible systems that can be tailored to meet the unique needs of diverse clients across various industries, including food, automotive, aerospace, and electronics.

Key Strategies to Ensure Scalability and Adaptability:

1. Modular Solutions:
   • BGR NEO’s automation systems are designed with modularity in mind. This approach allows clients to implement solutions that fit their current needs and scale up as their operations grow. For example, systems such as vision inspection and robotic handling can be upgraded or expanded over time, making them adaptable to changes in production volumes, product types, or new regulatory requirements​
   • Customization: Each solution is customized to fit the specific requirements of the client, whether it’s for a food production line with specific hygiene needs or a packaging system that requires flexibility for different product sizes. This allows BGR NEO to cater to a wide range of clients while ensuring that the solutions meet their precise requirements​.
2. Flexible Integration:
   • BGR NEO ensures that their automation solutions are compatible with existing production lines and legacy systems, enabling easy integration into a client’s operations without disrupting existing workflows. This flexibility is particularly important for clients who are looking to modernize or automate specific parts of their production without overhauling their entire infrastructure​.
3. Continuous Improvement and Upgrades:
   • The company also focuses on continuous improvement. As new technologies or industry trends emerge, BGR NEO ensures that its systems remain at the forefront by offering software upgrades, new features, or even hardware enhancements to keep pace with evolving client needs. This ongoing commitment to innovation ensures that clients can continually adapt their systems as their business and technological requirements change​.
4. Client-Centric Approach:
   • By maintaining a client-centric approach, BGR NEO works closely with clients to understand their specific needs and challenges. This collaboration enables the company to design and implement highly adaptable solutions that address industry-specific requirements while providing clients with the flexibility they need to stay competitive in a constantly evolving market​.

These strategies ensure that BGR NEO’s solutions not only meet the immediate needs of their clients but are also scalable and capable of adapting to future challenges, enabling long-term success and operational flexibility. 

8. Can you share some of BGR Neo’s future plans and upcoming innovations?

 Looking ahead, BGR Neo is investing heavily in advancements within the food industry. We are focusing on barrow automation and outbound automation solutions, which promise to revolutionize the sector. Our goal is to continue innovating and expanding our automation solutions, particularly in food processing and logistics, to meet evolving industry demands.

 BGR Neo is positioning itself for significant growth with plans to expand its offerings and enhance its technology portfolio. The company is focused on enhancing customer satisfaction through the continuous innovation of robotic and automation solutions. They aim to integrate advanced technologies like Artificial Intelligence (AI) and Machine Learning (ML) into their systems to boost performance, repeatability, and operational efficiency. This ongoing technological advancement allows them to address industries’ most critical needs for safety, efficiency, and reliability​.​

Moreover, BGR Neo is deeply invested in providing scalable solutions, ensuring that their automation systems evolve in tandem with their clients’ needs. As they expand into new markets such as food and beverage, electronics, and pharma, they are looking at ways to diversify their automation capabilities, offering tailored solutions like palletizing, assembly line automation, and vision inspection​.

 Their future direction includes further investments in next-gen technologies, alongside a commitment to high-quality engineering that meets the unique demands of each industry. In the coming years, BGR Neo is also expected to continue scaling their solutions, ensuring that as industries evolve, their systems remain agile, capable of adapting to changing market conditions and customer needs​. 

9. How is artificial intelligence contributing to BGR Neo’s automation solutions?

 AI plays a crucial role in enhancing our automation solutions. It enables us to train systems to adapt and improve over time, reducing the need for manual intervention. For instance, in our robotics and AGV solutions, AI helps in refining processes and making real-time adjustments. This leads to more efficient operations and reduces the need for extensive human oversight.

 BGR Neo integrates artificial intelligence (AI) across its automation solutions to significantly enhance productivity and efficiency. One of the key applications of AI is in their vision inspection systems, where AI-powered algorithms help in the real-time detection of defects and discrepancies in products. This helps ensure that the products meet quality standards while reducing the likelihood of human error. Additionally, AI is utilized in optimizing robot control systems and improving the accuracy of robotic handling and palletizing, further enhancing the overall automation process.

By employing AI-driven tools such as 2D and 3D vision systems, BGR Neo’s robots are equipped to handle tasks like bin picking, component inspection, and product sorting with a high degree of precision. These innovations contribute to streamlined workflows and significantly reduce the need for manual intervention, increasing operational efficiency across multiple industries, including food and beverage production​.​

Through its strategic use of AI, BGR Neo not only optimizes production but also advances their commitment to providing scalable, reliable, and highly adaptable automation solutions that cater to evolving market needs. 

10. The food industry is rapidly adopting Industry 4.0 technologies. How does BGR Neo align itself with these trends, and what role do you see the company playing in the sector’s future?

 BGR Neo is strategically aligned with the rapid adoption of Industry 4.0 technologies in the food industry by embracing advanced automation, AI, and robotics. The company is focusing on enhancing efficiency, quality control, and flexibility within food production, making it an ideal partner for businesses navigating the digital transformation.

1. Integration of Smart Automation and AI:

• BGR Neo’s solutions, such as vision inspection systems and robotic handling, incorporate AI-driven technologies that enable real-time quality control and precision in production. These tools help the food industry improve traceability, safety, and consistency—core pillars of Industry 4.0​.

AI also enhances the predictive maintenance of machinery, reducing downtime and improving the lifespan of equipment, which is critical for the fast-paced food industry.

2. Scalable and Modular Systems:

• BGR Neo’s approach to scalability ensures that solutions are adaptable as the food sector evolves. Their phased implementation allows businesses to start with smaller automation projects and gradually scale them as they incorporate new technologies and expand operations. This flexibility is in line with Industry 4.0, where modular systems enable businesses to continuously integrate new advancements as they emerge.

3. Focus on Hygiene and Food Safety:

• Industry 4.0’s focus on automation is coupled with a demand for higher hygiene standards in food production. BGR Neo’s systems are designed to address these needs, incorporating sanitary design principles and automated hygiene solutions to prevent contamination and ensure regulatory compliance. This is crucial as food companies face increasing pressure to meet global food safety standards​.

4. Digitalization and Data Integration:

• The use of data analytics and IoT (Internet of Things) in BGR Neo’s automation solutions enables real-time monitoring and continuous improvement across production lines. This data-driven approach aligns with Industry 4.0 principles, where businesses leverage big data to enhance decision-making and operational performance​.

5. Future Role in the Food Industry:

• As Industry 4.0 technologies continue to reshape the food sector, BGR Neo is poised to play a pivotal role by providing customized end-to-end automation solutions. Their focus on scalability, innovation, and quality control positions them as a key player in helping food manufacturers achieve higher operational efficiency, product consistency, and cost savings in the digital era​.

BGR Neo’s alignment with Industry 4.0 trends places it in a strong position to drive future advancements in the food industry, positioning the company as a leader in automation solutions that promote sustainability, productivity, and innovation. 

11. Can you name some major companies that BGR Neo collaborates with for automation solutions?

 BGR Neo has built strong partnerships with leading global companies, such as PepsiCo, Coca-Cola, Parle Agro, and ITC, showcasing their expertise in providing comprehensive automation solutions across a variety of industries, particularly in the food and beverage sector. These collaborations highlight BGR Neo’s ability to deliver innovative, scalable, and tailored automation systems that improve operational efficiency, product quality, and safety.

In addition to their strong presence in the food industry, BGR Neo also serves clients across sectors such as automotive, electronics, pharma, steel and infrastructure, and aerospace. They are known for integrating cutting-edge technologies, like AI-powered vision systems and robotic automation, which enhance precision, quality control, and efficiency in production processes​.​

This versatility in partnerships and solutions reinforces BGR Neo’s position as a leading provider of end-to-end automation solutions, addressing the needs of diverse markets globally. 

12. Could you elaborate on a specific automation solution you have provided to a major client?

 A notable automation solution provided by BGR Neo was for Coca-Cola, where the company automated the sugar debagging process. This task, which previously required four workers per shift, was fully automated, increasing throughput to 200 bags per hour and significantly reducing manual labor and error. This solution not only improved efficiency but also enhanced workplace safety and product consistency. It exemplifies BGR Neo’s ability to streamline labor-intensive processes while ensuring high hygiene standards in food production​.

Another key solution is BGR Neo’s case packing system, which automates the entire process of filling products into cases, sealing, taping, and palletizing. This end-to-end solution enhances efficiency, accuracy, and product handling throughout the packaging process. By automating each step, BGR Neo helps businesses reduce human intervention, improve packaging consistency, and maintain high standards of quality control​.

Both solutions reflect BGR Neo’s focus on delivering customized automation systems that drive operational efficiency, cost savings, and product quality for clients across various industries, particularly in food and beverage production​.

13. What are BGR Neo’s future plans for expanding its footprint in the food industry, both in India and globally? Are there any upcoming innovations or technologies that you are excited to introduce?

BGR Neo is on a rapid growth trajectory since its inception in 2019, with the ambitious goal of reaching 100 crore in revenue this year and aiming to become a 1,000 crore company in the next five years. This expansion will further solidify its footprint across various industries, particularly in automation solutions for sectors like food and beverage, automotive, and pharma.

As the company continues to grow, it remains focused on enhancing its end-to-end automation solutions, leveraging technologies such as AI and data analytics to provide more efficient and scalable systems. These innovations are especially pertinent in the food industry, where automation plays a key role in enhancing productivity, efficiency, and food safety​.

In terms of specific developments, BGR Neo has recently introduced significant innovations, such as automating the sugar debagging process for Coca-Cola, which previously required manual labor. This solution increased throughput to 200 bags per hour, reducing labor costs and improving efficiency​.

Another major example is their case packing system, which automates the entire packaging process, improving accuracy and reducing human intervention​.

Looking to the future, BGR Neo plans to expand its presence both in India and internationally, deepening its collaborations with global industry leaders like PepsiCo, Coca-Cola, Parle Agro, and ITC. The company is also exploring new opportunities to integrate emerging technologies that will further enhance operational efficiency and quality control​.

This growth is supported by the company’s client-centric approach, which has been crucial in tailoring solutions that meet the specific needs of their diverse clientele. Over the next five years, BGR Neo plans to solidify its position as a leader in the automation space by delivering innovative, scalable solutions that address the challenges of the modern industrial landscape.