Puffin Produce is a grower-owned potato processor based in the United Kingdom, supplying major retailers such as Tesco and Aldi. Each year, Puffin processes and packs more than 65,000 tonnes of potatoes, sourced from 60 local growers.
Operating in a sector defined by natural raw material variability, Puffin continuously faces changing quality characteristics influenced by origin, storage conditions and time. To scale operations while maintaining yield, quality and traceability, Puffin partnered with Brighteye to extend its Momentum MOM platform with AI-driven predictive quality intelligence.
The challenge
In potato processing, quality is never static — yet decisions often are.
Puffin faced challenges typical for fresh food processors working with natural raw materials:
- Continuous quality variability across lots due to time, storage and environmental factors
- Lot selection and product allocation based mainly on historical averages and experience
- Limited forward-looking insight into quality degradation and yield loss
- Reactive process adjustments instead of predictive control
To remain competitive, Puffin wanted to move beyond reactive decision-making and introduce predictive, risk-aware intelligence directly into its MOM environment.
The approach — from MES data to predictive intelligence
Together with Brighteye, Puffin implemented a data-driven approach on top of its existing Momentum MOM scope (MES, QMS, WMS, APS).
The solution combines:
- Intake quality data and in-process measurements
- End-to-end traceability and origin data
- Storage history and contextual data
- Machine learning models trained on historical and real-time data
Rather than aiming for perfect predictions, the models focus on trend sensitivity and risk direction — answering questions such as:
- Which lots are likely to degrade faster?
- Which lots are best suited for which end products today?
- Where is yield loss most likely to occur?
Key figures — from reactive to predictive
The integration of predictive intelligence quickly delivered tangible value:
Operational gains
- Expected quality estimated already at intake
- Smarter lot allocation and scheduling decisions
- Process parameters adjusted proactively based on predicted quality trends
Reduced raw material losses through better timing and destination of lots
Business impact
- +2.13% yield improvement through optimized scheduling
Less waste, more control, better decisions
Puffin can now anticipate quality evolution instead of reacting to it — turning variability into a competitive advantage.
The outcome
By extending Momentum with AI-driven predictive intelligence, Puffin has achieved:
- A shift from reactive to predictive operations
- Better yield control in an environment of natural variability
- Data-driven decision support embedded in daily operations
- A scalable foundation for further optimization and automation
Momentum has evolved from a MOM platform into an intelligent decision layer — supporting Puffin’s growth strategy in a complex and variable food production landscape.
Why it matters for the potato & food sector
Producers working with natural raw materials face increasing pressure on yield, waste reduction and operational efficiency. Puffin demonstrates that predictive intelligence, embedded in a modular MOM platform, enables food manufacturers to scale while staying flexible, compliant and data-driven.
MOMENTUM turns operational data into a growth engine
— for Puffin, and for every food manufacturer aiming for data-driven excellence.
Explore how Momentum can transform your production.
Get in touch for a demo or talk to our specialists about your operational challenges.