Case Study: Mayr‑Melnhof Group achieves 20% raw‑material cost savings with Elastic

Powering the Search for Real-Time Cost Savings

Mayr‑Melnhof Karton, part of the Mayr‑Melnhof Group and the world’s largest producer of coated recycled cartonboard, faced a visibility problem on the shop floor: over 25,000 sensors generated ~2 TB of fragmented time‑series data across OT systems, and deviations in moisture, fiber and costly raw‑material usage could take hours or days to detect, driving up waste and costs. Closing that gap was critical to maintaining product quality and competitive pricing.

MM Karton implemented the Elastic Stack (Elasticsearch, Logstash, Beats and Kibana) to ingest, unify and visualize real‑time process and recipe data via easy-to-build dashboards and an Internal Material Costing formula. Within weeks operators were self‑serving with dashboards, and within four months the company cut consumption of a high‑cost material by 20% while keeping output constant, sped up production, eliminated storage needs at one mill, and established a scalable platform for wider rollout.

Mayr-Melnhof Group

Jürgen Kerner

Head of Operations, Corporate IT