Overview

Our client, a leading food and beverage manufacturer, specializes in producing a diverse range of products that require precise ingredient mixing (liquids, powders and granules). To enhance operational efficiency and ensure consistent product quality, the client sought to optimize their batch processing operations by implementing an upstream weighing and batching system. Their primary goal was to accurately measure and discharge various ingredients into their mixing equipment.

Challenges

1. Cumbersome Material Discharge: Discharging multiple ingredients into the central mixing equipment at the right time and weight was a complex and labor-intensive task.

2. Subsystem Coordination: Lack of coordination among subsystems led to increased idle time, affecting overall production efficiency.

3. Weighment Inaccuracy: Inaccurate weighment of ingredients resulted in high rejection rates and increased material wastage.

4. Manual Recipe Handling: Manual handling of recipes led to errors and inefficiencies, hindering throughput and production planning.

Solution implemented

To address these challenges, our team proposed the implementation of an advanced upstream weighing and batching system tailored to the client’s specific needs. Key components of the solution included:

1. Centralized Recipe Management System (CRMS) and Stores Management System (SMS): Developed using the Ignition platform, these systems streamlined recipe management and inventory control.

2. Integrated Control: Seamlessly integrated and controlled all subsystems involved in the weighing and batching process, ensuring synchronization and efficiency.

3. Precision Weighment: Implemented a high-precision weighing system capable of accurately measuring ingredients to 1 gram accuracy.

4. Adaptive Control: Employed adaptive control algorithms to optimize motor performance and ensure precise ingredient discharge.

5. Real-time Monitoring and Alerts: Configured the system to provide real-time monitoring of weighment processes and trigger alerts in case of deviations or errors.

6. Comprehensive Reporting: Generated detailed reports for audit trail purposes, facilitating traceability and compliance with quality standards.

Results

Over the subsequent 12-month period following implementation, the client realized significant improvements:

1. Reduced Idle Time: Idle time of the central mixing equipment decreased by 40%, resulting in enhanced production throughput.

2. Decreased Rejection Rates: Product rejection rates were reduced from 5% to less than 1%, leading to substantial cost savings and improved product quality.

3. Increased Throughput: Factory throughput increased by 20%, driven by improved coordination among subsystems and optimized batch processing.

4. Eliminated Material Shortages: The system effectively eliminated instances of material shortages at the mixer, ensuring uninterrupted production flow.

5. Streamlined Operations: Automated weighing and batching processes streamlined operations, reducing manual errors and complexity.

ROI Calculation

Data collected over 12 months post-implementation revealed a total ROI of $1.3 million USD on a $300k USD investment. This ROI was attributed to increased throughput, reduced material wastage, and improved operational efficiency.

Conclusion

By leveraging advanced technology and tailored solutions, our client successfully overcame operational challenges and achieved significant improvements in efficiency, quality, and profitability.

The implementation of the upstream weighing and batching system not only optimized batch processing but also positioned the client for sustained growth and competitiveness in the food and beverage industry.

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