The global market leader in CPG & food manufacturing sets up various green field facilities for manufacturing of various Consumer products with Best in class technology for Batch & Continuous Process Automation resulting in faster time to market manufacturing large product variants.
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Challenge
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Due to fast changing consumer needs plant expected system to configure & retune in shortest time to gain the Market share
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Product quality being critical highly accurate dosing system required.
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Production is Campaign based with short batch cycle time
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Seamless integration of Up-stream batch process & down-stream continuous process equipment’s (Packing lines etc.)
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Auto batch records for regulatory compliances
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Solution
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Rockwell Process Automation system with Ethernet DLR as Network
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High end flexible Recipe management system based on specialized package enabling on the fly change of recipes
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Special software features to ensure consistently accurate dosing of ingredients
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Special techniques like look ahead batching to decrease the batch cycle time beyond the standard expected batch cycle times
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Software developed for seamless integration of up-stream and down stream process equipment’s resulting in optimum utilization of plant assets
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Results
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Quick go-to market time after product changeover enabling customer to leverage the 1st mover advantage and increase the market share & maintain the leadership
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Highly optimum utilization of plant assets
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Consistent and accurate product quality resulted in less recycle and wastage of raw material, packaging material, Utilities etc.
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Highly accurate batch recording & reporting system