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Batch & continuous process automation for consumer products manufacturing plants.

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.

Challenge

Due to fast changing consumer needs plant expected system to configure & retune in shortest time to gain the Market share
Product quality being critical highly accurate dosing system required.
Production is Campaign based with short batch cycle time
Seamless integration of Up-stream batch process & down-stream continuous process equipment's (Packing lines etc.)
Auto batch records for regulatory compliances

Solution

Rockwell Process Automation system with Ethernet DLR as Network
High end flexible Recipe management system based on specialized package enabling on the fly change of recipes
Special software features to ensure consistently accurate dosing of ingredients
Special techniques like look ahead batching to decrease the batch cycle time beyond the standard expected batch cycle times
Software developed for seamless integration of up-stream and down stream process equipment's resulting in optimum utilization of plant assets

Result

Quick go-to market time after product changeover enabling customer to leverage the 1st mover advantage and increase the market share & maintain the leadership
Highly optimum utilization of plant assets
Consistent and accurate product quality resulted in less recycle and wastage of raw material, packaging material, Utilities etc.
Highly accurate batch recording & reporting system

Batch & continuous process automation for consumer products manufacturing plants.

Batch & continuous process automation for consumer products manufacturing plants.

Challenge

Solution

Result

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