Is this your batch and recipe management system?

 

Are you in a batch processing industry?

Consumer Products  OR  Chemicals  OR   Health & Beauty Aids

Our Customers have one experience in common.

Problem batches created quality issues that decreased profitability.

 

Do these issues sound familiar?

  • Inconsistent or poor quality aka "bad batch"

  • Lower than projected output

  • Incorrect final consumer characteristics

    • wrong color | wrong texture | wrong appearance

  • Bacterial contamination

  • Recalls – a bad batch was not identified and was sent out the door

    • negative impact on profitability

    • loss of good will and reputation from the supply chain and customer

  • FDA requirements in documentation and measurable results not met

One of our Customers asked us to automate their recipe systems in three plants.   Their goals were to increase output and decrease unit costs.  Batch operators input manually from a paper recipe.

 

Their QC Department figured out that problems were resulting from:

  • the mix of ingredients

  • the timing of temperature changes

  • the timing and speed of mixing

We learned that Operators, during their manual input, were “interpreting” recipes in an honest effort to improve them!

Automating the recipe system removed these unwanted "interpretations".

Eliminating input variances minimized “bad” batches.

The Customer started achieving their KPIs and other goals.

  1. Increased output

  2. Decreased unit cost

  3. Improved quality control

  4. Improved profitability

  5. Quick ROI

An automated recipe system removed variability from the process.

Data collection provided actionable process history that the QC Department used to:

  • Identify a bad batch more quickly

  • Identify what made the batch bad

  • Rectify a bad batch through a rework

  • Prevent a bad batch from happening in the future

Conclusion

Batch and recipe automation can make your process better.

Primary Systems Inc. - Control and Automation Solutions

30 NJ-18 | Suite 1 | Old Bridge NJ 08857 | USA

732.679.2200

Scott Alter, VP Control and Automation Solutions

©2019 PRIMARY SYSTEMS INC.