Ingredients and Bio-Chemical industries

The Ingredients Industry can be challenging. Often dealing with strict (food safety) regulations. Often dealing with production processes based on bio-technology.  Nevertheless you need to produce the expected volumes and – even more challenging – a consistent end-product quality. Whether you products end up in the shape of liquids or powders, in all cases a the processing conditions are demanding and require full control at all times. Is there still too much variance in batch duration of bio-chemical or drying processes? Which process conditions influence the batch duration? How do we enable early identification of quality problems in reaction processes?

Meanwhile you’re surely focused on getting the most out of your installations, you are always trying to increase your volumes and you need to deal with unplanned downtimes. And what about optimizing yield, controlling pH values, and improving your product quality performance?

Yes! It is a challenging game. And to perform as the best in this game you need to have a perfect insight into the characteristics of your raw materials, processing conditions within your factory, operator observations, and in the end your product quality performance. Dealing with varieties in raw material composition, monitoring product characteristic change curves at all times, and – in the end – knowing exactly your actual cost-price per product and batch.

The HAI smart4industries software collects all these data, identifies anomalies in real-time, and provides trending and in-depths statistics and analysis. You are the expert, we provide you with the information you need to be successful.

                                                                                                                                                                     Read more about HAI software at:

Quote from a bio- process technologist about a fermentation process: at:         

“By closely monitoring the processing conditions that occurred in line with the pH curve, we were able to better understand and control the batch duration of our fermentation process. Shorting batch duration pays off immediately, because you win valuable processing capacity.” 

CSK Food Enrichment Smart Factory Software
Yakult HAI*QPM software package paperless
image_2019_05_03T07_17_06_606Z

   What you’ll have

  • One database with production & quality data from multiple sources:
    SCADA/PLC/Historian, SKU/batchnumbers, Lab test results, Operator Logsheets, In-line Process Control records, Microbiology Lab results, etc.
  • Your current paper-based records for organoleptic tests, operator control points (CCP’s), start-up checklists, cleaning records and excel sheets can be replaced by the abovementioned database.
  • Trending, correlations and other SPC analyses for trouble shooting, process improvement opportunities, etc.
  • Use your in-line product quality measurements (for pH, moisture, etc.) for real-time predictive analytics on your end-product pH, moisture, etc.
  • Real-time visualisation of batch characteristic trends, compared to the Golden Batch
  • Batch duration analysis
  • OEE on your process & downtime analyses
  • Real-time compliance display for process conditions & quality
  • Early warning system to prevent out-of-spec
  • Tracking & Tracing, exceptions reports, cost-price validation, etc.
  • A Plant BI-Tool for all your plant and quality reports and dashboards

   Your benefits

  • In case of any questions, quality issues or complaints: no more extensive searching in operator control records, SCADA, ERP, Excel and lab systems. All the information you need immediately available in one database: one mouse click away!
  • Reduce rejected batches
  • Early identification of batches that deviate from the regular trend curve
  • Find optimum process settings for fast and stable production
  • Improve product quality consistency
  • Minimize downtimes/maximize speed/improve OEE
  • Reduce energy consumption and prevent fouling
  • Optimize your CIP process and your maintenance strategy
  • Unparalleled insight into the performance of your reactors, fermentors, and other processes.

“80% of my time was lost on combining data from operator logs, excel, historian, scada and quality test results. After “cleaning” these data, I could finally start analyzing the data, and find answers to my questions. Now I can concentrate 100% on analysis and interpretation of the data.”

 

Simply available in the Cloud …. No capital investment …. Subscription-based

ingredients and bio-chemical industries

Data and analysis one mouse click away