Customer Highlights Large, National Food Manufacturing Company

Large, National Food Manufacturing Company

Automated Product Life Tracking for Batch Process Compliance

Industry Food

Product/Material Handled Perishable food ingredients and batch products

System Deliverables

Automated Batch Life Monitoring

Timers now track product life across vessels, replacing manual logs and preventing overlooked time violations.

Vessel-Level Time Visibility

Unit-specific timers and HMI dashboards give operators a live view of product life, clean time, and processing duration for every vessel on the floor.

Seamless System Integration

The timed logic was integrated into the existing ControlLogix system without changing any FactoryTalk Batch recipes or overall system architecture.

Results in Action

Reduced Product Scrap Risk

Automated tracking enforces strict time limits, significantly lowering the risk of batches being discarded over expiration violations.

Improved Operational Accuracy

Manual tracking errors are gone, which means process data is more reliable-and so is the quality control and compliance work that depends on it.

Enhanced Operator Efficiency

Real-time dashboards and visual gauges make monitoring straightforward, helping operators make faster decisions with less cognitive overhead.

The automation modifications reduced variability in the manual procedure, reduced errors, and provided a visualization tool to the operators.

— Magnum’s Controls & Process Automation Group case study narrative.
Magnum’s Controls & Process Automation Group developed and applied the timers to multiple vessels and provided the necessary programming and configuration modifications to the ControlLogix controllers and the HMI’s to track times as the batch is processed. Timer logic was added to the appropriate unit and equipment module logic within the controller, eliminating any need to change the FactoryTalk Batch recipes or area model. A dashboard was set up for the operators to see the times to show the Batch Product Life and an individual virtual gauge was generated for each vessel on the HMI to show the unit times.

— Magnum’s Controls & Process Automation Group Case Study Narrative

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