Customer Highlights Major Food Manufacturer (Salad Dressing)

Major Food Manufacturer (Salad Dressing)

Fully Automated, Paperless Salad Dressing Production System

Industry Food

Product/Material Handled Salad dressings, liquid food products, batch ingredients

System Deliverables

End-to-End Batch Automation with ERP Integration

FactoryTalk Batch and the ERP system now communicate in real time-scheduling, inventory tracking, and data flow happen automatically without manual paperwork.

Advanced Kitting and Ingredient Traceability

Barcode-enabled kitting with step-by-step operator guidance cut ingredient errors significantly and made batch accuracy and traceability much easier to maintain.

Model-Based Design and Simulation Training

S88 model-based configuration combined with simulation training ensured the team was ready before go-live-enabling rapid deployment, operator readiness, and zero commissioning disruption.

Results in Action

Reduced Errors and Improved Product Quality

Automated batch execution and guided kitting eliminated human error across more than 75 formulations. And quality remained consistent.

Faster Deployment and Time-to-Production

Building and simulating the system simultaneously allowed operators to train early, enabling faster commissioning when it was time to go live.

Increased Flexibility and Lower Operating Costs

Recipe-driven automation cuts equipment needs and lets staff modify products without touching one line of code, reducing both operational and support costs.

Magnum’s Controls & Process Automation Group effectively created a gateway between our manufacturing floor applications and our legacy ERP system. This allowed transactions between the two systems for real time data either to be sent up for inventory tracking or pushed down for scheduling and production needs.

— Food Manufacturer Representative
Thus, it was possible to construct a solution that consistently delivered high quality products at the lowest possible cost.

— Magnum’s Controls & Process Automation Group Case Study Narrative
The use of FactoryTalkBatch not only allowed the amount of equipment required to be reduced, it also put the ability to modify recipes into the hands of the plant personnel, without any need for knowledge of controller programming. New recipes, new products, could be evaluated using FactoryTalkBatch, which had simplified the processes occurring in the kitchen.

— Magnum’s Controls & Process Automation Group Case Study Narrative
The control system was integrated with the plant ERP system (both top-down and bottom-up), allowing (a) production shop orders to be sent to the plant floor system for execution and (b) material usage, lot data, and production totals to be reported back to the plant ERP system.

— Magnum’s Controls & Process Automation Group Case Study Narrative
Integration of the CIP systems with Factory Talk Batch simplified the creation, operation, optimization, and maintenance of the CIP procedures.

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

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