Recipe Management System Enhances Quality Control

Malisko Engineering, Inc was asked to provide a SCADA-based recipe management system allowing operators to easily retrieve all required information to batch powdered beverages on two independent Batching Systems.

Recipe system

Goals:

  • Assure high product quality by eliminating operator-induced inaccuracies
  • More accurate inventory usage reporting
  • Automatic batch event tracking and archiving

System Features

The System retrieves the following batch information from a SQL Server Database:

  • Material stock number
  • Material status
  • Description of each material
  • Amount of each material to blend
  • Recipe Comments and Special Instructions for the Operator's reference
Recipe chart

The System auto-calculates each material weight based on an operator-specified Total Batch Weight.Material amounts are displayed in the units (lbs. or grams) the operator uses to measure.

The operator uses a wireless bar code reader to scan material pallet numbers and verify the material is correct against the Asset Number and Formula thus improving their efficiency and assuring high product quality.


Once the batch is completed, usage and stock information is updated in the SQL Server Database:

  • Amount of each material used from a material pallet
  • Total weight of the Batch
  • Weight and Identification of each Finished Product Tote
  • Operator Notes and Deviations that occur during the batching for Quality Control personnel to review

Engineering Tasks & Services

  • Integrated Intellution, Allen-Bradley, Symbol wireless Bar Code Readers and SQL Server Database
  • Created the Technical Specification
  • On-site and remote Start-Up Support
  • Validation Support after Installation