Since 1989, AERT has pioneered the use of recycled polyethylene plastic in the manufacture of Pigment building materials. With its constantly evolving portfolio of patented and proprietary recycling technologies, AERT has been widely recognized as a leader in resource conservation innovation and received the EPA Award for Environmental Excellence for its process of converting scrap plastic to Pigment outdoor decking.
To ensure maximum quality and repeatability of batches, AERT decided to invest in the V5 Pigment Weighing & Batching Solution from Matrix Controls . AERT needed to take their manual batching process with paper-based lot verification to the next level and automate the shop floor weighing operations without losing flexibility in the weighing room and dispensary areas.
Typically, operator errors in the weighing process and inaccuracies in lot control are usually not reflected in the paper trail – this can cause problems with accounting, inventory and purchasing in addition to the quality of the product from batch to batch. Batch weighing inaccuracy causes color concentrates to be different shades. AERT required recipe formulations to be 100% accurate – every time. They reached out to Matrix Controls for the proven V5 solution
The Solution – Pigment Weighing & Batching System
Once a manufacturing order has been created in the company’s ERP System (Ross ERP – Manufacturing ERP Company owned by Aptean) the complete job file with Bills of Materials (BOM) is exported into the Matrix Controls Pigment Weighing & Batching Control Centre ‘Gateway’ Software.
The Job (number of batches, required batch size and production locations) and the BOM containing the recipe steps, weighing sequence and target weights is available at the operator workstations located throughout the Ohio facility. The 2 workstation consists of a V5 Pigment Weighing & Batching Touch Screen User Interface, Label Printers and a variety of platform scales and high resolution balances.
The V5 Touch Screen User Interface allows the area specific Production Plan to be displayed using easy to follow screens. This eliminates paper schedules and prevents operators making incorrect or out of sequence formulations. After selecting the required formula, the operator follows simple screens which prompt for lot number of each color pigment. A speedometer display ensures the weighed items are portioned correctly and within tight, management set tolerances. The operator cannot weigh up too much or too little as the system will not accept out of tolerance weighing. This has a big impact on improving batch consistency and overall product quality – something that AERT business model is dependent on.
‘Mistake Free’ Pigment Weighing & Batching System Reports
Electronic reports detailing which operator has weighed up the respective steps are available at the main PC, detailing the lot number and scaled amount. The Recipe Batch Log allows this visibility, detailing the exact amounts of each of the pigment weighed into the batch. The Matrix Controls V5 Software has automated this process to ensure fast and accurate batch sign off of Pigment formulations.
As the jobs can consist of many batches, small changes in the formula take place to adjust for the strength of the color compounds which vary between lots. The changes are made in Ross ERP and then exported into the Matrix Controls database. This allows current jobs to be edited in real time ‘mid-flight’.
The V5 Pigment Weighing & Batching System allows recipe formulations to be reworked. As each pigment is weighed into a separate container, the software allows batch retrieval to take place, effectively allowing trusted operators to open up previously weighed batches and make additions or subtractions to the weighed amounts. The System also allows other ingredients to added to a batch, allowing complete flexibility of the batch to supervisors.
To provide paperless lot traceability, the V5 Pigment Weighing & Batching System creates inventory usage data in real time (after each batch / job is complete) which are in turn used to reduce inventory. This improves inventory visibility, reduces man hours spend on data entry and saves time double handling data. In addition, the V5 System provides actual usage based on the scaling weights, instead of theoretical usage based on target weights. This allows accurate yields to be calculated which provides visibility for supplier inventory accuracy.
The system guarantees a reduction in the waste caused by a conventional scale system
Lenny Tyc, Northeast Foods
With the waste now eliminated, dollars are saved
Dave Harris, Original Bagel Company
The System provides total control over our production process and gives us 100% Traceability - Absolutely brilliant
Gareth Franks, Dominos Pizza
Tolerances on the scale system removed ingredient over weighing and improved our batch consistency
Michael Calise, Calise & Sons Bakery
Matrix Controls Company, Inc.
330 Elizabeth Avenue, Somerset NJ 08873
Phone: (732) 469-5551Email: email@example.com