The Challenge: For several years Brock has partnered with
a leading Cosmetics OEM, Soleri Amerique, to supply and
implement S88 Batch Control Systems on autonomous production Skids.
Soleri Amerique designs, builds and supplies modular
manufacturing platforms – otherwise known as ‘Skids’. The Skids are used
by Cosmetic customers to manufacture such products as shampoo,
conditioner, lotions, creams, etc. The size and mechanical design
typically vary depending on the throughput and product requirements.
The Solution: The Soleri Skid, built with Brock’s proven control system design,
produced an effective and complete turnkey solution. Our customers have
benefited from the following features:
- Superior Proven Mixing system – Enhances product quality, produces
faster heating & cooling rates and reduces Batch cycle time.
- Unique Mechanical design of the skid allows more effective and
faster CIP and SIP of the Skid and associated piping – No contamination,
better product quality and reduced Batch cycle time.
- Recipe-based Manufacturing and Batch History – Forces operator
accountability reducing the Batch cycle time. Also yields product
consistency Batch after Batch.
- Well-designed modular re-usable procedures allow for easy and
faster Recipe creation and modifications.
- Flexible equipment-independent procedural design allows for Recipes
to be transferable from Skid to Skid.
The Benefits: Brock Solutions’ approach
to the design and implementation of the Skids facilitated the following
benefits:
- Modularity: Recipe
phases, operations, equipment modules and control modules can be re-used
in subsequent systems thus reducing implementation costs. Modularity
also allowed for easier validation and simpler process modifications.
- Accurate Data Collection: The Batch Server generates a comprehensive Batch Journal
containing the targets, actuals and time stamps for all process steps
generated by the recipe. Continuous process data such as temperature and
pressure is logged during the Batch and used to display real time and
historical trend data.
- Corporate Standardization: By introducing a common S88
platform on all Skids across all plants, the customer can build the
necessary framework to effectively integrate its manufacturing facilities
to ERP and Supply chain management systems.
