As the bakery Ingredients industry incorporates more automation on the production floor, product dispensing, mixing, and blending systems are crucial to successful process automation. Mixing, blending, and dispensing of bakery ingredients can be a serious challenge for high volume production since each machine provides a highly specialized function. Often each machine is segregated and do not communicate for automated movement of product flow. Also, several aspects of the manufacturing of blending bakery ingredients is done manually by operators. Therefore, the operator controls a major percentage of the manufacturing process. IndustLabs has a develop a unique solution for high volume production of blending, mixing, and dispensing of bakery ingredients via automatic systems and custom software for optimizing production outputs.

Customer Benefits

  • Automatic dispensing, mixing, and blending of bakery Ingredients
  • Factory was able to operate the dispensing, mixing and blending of ingredients with 1 Operator for 2 production lines
  • Double the Production Output of existing Factory by Optimizing of Processes
  • Save customer the cost of building 1 new factory
  • Integration with existing packaging systems
  • Convert all Manual Process into Automated System
  • Simple controls and ease of use in production

Technologies

  • Allen Bradley CompactLogix Series PLC
  • Allen Bradley PanelView Plus Graphical Terminal
  • DeviceNet Network Communications
  • RSLogix 5000 PLC Programming Software
  • Mettler Toledo Load Cell Controller for weight dispensing

 

Solution

As a leading automation software service provider, IndustLabs was able to support the deployment of a custom blends of bakery ingredients system responsible for managing product in transit from dispensing, mixing, blending, to packaging. In partnership with mechanical design and service providers, IndustLabs served as the primary software developer for control of the Allen Bradley PLC and HMI Platform.

By developing flexible and reusable bakery blending, mixing, and dispensing controls, IndustLabs rapidly supported the successful deployment and commissioning of a mission-critical system. Before IndustLabs was commission for the project, the blending, mixing, and dispensing of the bakery ingredients was controlled by hand. The production line was staffed by 5 operators that would manually load the bakery ingredients into mixing equipment manually by pre determined weighted silos of 1000lbs of bakery ingredients. Also, the operators would have to keep track of the correct mixing time of the ingredients. And finally the operators would have to manually feed all bakery ingredients to packaging equipment. The management team of the factory realized that this process was costing revenue losses in terms of bad quality, rejects of product, high labor cost, and low production output.

IndustLabs developed a custom automated solution for the dispensing, blending, and mixing of bakery ingredients for 2 production lines. IndustLabs custom solution increased the production output of the bakery ingredients from 14,000 lbs. per production line per day to up to 30,000 lbs. per day. Doubling the manufacturing output utilizing the same system and same production lines. Prior to the IndustLabs proposal the customer was in the process of evaluating a second facility to build in order to meet customer demand.

In summary, IndustLabs develop custom software for the dispensing, mixing, and blending of high production of bakery ingredients. IndustLabs software solutions provided numerous benefits for the bakery,  mixing and dispending industry, but they also require a great deal of care and expertise to deploy successfully. IndustLabs goes beyond automating manufacturing process and offers expertise in optimizing production by utilizing well plan and executed manufacturing software. IndustLabs is committed to providing expert solutions in dynamic manufacturing environments by helping reduce risk in the deployment of complex custom solutions. Learn more about our Manufacturing Automation solutions.