Automating Batch Processing System for a National Ingredient Supplier

EPIC Systems helped a national ingredient supplier to upgrade from manual to automated batch processing system by evaluating their existing manual process, developing a user-friendly control application, and integrating used equipment into the new automated system. The automation led to enhanced efficiency, consistent product quality, cost savings, and quick adaptation by the operations staff, positioning the company for scalable growth. 

Speak to an engineer
Hygienic Process System Design

Project

Overview

  • Industry: Food & Beverage
  • Company Size: Mid-size
  • Location: Missouri, USA
  • Customer Use Case: Controls Conversions

Customer’s

Challenge

A national supplier of ingredients and customized ingredient systems faced challenges with their batch process manufacturing system. The process was largely manual, leading to inefficiencies, inconsistencies in product quality, and a higher risk of human error. As the company expanded, the need to automate these manual processes became critical to meet growing demand, maintain product quality, and improve operational efficiency. The customer also required integration of some used equipment from an old facility into the new automated system, adding complexity to the project. 

Epic

Solution

EPIC Systems stepped in to address these challenges by first defining the procedures for the existing manual batch process. This comprehensive assessment allowed the EPIC team to identify the best approach for automating the process while ensuring the solution was tailored to the specific needs of the customer. 

 

To ensure a smooth transition for operators accustomed to manual operations, EPIC developed an easy-to-use control application and architecture. The user interface was designed with simplicity in mind, enabling operators to quickly learn and adapt to the new system. EPIC also integrated the used equipment from the old facility into the new automated system, ensuring compatibility and seamless operation. 

 

In addition to the automation, EPIC provided thorough training to the operations staff. This training covered not only the basics of using the new system but also included troubleshooting features and problem guides. These resources empowered the staff to efficiently manage the system and quickly resolve any issues that might arise. 

Project

Impact

  • Enhanced Efficiency: The automated system streamlined batch processing, significantly improving production speed and reducing operational bottlenecks. 
  • Consistent Product Quality: Automation minimized the risk of human error, ensuring uniformity and high quality across all product batches.
  • Cost Savings: By integrating used equipment from the old facility, the customer avoided unnecessary expenses while upgrading to a modern, automated system.
  • Quick Adaptation: The user-friendly control application and thorough training enabled the operations staff to quickly adapt to the new system, minimizing downtime.

unlock your manufacturing potential

Connect with an EPIC engineer to discuss how our solutions can revolutionize your business.

Speak to an Engineer
« Return to Case Studies

More Client

Success Stories

Multi-Skid Process System for a New Time-Release Fragrance Technology

Multi-Skid Process System for a New Time-Release Fragrance Technology

EPIC’s innovative solutions and meticulous project management enabled the successful design, fabrication, and delivery of multi-skid systems, addressing many challenges faced by the consumer fragrance company and ensuring seamless production of their new product.

Read Case Study

Our Solutions

EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

Process Systems

Learn More

Machine Vision

Learn More

Robotics

Learn More

Industrial Automation

Learn More