IFF returns to Marco

01 February 2007

IFF has invested in a fourth Trac-IT factory floor efficiency system, from Marco, to increase control and traceability of complex recipe formulations at its Haverhill plant.

The flavour and fragrance manufacturer will integrate the Marco system with IFF’s global SAP ERP installation, with Trac-IT acting as a ‘Thin Client’ to SAP. Real time data from the factory floor is used within SAP to provide traceability and react to changing business requirements.

Toine Blankers, automation manager at IFF, said: “Precise recipe instructions are communicated from SAP to the Marco system to ensure product quality, integrity and consistency.”

In addition, the weight-based systems establish a base for the procedural control of other functions, including vessel cleaning control, stock utilisation and stock replenishment.

Blankers said: “Track-IT takes control of the process, ensuring not only that each sub-batch is correct but also that all those required for a particular end product are placed in the mixing vessels. The new system scans and logs the collected batches and only allows final mixing when all have been confirmed to be OK.

“A batch vessel cannot be used for another job until it has been confirmed as ‘discharged’ into the large mixing tank. After filling, this tank in turn cannot be loaded with the next job until CIP has taken place and Quality Control has passed the tank for use.”

An operator will only be allowed to continue if the system has recognised that the correct amount of the correct ingredient has been picked up. The scheduled work plan is downloaded to workstations from SAP and the batches filtered to ensure correct permissions are granted.

Blankers concluded: “Trac-IT, in combination with the mobile workstations, allows us to securely ‘pour where we store’. Marco personnel continue to take the time to listen and understand our requirements. This ability together with their enthusiasm, ingenuity and innovation is ensuring ongoing success.”

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