Integrate Your Operations, Improve Performance & Provide Product Consistency
Smart manufacturing in food and beverage operations is centered around flexibility, productivity, and yield while meeting quality and safety requirements. Our secure plantwide solutions deliver flexibility and efficiency throughout your entire facility while also ensuring FDA compliance in all aspects with designs that give you access to relevant, real-time information — including traceability.
Cybertrol's knowledge-driven solutions will help you improve yield, increase productivity, mitigate security risks, and optimize resources.
Whether you’re looking to upgrade or reconfigure your existing system or are interested in an entirely new implementation, Cybertrol has the expertise and experience to provide information-enabled manufacturing, giving you the visibility to improve your entire operation. Our plantwide capabilities in the food and beverage industry include:
Automation Process Expertise
Cybertrol provides quality process automation engineering and control integration in all areas of food and beverage production, from receiving raw ingredients through packaging finished products. We offer 24/7 service and support to allow for continuous improvement and rapid response. As a result, our customers optimize productivity, reduce expenses, minimize risk, and increase profits.
Different batch applications require appropriate solutions to maximize your return on investment. We take the time to understand your requirements in recipes and formulations, raw ingredients delivery systems, kitting of minor ingredients and hand additions, agitation and tempering, quality verification process, and accuracy; all while ensuring food safety.
If your process includes receiving and storage, pasteurization, product standardization, filtration fermentation, evaporation, or dryer applications, our engineers have strong process knowledge and understand the dynamics of the equipment. We provide an optimal control strategy while ensuring a safe operator environment and protecting equipment.
Retrofits & Utilities Integration
Operating with legacy or obsolete equipment puts you at risk. We understand the benefits of today’s control technology and expanded functionality. ROI shouldn't be based solely on the fear of lost revenue due to hardware failure, but on increased revenue provided by accessibility of data, equipment effectiveness, product quality, ingredient usage, and increased yields.
Continuous in-line blending applications can replace certain batch applications and allow food and beverage producers to maximize yields with minimal equipment expense. Cybertrol's process knowledge extends beyond typical ratio control strategies and helps achieve desired product consistency from start to finish.
Clean-in-Place (CIP) Process
Product quality and food safety programs are highly impacted by the sanitation process. We design a CIP strategy concurrent to process control, for a fully integrated solution. Product, operator, and consumer safety is at the forefront of our designs. We use technology that verifies the system has been cleaned, but minimizes chemicals, water, and time.
Documentation delivered in a timely manner allows your staff to train new operators and maintain the system. If needed, Cybertrol will help protect your investment with 24/7/365 phone and remote support services and onsite engineering services.
Manufacturing Intelligence Solutions – Analytics & Reporting
Analyzing data correctly can lead to breakthroughs in efficiency. Cybertrol's manufacturing intelligence solutions deliver real-time production data to support decision-making and continuous improvement. Our intuitive dashboards and reporting solutions transform raw data into actionable insights. We integrate real-time operational data with business information systems to provide a comprehensive overview of your plant's performance, so that you can make informed, data-driven decisions to improve operational efficiency, reduce waste, and increase productivity. We understand the requirements for the FDA, including CCP (Critical Control Point) and CIP (Clean-in-place) requirements. We replace traditional methods with electronic records that include automated and real-time data analysis that is better organized and more readily accessible.
- Production dashboards
- OEE (Overall Equipment Effectiveness)
- Unit operations
- CIP (Clean-in-place)/SIP (Sterilize-in-place)/COP (Clean-out-of-place) reports
- Quality and CCP (Critical Control Point)
- Raw material receiving
All of this data can be summarized into reports:
- Product code
- Production line
Compliance & Electronic Records
Cybertrol's extensive experience in the food and beverage landscape has given us a comprehensive understanding of the electronic record requirements for the FDA and USDA. Our systems are designed to maintain detailed production records, traceability, and quality control metrics to ensure full compliance with industry standards and regulations. We specify data acquisition server systems, thoroughly validate systems in-house with test procedures, have written corporate standards to help companies comply with 21 CFR Part 11, and more.
Featured Case Study
A multinational food manufacturer had recently purchased an existing manufacturing plant and the staff quickly realized the custom batch software and HMI system were obsolete, causing them increased maintenance costs, wasted batches, and limited flexibility.