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PRIMS Automated

PRIMS

Production, Recipe, Ingredient, Management Software

Fully Automated Batching” (Bulk and Hand Scaling Systems)

 

Increase Production Yield! Reduce Batch Cycle Times! Eliminate Operator Errors! Reduce Ingredient Losses By 95%! Get a Perfect Batch Every Time !

Matrix Controls - Learn PRIMS Fast

PRIMS is short for Production, Recipe, Ingredient, Management Software. It automates the batching of Ingredients at mixers and scaling stations. The mixer might be mixing bread dough, food, non-food, dry mixes, or liquid mixes. The PRIMS Operator Stations record the scaling deviations for those Ingredients that are automatically fed or scaled into the mixer. It also records the processes (temperature, mix times, etc., that the batch is subjected to), piece weights, Ingredient lot numbers and batch numbers.PRIMS keeps track of recipe proportions and procedures, ensuring consistent quality for each and every product you manufacture. PRIMS ensures brand protection, with the ability to email the FDA tracking reports in minutes, not weeks, and satisfy 2003 Title III Bio-terrorism requirements.Utilizing PRIMS, the production supervisor can stop problem batches, scaling and operator errors, and diagnose quality control issues rapidly. Records:

  • Inventory Used
  • Ingredient Lot Numbers
  • Scaling Deviations
  • Operator Adjustments
  • Manual Scaling Operations
  • Piece Weight at Check Stations

Performs:

  • Bulk Handling
  • Ingredient Food Batching
  • Ingredient Lot Food Tracking

The PRIMS Process:

  1. Your product’s formula (recipe and process) is entered into PRIMS.
  2. The manager uses PRIMS to establish a production schedule.
  3. PRIMS communicates the formula and schedule to the equipment and operators.
  4. PRIMS performs all automated ingredient additions.
  5. PRIMS informs the operator of the ingredients to be added manually, in proper sequence.
  6. PRIMS interfaces with the equipment to establish appropriate equipment settings.
  7. PRIMS records the production results, along with other data, to provide a numberof reports — including a lot tracking report that meets all Title III requirements.
  8. PRIMS performs inventory management.

How PRIMS handles Ingredients, Formulas, Work Plans, and Reporting:

PRIMS Ingredients (PDF)

The ingredient database consists of all ingredient used processes, and instructions in the formula, with assignment to 6 categories or types.

PRIMS Formulas (PDF)

Using the Ingredients in the Ingredient database, the production supervisor creates the formulations to be run from PRIMS.

PRIMS Work Plans (PDF)

A work plan in PRIMS is an effective way to communicate with your operational staff on the plant floor. The production schedule is either entered or read back into the work plan depending on the type of plan you use. These include:

  • Scheduled Work Plan
  • Split Work Plan
  • Work Plan Created at the Mixer/Scale
  • Read Only Work Plan

PRIMS Reporting (PDF)

PRIMS has an expansive amount of reports that are easy to select the desired output for. These reports include:

  • Ingredient Report
  • Formula Report
  • Production Report
  • Batch or Scaling Report
  • Ingredient Usage Report
  • Lot Number Report

PRIMS Reduces or Eliminates Waste and Lost Profit, and after that Rapid R.O.I., it is all Major Additions to your Bottom Line:

For more than a decade, PRIMS has earned a reputation for 100% reliability. It eliminates operator error for a perfect batch every time. With its easy-to-learn operation, your company can realize a 20% reduction in batch cycle times, and a 5% increase in production yield, while cutting ingredient losses by 95%. The Industry standard of 6% Manual Over –Scaling, is reduced to under 1 / 2 %. This is an easy R.O.I calculation, and by itself provides major motivation for the PRIMS system.

Return on Investment

PRIMS assures a perfect batch every time. No raw materials are wasted. Every procedure and material utilized, is recorded and presented in a variety of reporting formats. PRIMS technology begins to pay for rapidly by…

  • Eliminating Operator Errors
  • Assuring a Perfect Batch Every Time
  • Reducing Ingredient Losses by 95%
  • Reducing Batch Cycle Times by 20%
  • Ensuring 100% Conformance to Batch Specifications
  • Increasing Production Yield by at least 5% (conservative)

One customer was experiencing an average of 8 bad batches per week at a cost of $640 per batch, which equaled $5,120 per week or $266,240 per year. Now, and in addition to, see what the savings in his ingredient usage on just 5 ingredients can be just by reducing losses from 4% to 1%.

Using the following prices for these bulk ingredients, based on making a 3% improvement in scaling operations alone (not even the 6% to under .5% typically seen), the total estimated savings for these 5 ingredients for the first year are as follows, with a total savings of $299,070.

Ingredient Savings

The total saved for just the 5 ingredients was $299,070.

Add to this, the $266,240 saved per year from eliminating the bad batches (8 bad batches per week at $640 per batch) and you have a very nice new Total = $565,310 saved per year.

Upgrade Any Time

You can gain advanced functionality to the PRIMS-CISS system at any time by adding any of the following PRIMS Add on Modules:

  • Lot Tracking Module
  • Time Scheduling and Efficiency Module
  • Receiving-Inventory Module with Reconciliation and Barcode Label Printing
  • Production Scheduling, Material Requirement and  Workplan Template Module
  • Finished Goods Inventory and Shipping Module
  • Purchasing Module
  • Security and Historian Module
  • Costing Module
  • ODBC Data Driver
  • Network Module
  • Multi-Language Module
  • PRIMS Microsoft Sequel Server Data Base Adder   

PRIMS Food & Beverage ROI Calculator $$ (XLS)

Please contact Matrix Controls with any questions, or feel free to fill out a Needs Analysis Form , where we can further provide solutions for your company.