Case Study

Car Polish Factory Starts Using Imperium4Batch System

Our Imperium4Batch system has recently gone into full production at a car polish factory in Hertfordshire. The system consists of two mixing vessels, a powder handling system interface and a hot water system that is used for CIP operations.

Flowchart of a liquid feed system with tanks, mixers, and piping, labeled with components like "Hot Water," "Mixer 4," and "MX-ZZ," showing volume, temperature, and control indicators.

At the heart of the surface preparation process control system is the new Imperium4Batch recipe configuration and creation software, this powerful tool allows customised recipe steps to be configured to meet a customer’s specific control requirements. Once a suite of recipe steps has been configured they can be used to create product recipes, these define the manufacturing control sequences and plant operator interactions required to make the specified product. Custom operator prompts and Health & Safety messages are also integrated into the recipes, adding further system flexibility.

Mixer production runs are scheduled on Day Programmes, which are then produced by the system as a series of batches. The real-time progress of a batch can then be monitored via Mixer control screens, which also allow operators to view historic and upcoming manufacturing steps in the recipe. Once completed, historic batches can be viewed, printed or exported.  The user HMI is via standard web browsers enabling multi-user systems to be set up easily. Other standard Imperium4 packages such as CMMS, OEE and Video Replay, are also available to be easily integrated into the system.

  • Batch Day Programme

    Screenshot of a table titled 'Batch Day Programme for MX-4 (Mixer 4).' It shows a batch program with columns for Recipe Code, Recipe Name, Batch Size, Batches Required, Batches Complete, Line On Hold, and an Explode option. Contains one entry with details: Recipe Code 'A,' Recipe Name 'Flexicon Test,' Batch Size '1000.000 (kgs),' Batches Required '10,' Batches Complete '0,' Line On Hold 'No.' Offers options to Enable Edit or Explode at the top, and navigation buttons 'Previous' and 'Next' at the bottom.

  • Production Recipe

    Production recipe table showing step-by-step instructions for a mixing process, including step identification, vessel usage, and detailed actions such as automatic and manual feed, mixing, and waiting for feeds to complete.

  • Mixer Control Screen

    Screenshot of a mixer control screen showing batch and feed details, with progress bars and control buttons for operations like stop, confirm, and batch.

  • Manufacturing Batch Display

    A screenshot of a manufacturing batch display for batch number 556, showing steps, dates, times, and statuses for a process including details like 'Auto Feed Liquid' and 'Feed and Continue.'

Ready to experience the benefits of our advanced process control system? Contact us to get a personalized demo and discover how it can streamline operations, enhance efficiency, and drive growth for your business.