Soap & Cosmetics Process Control System

Imperium4Batch is a process control, planning and information system that is designed for specialist batch manufacturing plants in various industries such as Surface Coatings, Food and Beverages, Cosmetics & Adhesives.

Imperium4Batch is simple and intuitive to operate. It provides highly sophisticated techniques to optimise production and allow unmanned operation where possible.

Imperium4Batch is fully user-configureble and built from a number of modular blocks to control your plant. This includes the intake of raw materials, blending, grinding and mixing of batches, Machine control and packing.

The system is fully scalable and can be configured for all batch processes, from the smallest to the largest of plants. It may be
used to control one area of a plant initially and then be extended as circumstances permit. Many modifications can be made to the system even while production is running.

Imperium4Batch may be used to control:

Weighbridge in, intake/receiving, weighing and batching, hand weighing, disperser control, mixing with liquids control, routing to finished product vessels, filling/packing machines, bulk out loading, packing, warehouse, weighbridge out.

Imperium4Batch has a built-in simulation system which is a useful testing and training facility.

When the system is configured with real-time simulation parameters, it can be used to help engineers redesign a plant and identify potential bottlenecks.

Imperium4Batch is based on one or more standard Microsoft Windows PCs and readily connects to most common PLC and Input/Output systems e.g. Allen Bradley, Mitsubishi and Siemens. This allows competitor or legacy process control systems to be economically upgraded with minimal disruption and wiring changes by reusing the existing PLCs.

Windows server may be used for larger systems with Thin Client PCs used for operator workstations. Thin Client computers are suitable for industrial environments as they do not have a hard disk. This makes them easier to set up and they are more rugged and more reliable.

Imperium4Batch’s software is a mature and well proven system with many installations across the world. Imperium4Batch has an secure menu system that prevents unauthorised access. In the unlikely event of a serious fault with the control server, a standby server can take over to minimise downtime.

A rugged PC that has been installed with Imperium4Batch, allowing operators and maintenance staff to go about their tasks without having to be tied to a workstation. All the facilities of Imperium4Batch are particularly useful when you are on the move.

Imperium4Feed will log all intake transactions, batch records, stocks audits/alarms, usages, production, pellet press/extruder runs and out loading transactions. This data is stored online for up to seven years and can be viewed with Imperium4Feed’s simple-to-use facilities. This satisfies most sites’ requirements and helps mills to achieve the required quality standards and approvals. Data may be printed and can be exported to a spreadsheet of another computer system.

Imperium4Batch has facilities to integrate with a wide variety of IT, ERP and formulation systems in the following areas:

Intake/Receiving

Order and production

Batch production details

Truck operations

Bin/Silo contents

Recipe, declaration and product information

Imperium4Batch has been successfully integrated with Format International, Microsoft Dynamics, SAP, SAGE, Plex in addition to many bespoke and local systems.