Automation and Control Systems:
FFCE’s technological support incorporates the latest automation and control systems into your food processing line as its area of operation. Some of these systems are; Programmable Logic Controllers (PLCs) Supervisory Control And Data Acquisition (SCADA) systems and Distributed Control Systems (DCS). Some of our automation solutions can help accurately manage several production aspects including temperature, pressure, flow rates, and the mixing time. In many cases, specific repetitive and complex chores are used to upgrade productivity rates and minimize variability in product quality. We as a food industry consultant, implement systems prescribed to modularity and factor in future growth, where changes and additions are easily accommodated.
Advanced Process Monitoring and Control:
We put in place most advanced process control systems that help track various process factors including the rate of production, energy usage and conditions of equipment in real-time, hence various KPIs. They include sensoring system, data logging and analytical system that are used to keep track of key variables in the process. All the real-time data is presented on clear panels, and operators can make decisions in a few moments. There are also alarm and notification capabilities of our monitoring systems, through which operators are notified whenever there is a variation from set standards so that necessary corrective actions can be taken quickly to reduce on downtime.
Integration of IoT (Internet of Things) Solutions:
FFCE takes advantage of IoT technologies to enable different appliance and systems in your plant to communicate and be controlled. With our IoT solutions, data can pass from one piece of equipment to another with ease of monitoring and managing. This interconnectivity enables the monitoring of the equipment without physical contact, the prediction of when equipment will need maintenance, and the control of processes concurrently with production. IoT connected systems also have analytical capabilities where it can get real time data of operations and work out problems on its own. The result of IoT is increased operational visibility, better management of resources and an overall increase in organizational performance.
Data Analytics and Reporting Systems:
Information is key when it comes to enhancing the performance of some of the best food processing consultants in the market. FFCE includes highly detailed data analytics and production reporting frameworks designed to centralize production data. Our systems employ complex methodologies including artificial intelligence in order to examine your data for trends and patterns. This information enables the uncovering of opportunities for cost reduction, rationalization of the consumption of resources and enhancement of product quality. Our reporting tools produce an array of reports and graphical interface that allows you to monitor and evaluate your performance to transform your operations.
ERP (Enterprise Resource Planning) Solutions:
Our enterprise resource planning systems incorporate the manufacturing, material, and supply chain, sales and even the financials of the business. These integration bring together work activities that are usually dispersed resulting in increased flow of work and elimination of unnecessary duplication of work in different department. Designed to help you improve your understanding of your business, FFCE’s ERP systems ensure that real time information is available with regards to the location of resources, stock control or even the company’s financial position. Customized to the industry and needs of the food market, our ERP solutions are designed to help clients manage food safety compliance and track food products.
Manufacturing Execution Systems (MES):
MES solutions offered by FFCE offer full coverage of the manufacturing process control, including raw material receipt and product delivery. MES systems are used in recording and conveying information of each process in the manufacturing sector. These consist of production planning and scheduling, work order control, batch control and quality control. MES systems also feed other business systems like the ERP and SCADA making it easy to have an overall look at the production activity. This integration allows a real-time decision making, keeps down the cost of production and is reproductive of industry norms and standards.
Traceability and Tracking Solutions:
Trace and traceability of products is very important to prevent the spread of food borne illnesses, and to meet regulatory requirements. FFCE operates stringent traceability programs as a method of capturing products at varying stages in the value chain, right from the inputs level to that of the outputs. The technologies that our systems employ include barcodes, RFID tags, and blockchain that enable capturing and storing information on production and distribution of products. This data give understanding of the origin, processing and handling of products and ensures quick response where the products have made their way to the market only to be recalled due to some nonconformity. Our traceability solutions also cover integration into other food safety regulation including FSMA, GFSI and ISO among others.
Predictive Maintenance Systems:
FFCE provide solutions for predictive maintenance that can help the company to accurately forecast equipment failures and when maintenance is necessary. We implement a real-time performance tracking system for equipment and assess parameters like vibration and temperature, as well as usage history, for potential signs of equipment failure. Failing to plan is planning to fail – that is why our prognostic and diagnostic solutions minimize interruptions, lower the risks of equipment deterioration, and curtail your expenses on maintenance. This strategic method of maintaining your production lines help in reducing any undesired roadblocks and maximization of production.
