Challenges of process data capture
Diversity of processes and products
The confectionery industry covers a wide range of products, from chocolates and candies to cookies and ice cream. Each of these product categories requires specific manufacturing processes and flexible data collection systems that can quickly adapt to recipe changes. This heterogeneity places high demands on the flexibility of the data acquisition systems.
Quality control and traceability
To ensure consistently high quality standards, numerous process parameters must be monitored in real time. Seamless documentation of the entire production chain is required to respond quickly and effectively in the event of a product recall. This is a significant challenge for companies, as it requires continuous monitoring and documentation of all production steps.
Technology and data management challenges
Many manufacturing facilities use machines and systems from multiple vendors, each with its own data systems. Integrating these heterogeneous systems requires powerful IT solutions. In addition, different data formats and units must be standardized and harmonized. Collecting and storing large amounts of real-time process data requires robust IT infrastructures. In addition to storage, analyzing the collected data to gain valuable insights for process optimization is a major challenge.
The solution: BRAIN2 Capture
To meet these challenges, Bizerba has developed the BRAIN2 Capture software. This powerful solution enables the acquisition and evaluation of process data from a wide range of Bizerba devices such as price labelers, inspection systems and checkweighers.
Automated data capture and integration
BRAIN2 Capture automatically collects data such as individual values, summary data records, as well as information on metal findings and metal detector audits, and stores them in a central SQL database. This saves time and reduces errors by eliminating manual documentation. Data can be delivered via web service and CSV file, allowing seamless integration into existing business processes and facilitating data transfer to higher-level systems.
Comprehensive reporting and export functions
BRAIN2 Capture offers detailed reporting functions that allow a comprehensive evaluation of daily production, batch evaluation and metal detector audits. These reports are essential for quality control and internal audits. The ability to export the collected data as a CSV file is particularly useful for programmers and IT specialists, as they can use the data for further analysis and integration.
Long-term data storage and compliance
Another key benefit of BRAIN2 Capture software is the ability to archive production data over a defined period of time. This ensures traceability and facilitates the creation of compliance reports. For comprehensive compliance requirements and the calculation of statistical values, BRAIN2 Capture is complemented by BRAIN2 Prepack_Compliance. This software captures and calculates the necessary statistical values to ensure that all regulatory requirements are met. Together, these solutions provide a reliable platform for long-term data archiving and compliance in the confectionery industry.
