Overview:

PRIMS is short for Production, Recipe, Ingredient, Management Software. It automates the batching of ingredients at a mixer or scaling station. This mixer could be mixing bread dough, food, non-food, dry mixes, or liquid mixes. It records the scaling deviations for those ingredients that are automatically fed or scaled into the mixer. It also records the processes (temperatures, dwell times, weights, etc. that the batch is subjected to), ingredient lot numbers and batch numbers. Through PRIMS’ reporting modules, the production supervisor can look up problem batches and diagnose quality control issues.

A smaller version of PRIMS-CISS, is a Computer Integrated Scale Software, which records both the lot number and the hand-scaled amount for an ingredient when small batches or a pre-scale mix is scaled. The Computer Integrated Scale improves quality control as it will not let the operator move to the next ingredient unless the weight is within an allowable tolerance.

Ingredients:

The ingredient database consists of all of the ingredients that production uses. The only limitation on the amount of ingredients to be entered into the ingredient database is the size of the hard drive on the users computer. PRIMS assigns ingredients to 6 categories or types as follows:

Formulas:

Using the ingredients entered into the ingredient database, the production supervisor creates the formulations to be run from PRIMS. The only limitation on the amount of formulas to be entered into the formula database is the size of the hard drive on his computer.

When PRIMS starts, it sends a formula to the PLC. The operator will then follow each step until the formula is completed. When a formula has completed, PRIMS will then record the results and move to the next formula.

Work Plans:

A work plan in PRIMS communicates to a mixer or scale, out on the plant floor. The production schedule is either entered into the work plan or read back into the work plan depending on what type of work plan is configured. There are 4 types of work plans: Scheduled Work plan, Split Work plan, Work plan Created at the Mixer/Scale, and Read Only Work plan.

Scheduled Work Plan:

A scheduled work plan is used when the supervisor wants to create a schedule within PRIMS. The supervisor creates a schedule by inserting the formula, the amount of batches to be made, and the batch size into the work plan. After the schedule is made, the supervisor presses the start button. PRIMS will then send down the first formula in the schedule to be made to the mixer or scale. When the first set of batches are completed, PRIMS will then send down the next formula in the work plan schedule. It will continue like this until the last formula is completed.

Split Work plan:

A split work plan is used when the supervisor wants to use one work plan for two mixers. The supervisor enters the schedule like a regular work plan, but when the schedule is completely entered he presses the Split button. This will automatically divide the quantity of batches between the 2 mixers. When the Start button is pressed, PRIMS will then send the first formula with the correct amount of batches to be made to the appropriate mixer. The split work plan is also flexible to the point that the supervisor can only choose one mixer or the other. Both mixers don’t have to be used. Although, if both mixers are being used and one mixer goes down, the supervisor can reallocate all of the batches on the downed mixer to the mixer that is still running.

Work plan Created at the Mixer or Scale:

This work plan is used when the supervisor wants the operator to request the formula to be made at the Mixer or Scale station. The operator enters the formula code for the formula to be made at his station. PRIMS then sends down a confirmation string to make sure that the operator entered the right formula code. If the formula is correct, the operator presses the Yes button and PRIMS then sends down that formula’s information. The operator then proceeds to make the formula. The status of the formula that was sent down to the operator will show up in the work plan. This gives the supervisor a record of what formulas the operator requested and how many.

If the formula wasn't correct when the operator first entered his request, the operator presses the No button and re-enters the formula code and starts over.

Read Only Work plan:

This work plan only reads back what formula is being run. This would primarily be used when no batch control is needed. This work plan records what formulas were mixed along with their scaling results, processes and lot numbers.

Reporting: PRIMS generates 6 types of reports:

1. Ingredient Report - gives a listing of a selected range of ingredients along with their codes, types, and percent maximum to weight.
   
2. Formula Report - gives a listing of a selected range of formulas along with their ingredients and associated step number, weight of each ingredient, and ingredient type.
   
3. Production Report - gives a listing of finished products along with their date, end time, how many were ordered versus how many were produced, and status of product (either M for modified, A for aborted, or C for complete).
   
   
   
4. Batch or Scaling Report - gives a history of the ingredients of every batch sent to or read from each mixer. It shows the amount ordered and the amount scaled along with the difference and percent difference for each automatic ingredient as well as showing the processes for a batch such as temperature, weights, or dwell times.
   
   
   
5. Ingredient Usage Report - shows the total amount of each automatic or scaled ingredient used in each mixer. It also shows the total amount of each automatic ingredient used for all the mixers combined.
   
   
   
6. Lot Number Report - shows the lot number(s) for each ingredient for a produced batch. The report can show up to 3 lot numbers for each ingredient in a batch.
   
   
   

Can the plant install the PRIMS system themselves?
Yes, their internal engineering department can or they can assign the job to their local controls integrator.

Will the PRIMS software integrate with the plant’s sales/accounting software?
Yes, the PRIMS software has a special module to make the data flow between softwares.

If you would like to discuss your needs and requirements you may call one of our application engineers. He will assess your situation so you can determine the steps you must take toward implementation.