Controls that keep the line running, and the product safe.
ISA-88 batch control, inline vision, and PLC programming for food and beverage manufacturers. Built for washdown environments, sanitary design, and the regulatory weight of FSMA, HACCP, SQF, and BRC. Engineered for plants that run twenty hours a day.
Three things eating into food plant margin.
Changeover that costs hours
Multi-product lines run six SKUs and change over between every shift. When new products require a controls engineer to edit PLC code, product launches stall and operators wait. Recipe-driven batching solves this. Most legacy plants still don't have it.
OEE estimated, not measured
Shift reports filled out by hand. Downtime categorized differently by every operator. Numbers that swing wildly between weeks. Management can't make investment decisions on data they don't trust, and the real bottlenecks stay invisible.
Quality caught too late
Manual visual inspection misses fill-level errors, mislabeled cases, and seal defects until product is already on the truck. Paper CCP forms and manual CIP records make traceability a fire drill every audit. Inline inspection and automated batch records exist for a reason.
Three systems we build for every food and beverage line.
Higher throughput,
less waste in the line.
Outcomes from recent batch control, inline vision, and OEE deployments across beverage, snack, and dairy plants. Specific projects scoped on request.
Got a line that should be running better?
Straight answers.
Yes. Food plants run 20+ hours a day and we plan every phase — commissioning, controller migrations, HMI replacements, and network upgrades — around scheduled sanitation breaks, weekend shutdowns, and planned maintenance windows. We stay until the line runs at production rate, not until the punchlist looks manageable.
We design batch control per ISA-88 for recipe-driven processes — mixing, blending, cooking, fermentation, and CIP/SIP sequencing. Recipe management is exposed through the HMI so operations can launch and modify SKUs without calling a controls engineer to edit PLC code.
Yes. We integrate machine vision at fill, label, and seal inspection points on lines that were originally designed for manual quality checks — cameras, lighting, reject systems tied into the line PLC, and inspection data logged to the SCADA system for batch traceability and quality trending.
Most food packaging lines mix equipment from different manufacturers. We communicate with each OEM's PLC via the appropriate protocol and normalize the data into a unified SCADA platform — one production view across fillers, labelers, case packers, and palletizers regardless of vintage or vendor.
Yes. CCP data, batch records, and CIP cycle documentation are captured automatically from the control system into the historian and surfaced in the formats your quality and regulatory teams need — not on paper forms that operators fill out during a busy shift.
Allen-Bradley ControlLogix and CompactLogix, Siemens S7-1500 and S7-1200, and Beckhoff TwinCAT for controls. Ignition, FactoryTalk (SE and Optix), Siemens WinCC, and AVEVA for SCADA and HMI. FANUC, ABB, KUKA, and Universal Robots for robotics. We select the platform based on the application and site standards, not personal preference.
Ready to talk about your plant?
Whether it's a batching system, a packaging line, or a full plant control upgrade — tell us about the project and we'll figure out the best way to help.