The dosing of materials considerably impacts the manufacturing process in several industries. An error in the recipe-based dosing process for a regulated industry, such as the chemical, can mean the loss of the entire batch, compromise product quality, or non-compliance with industry regulatory standards. For the chemical industry, following the recipe precisely without errors in dosing is mandatory.

Therefore, chemical companies with a manual dosing process are more prone to errors. In addition, a manual process results in excessive paperwork and risks issuing expired materials, a bad batch, or human errors. All this is associated with economic and time costs that harm the company's productivity.   

Paperless and error-free

The solution lies in digital. A recipe-based dosing digital system optimizes materials use, traceability, and control, improving quality constantly and saving resources.

"The advantages of a digital system outweigh that of a manual process," says Sergio Hernández, Execution Systems Director at AG Solution Group. "A digital system dosing solution increase revenue, ensures quality, and follows the ISA 95 MOM standard guidelines".

Sergio also shares what a complete digitalized recipe-based dosing system should have:

• Digital Operational Guides: Facilitate operators work by clearly indicating the actions to be continuously taken, avoiding human error.
• Control and traceability: Centralize material master data, allowing tracking of materials throughout the process.
• Integration: Integrates with scales, plant equipment, and ERP; customizable to any management platform. Interfacing with Quality or other MOM systems is possible.
• Quality: It's strengthened with verification on wireless handheld devices, simplified validation of processes and commissioning, consistent dosing processes, and priority-based planning.
• Business rule compliance: Ensure compliance with current regulations and best production practices (GMP, CFR21) through functionalities such as signature verification or audit trails.

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Benefits for your production

There are several benefits when you digitalize your dosing processes: 

• Production optimization: The labor and overtime are reduced for manual processes, eliminating paperwork with Weighing Operations reports, cleaning room, and equipment logbooks. 
• Quality assurance: Achieve operation and control of the cleaning process and equipment calibration. Environmental checklists and guidelines to avoid cross-contamination are also provided.
• Less waste: Know what material to use, in what order, and how to do it. The system also can flexibly use FEFO strategies to adapt to your production needs.
• Cost reduction: Avoid waste, rework, and save costs by having control and traceability of materials on a single platform.
• Integration: Eliminate manual inputs and saves operators time. ERP and automation systems integrations are also possible.
• Performance reports: Generate multiple reports for performance or quality, having complete control of the system. Select the KPIs you need to optimize your production further.

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Digitalization made easy

At AG Solution Group, we have been helping companies in the chemical industry to digitalize their processes for almost 15 years. So start your journey towards digital transformation today and discover the benefits of intelligent manufacturing.

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