i-control automation software

i-control automation software

i-control overview i-control overview Productivity I-Control helps you achieve maximum efficiency in today s competitive market by minimizing downtime, maximizing equipment use and streamlining production. I-Control is constantly monitoring your operation for peak productivity. Interstates Control Systems understands the complex needs of your facility. Our response to your needs is the I-Control system. I-Control provides the benefits of custom-designed software at a competitive price. Our modular architecture positions us to meet the needs of a variety of industries. quality Your customers deserve a quality product and I-Control helps you deliver. Tolerance alarms, automatic sequencing, and source/destination holds help to secure ultimate quality. In the event of a quality concern, I-Control s detailed Track and Trace reports allow you to isolate concerns in minutes. technology The I-Control architecture provides a stable, reliable foundation. The core of the I-Control system is a SQL Server Database. This allows you to gather, report, and export information so you can effectively manage your facility. HMI screens customized to match your process flow allow you to quickly utilize the system. Individual PC s coupled with extensive security options allow you to control access to specific systems. support Emergencies happen. In the event of an emergency, Interstates Support Team is available 24/7. We will quickly diagnose the problem and move to a resolution. Your team of individuals was incredible! Their work ethic, commitment, dedication and passion was unbelievable. From the PM all across the entire team they were the best team that I have ever been involved with in 30 years of milling. Thanks to all of them! HALL OF FAME John Hultman, Decatur, AL 2 Understanding Needs Delivering Results 3

receiving milling The I-Control Receiving module provides an automated receiving process to ensure accurate, efficient and cost effective receiving management. To reduce errors and entry time, the I-Control Receiving module will import orders from an ERP or purchasing system. Orders can also be manually entered for added flexibility. Automated routing controls ensure accuracy in unloading product and eliminate cross contamination. Necessary lot tracking information can be entered to provide beginning to end traceability. Control the system with the user-friendly graphical interface. Alarms are easily acknowledged and security based manual override controls are available. In the event of an error, extensive event logging provides data so you know what was done by whom. Interstates Control Systems understands the industry s receiving needs and is able to deliver the necessary programming to meet those needs. The I-Control milling module efficiently controls all types of milling equipment including hammer mills, cracking mills, flaking mills and roll stands. Automated cycling of source and destination bins allows for uninterrupted milling, providing a continuous supply of the necessary ingredient. At times, it is necessary to restrict product from entering or leaving a bin. With I-Control s source and destination holds, you can manage which ingredients are available and when they are available. Bins can be placed on hold for a designated amount of time to allow for tempering or other time based restrictions. This gives an added level of control, making sure the right product is used when you want to use it. I-Control tracks lot codes in Pre-Batching and Post-Batching systems. This ensures seamless Track & Trace capabilities as product moves between systems. No matter your milling needs, I-Control provides optimum performance and maximum throughput. 4 5

batching batching Key Benefits Auto downloads Formula / order imports from ERP Production data exporting Dry & liquid application Simultaneous scaling of bins Sequencing logic Track & trace enforcement & reporting Ingredient substitution Tolerance alarming & notification Automatic free fall correction expanded features Integrated bar coded hand add system In-depth track & trace reporting If batching is the core of your facility, I-Control is the right tool to ensure you produce the highest quality product with the greatest efficiency. Providing the best tools to meet your batching needs starts with full dry and liquid automation. It continues with automated downloads allowing for continuous uninterrupted production. We have the ability to cycle both source and destination bins, providing for maximum uptime while also enforcing strict sequencing rules to eliminate cross contamination. Gain additional efficiency by simultaneously scaling your major, minor and micro bins with constant monitoring to automatically correct for free fall, thereby reducing jogs and associated inefficiencies. In the event that you run short of an ingredient, the automated substitution feature suggests a preauthorized substitution to make sure the recipe continues to meet quality and dietary requirements. All of our batching controls are integrated to ensure the strictest monitoring of your track and trace needs, providing the ability to meet the demands of the latest government regulations. I-Control s Automated batching system provides operators with an easy to use interface. Whether importing, creating, or modifying recipes, the system allows for quick setup. The system can automatically select production sources and destinations or they can be dynamically selected through a process wizard. Each run undergoes extensive review to determine that all sequencing requirements, inventory requirements, interlocking, safety needs and scale capacities are not exceeded prior to releasing a run into production. I-Control s batching solution is a stable, time tested solution that is flexible enough to meet your individual needs. Custom batching solutions are our specialty and we welcome unique challenges you may have. hand-add module The I-Control Hand Add application is a powerful tool to manage the addition of hand adds. The I-Control system allows you to pre-weigh hand adds, affix a bar code, track all the lots of the ingredients and then stage the hand adds for later addition. key benefits Increased accuracy Pre-weighed for efficiency Bar coded for quick verification Lot tracking Event & user logging 6 7

processing loadout I-Control automates all aspects of the pelleting and extruding process. Our Industrytested algorithms are used to constantly monitor the mill, resulting in optimal capacity and quality. I-Control s pelleting algorithms often provide better management of the pelleting hardware than those of the original manufacturer. Source and destination routing, liquid application and cooler control are integrated to provide the most efficient pelleting control. Automated sequencing of source and destination bins provides for efficient and uninterrupted mill operation. To quickly reach peak performance, we utilize adjustable ramp settings for you to select how aggressively the mill reaches its target run mode. I-Control constantly monitors process variables to detect a potential choke situation and adjusts the proper settings to prevent chokes. key benefits Adjustable ramp settings Choke detection & recovery Complete track & trace Liquid application control The I-Control Loadout module manages movement of product from your storage bins to the customer s facility. By providing customized programming, we can offer a solution that fits your facility, giving you the maximum throughput of your products. Automated loading will accurately load your product, record detailed information regarding the loading process and give you the necessary reports to track the movement of product to the customer. These features provide the information needed to meet current government regulations. With our ability to customize the application to meet your specific loadout needs, we can configure the system so truck drivers or loadout operators can operate the system. Areas of customization include automated positioning for compartment loading as well as predetermined loading patterns to meet legal loading needs. Orders can be imported from your ERP or other systems, or they can be manually entered. Loadout data can also be exported from the I-Control system to offer integration with other business systems. key benefits Automatic compartment filling Complete track & trace Customized loadout application Efficient loadout capabilities Pre-configured trailer layouts ERP integrations Expanded Features Automated lorry Automated fill RFID integrations 8 9

console reportnet Through customized PLC and HMI programming, and the powerful flexibility of I-Control, we can configure the system to meet your specific needs. Our easy to use I-Control Console is a comprehensive one-stop command center for complete mill configuration. It ensures maximum efficiency, safety and security. I-Control console provides tools to monitor the control system without the need for a HMI screen I-Control s web based reporting provides internal and external access to an extensive report library. Both plant and corporate personnel have easy access to real-time data. ReportNet is integrated into I-Control s extensive security configuration enabling only those who need the data to access the data. Customized reporting provides the ability to add reports that display data as you would like to see it. key areas Product Maintenance: Set up and maintain items, recipes and sequencing requirements. Manage lot requirements and acti vate and deactivate lots as needed. Plant Maintenance: Configure, modify and monitor all equipment and systems. Backup and restore PLC settings to a database. Dynamically configure routes. Manage inventory including event monitoring, source and destination holds, adjustments, bin reassignment, bin configuration and new measurement entry. Control Maintenance: Manage the queue and work orders that need to be created. Monitor and modify systems in your facility. Utilize event logging to diagnose issues, determine the time of the event and ensure it doesn t happen again. Security Maintenance: Use Windows authentication, I-Control integrated security, or have the option to uti lize additional security capabilities such as RFID, card swipes, or I-Button. Comprehensive event logging tracks every initiated command, giving infor mation such as time, event and the user who was logged in at the time. ReportNet Access: Access ReportNet directly from the HMI or from any PC with a web browser. If you have access to the facility s intranet, you have access to ReportNet. Query: Query production information and event driven data. This includes Production, Inventory, Alarms, Exceptions, Events and Process Settings. Archive: Move data out of your current production database into an archive database. Reports can bridge across databases for seamless access. Enhanced Reporting: Expanded track and trace reports allow you to dive into production data to find exactly where an event originated and take corrective action. These reports reduce the reporting process from hours to minutes. 10 11

i-control automation software Interstates Control Systems 444 12th Street NE Sioux Center, IA 51250 www.interstates.com 1.800.355.0163