Read this case study to find out how a producer and supplier of animal nutrition supplements and premixes were able to increase traceability, inventory control and improve electronic batch records (EBR) after Cimlogic designed and implemented a fully comprehensive turn-key manufacturing solution for a completely new production line. The solutions comprised of: TrakSYS™ Manufacturing Execution System, Cimplicity SCADA System, Rockwell ControlLogix PLC Architecture and Pics Pro Simulation.

1. CASE STUDY
The Perfect Blend of Solutions:
How Cimlogic helped Premier Nutrition to the top of the pecking order
Company Profile
• Premier Nutrition was founded in 1991 and is a producer
and supplier of animal nutrition supplements and premixes
to the worlds largest producers of livestock feeds and pet
foods.
• Premier Nutrition has three manufacturing sites in Rugeley
(Staffordshire), and the company is owned by AB Agri Ltd,
the Agriculture Group of Associated British Foods plc.
• Premier Nutrition are committed to delivering wholesome,
safe, effective products that meet the animal’s productive The Business Requirements
needs whilst maintaining its health and welfare needs.
• A completely new production line (R4P) was created to
• The key principles adopted by Premier Nutrition in order to
replace previous paper-based manual processes.
achieve optimum food safety are control, traceability and
freedom from residues. • One of the key requirements was to use a company who
had the capability to provide a fully integrated systems
integration and turn-key control system solution for a new
“The aim of the new R4P production line was production line - from automation devices, automation
to create optimum traceability and food safety to process controls, manufacturing operations (MES) to
eliminate the chance of cross-contamination. In order business logistics systems (ERP).
to achieve this we needed to look at replacing our existing • The control system was required to provide increased
paper-based processes with electronic processes. throughput, traceability, capacity and to be fully integrated
We chose Cimlogic as they had the experience and with their existing ERP System.
capability of full systems integration and provided us with • Complex products and multiple recipe changeovers meant
a detailed and comprehensive turn-key solution covering that it was paramount that the new system eliminated the
all areas. We also required a control system that would risk of cross-contamination between batches and ensured
fully integrate with our existing ERP system, now and complete accuracy.
in the future – Cimlogic were able to do this.”
• It was also vital that the system provided full materials
management capability including material genealogy,
Randall Warin – Project Manager, Premier Nutrition traceability and receipt and batch management.

2. The Cimlogic Solution
• Cimlogic consulted, designed and implemented a fully
• Both RFID and Barcode Technology were fully integrated
comprehensive turn-key manufacturing solution comprising with TrakSYS™ Task Management, thereby enabling ‘Mix Up
of:- TrakSYS™ Manufacturing Execution System - for track and Prevention’ techniques to be adopted.
trace, fill and weigh, optimised planning, task management
• Advanced Planning and Scheduling (APS) was implemented
and importantly ERP integration. Cimplicity SCADA System
using TrakSYS™. Based on plant performance and business
- for tight control and diagnostic monitoring of the plant.
rules regarding contamination, the planning system was able
Rockwell ControlLogix PLC Architecture - for accurate and
to take a required input plan, shuffle the order of production
responsive plant control, tightly integrated into a range of
to meet the criteria of both optimised performance and
technologies such as RFID, bar-coding and labelling, and
avoidance of product contamination. In addition, planning
protocols such as Profibus, DeviceNet, EthernetIP. Pics Pro
took into account the availability of raw materials, also
Simulation - to emulate the plant and test the links between
monitored by TrakSYS™. This is a complex algorithm, and the
the ERP, MES and Automation Layer.
solution continually re-works the plan as the day progresses.
• The solution was seamlessly integrated into the clients
• Cimlogic utilised the Electronic Batch Record (EBR)
current ERP system. The interface was designed with the
functionality within TrakSYS™ to monitor and record usage
future in mind as the plan is to re-integrate with Microsoft
of raw materials (amounts and lot numbers), and provided
Dynamics AX in the near future.
complete traceability of the final product.
The Benefits
• Increased traceability and inventory control which has
improved product safety and genealogy.
“The project was delivered with absolute • Improved throughput , capacity utilisation, product quality
precision and expertise. and productivity.
Our processes are complex and we have variable
• Operator knowledge and experience was encapsulated and
products for multiple customers, and so the new system
put into the fabric of the solution, thereby improving plant
has helped us to manage these complex operations better,
performance, eliminating human error, and reducing waste.
whilst improving product quality, overall productivity and
Which importantly provides a leaner and more consistent
reducing costs.
delivery of service and products to the clients customers.
Cimlogic’s comprehensive turn-key solution has created
complete transparency within our factory and improved • Improved data management using electronic batch records
our data accuracy and management processes.” (EBR) and conforming to regulatory compliance.
• Premier Nutrition now has complete real-time visibility of
their entire operations in order to put further improvement
Randall Warin – Project Manager, Premier Nutrition initiatives in place.
Outstanding manufacturing solutions
e: enquiries@cimlogic.co.uk t: 01274 599 955 f: 0870 762 5559
Cimlogic Ltd, 11 Baildon Mills, Baildon, Shipley, West Yorkshire BD17 6JY
www.cimlogic.co.uk