Track & Trace
Since Four Roses uses a continuous batching process, Vertech decided to use the weigh scales under the bins to calculate the amount of grain inside and create batch records.
As the grain moves through each stage, new transactions are automatically created and associated with the batch record.
For easy operator access, Vertech leveraged Ignition’s extensive design capabilities to create 9 main screens for each of the following functions: Grains (storage), Cooking, Yeast, Fermenters, Distillation, Tank Farm, Quality, Dashboard (overview), and Logs.
The process stages of the facility are all linked through the Ignition connection to the MSSQL database. For example, as grain moves from the grain silos to the cookers, the tags associated with the process update various database tables; these tables provide a clear picture of how much of each grain moves into each cook batch and how much grain remains in the silos.
OEE (Efficiency Monitoring)
Vertech also designed an OEE system to monitor the high-speed bottling line, where the bourbon is blended and bottled.
The system has a process screen displaying the infeed count for the filler as well as various inspection points, including case weight, fill level, and label and cap inspection. It also monitors the rate of the labeler, the sealer, and the palletizer.
The OEE screen tracks overall equipment performance, including accurate production speed, line status, downtime (and reason code), and delays. It uses these inputs to calculate Four Roses' OEE score by production line, cell, product, shift, and timeframe. This data can be broken down further through the data analysis and history screens.
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