Case Study
Pre-Heating Perfection: How Corbion Digitalized Batch Production with TrakSYS
Corbion moved from paper-based batch records to fully electronic batch records (EBRs), giving real-time visibility into food safety and cleaning checks.
Real-time batch and production data helps teams and supervisors stay ahead of bottlenecks and machine, labor, and material issues.
Electronic signatures and mandatory card scans created a complete audit trail supporting allergen cleaning compliance.
The visibility of data has been a big win for us, and going paperless was a pretty big step. Performance data is starting to accumulate, and we've begun establishing run rates that let us accurately track OEE.
The Company
Corbion is the global market leader in lactic acid and its derivatives, and a leading supplier of emulsifiers, functional enzyme blends, minerals, vitamins, and algae ingredients. For over 100 years, the company has used its expertise in fermentation and other processes to deliver sustainable solutions for food production, health, and the planet.
The Challenge
At its facility in Totowa, New Jersey, Corbion manufactures mixes, bases, and concentrates for bread, cakes, bagels, tortillas, pretzels, and pastries. The facility's high number of raw materials and recipe variations led to complex kitting and blending processes, and paper-based records left the team with minimal insight into batch execution and production.
Corbion also had no efficient way to rapidly share information across teams and departments, making it difficult to ensure product quality and customer satisfaction as demand grew.
The Solution
Corbion reached out to Parsec Certified Partner Automated Control Concepts (ACC), who recommended building TrakSYS into the fiber of the operation. TrakSYS now stores recipe parameters for each product type, orchestrating the manufacturing process from kitting and blending through packaging and labeling. Leveraging a Level 2 automation and SCADA system ACC had previously deployed, the Corbion team digitalized the plant floor and removed paper from the process.
Operators use tablets to view customizable TrakSYS dashboards, follow production processes, capture photos, and review records that need approval, including a call-to-alert button that immediately contacts a supervisor. Traceability was implemented so production and quality teams could track components from raw materials to bulk ingredients to final pack-out in real time, and electronic signatures and mandatory card scans created a comprehensive audit trail.
The Impact
With TrakSYS, Corbion implemented Electronic Batch Records (EBRs), removing paper from the process and providing instant visibility into food safety and cleaning record checks while enforcing and verifying allergen cleaning compliance protocols.
Teams and supervisors now have real-time batch and production data to stay ahead of bottlenecks and machine, labor, and material issues, and MRP planning is linked to the automated scheduling of batches and batch components.
Get the Full Corbion Story
See how TrakSYS helped Corbion digitalize batch records, gain full traceability, and go paperless on the plant floor.
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