Epple Druckfarben AG produces sheetfed offset printing inks for packaging applications, including applications with indirect or direct food contact. This requires reliable batch information on raw materials and semi-finished products in order to systematically trace quality attributes such as viscosity. With the migration to a cloud-based ERP system (Microsoft Dynamics 365 Business Central), Epple was looking for a solution that would integrate manual and automated weighing operations in a unified way and reliably provide batch data. Innomat Automation supported the implementation with a central weighing system that maps the data flow between production and ERP in a fully digital, end-to-end process.
The challenge: standardized batch data despite heterogeneous weighing systems and rising requirements
In recipe-based and batch manufacturing at Epple Druckfarben, fully automated dosing lines as well as manual and semi-automated weighing stations are used in parallel. This evolved system landscape resulted in different user interfaces and separate data flows.
With stricter market requirements for seamless traceability, the need to track and report raw material batches and material combinations instantly – rather than through retrospective research in paper records – continues to grow.
Because raw materials are subject to natural variation, quality data must be captured as early as goods receipt and later remain clearly assignable throughout the batch history.
The introduction of an ERP system creates the foundation for structured batch information. However, to make data available across the entire system, all weighing processes – both automated and manual – must be digitally integrated, without parallel documentation paths and without additional effort for operators.
„Some customers specifically request seamless batch traceability – and expect us to be able to provide them with all relevant values within 24 hours."
– Tobias Friedrich, Epple Druckfarben AG
The solution: centrally integrated weighing with direct cloud-ERP connectivity
Epple integrated the existing dosing lines as well as six manual and semi-automated weighing workstations into a central weighing system. The technical implementation was carried out by Innomat Automation on the basis of the Kalisto software.
Innomat brings many years of experience in technically demanding batch processes with individual raw material and recipe variants. The combination of automation know-how and ERP-oriented integration ensured that operating procedures and data logic were precisely aligned with the real production process – without adding complexity at the workstations.
The practical implementation was consistently designed with usability in mind: all workstations use the same operating logic and UI elements. The control logic follows the actual process steps – orders can be completed with just a few interactions, with no additional steps or detours.
Production orders are transferred from Microsoft Dynamics 365 Business Central to the weighing system via a REST interface and buffered locally, so that production can continue autonomously even during short-term interruptions of the connection to the ERP.
Weighing is performed either automatically or manually, depending on the workstation. Automated dosing operations are executed on the control side and their values are transferred directly. For manual process steps, the respective batch numbers must be entered and are system-supported in being assigned to the material positions, including batch splits for multi-container scenarios.
The user interface is built identically at every station, so that workstations can be combined freely. All weighing data is documented immediately and made available to the ERP in structured form as soon as the process step is confirmed.
The result: a flexible weighing process and transparent batch data in the ERP
The integrated solution provides batch and weighing data to the ERP without delay, replaces parallel documentation paths and reduces onboarding times thanks to a unified user interface. Employees benefit immediately: workstations can be switched flexibly, because all of them function in the same way.
„Now everything is much more uniform. Previously, we had different systems in use – the interface looked different depending on the workstation."
– Tobias Friedrich, Epple Druckfarben AG
Orders can be processed with just a few clicks, which speeds up throughput. The system enforces the entry of correct batch numbers – missing or incorrect entries are thus systematically ruled out.
Thanks to central data storage, material combinations and raw material batches can be traced systematically – all the way back to the original raw material batch. Production orders can be flexibly started and continued at different workstations, because the entire process is managed in a single system.
The consolidated system architecture reduces the number of individual interfaces and thus simplifies operation and maintenance. The solution is designed to gradually connect additional workstations and to extend the concept to further production areas.
For industries with high quality and documentation obligations – such as the printing ink or chemical industry – the solution provides a transferable approach: uniform weighing processes, system-supported traceability and productive ERP integration without media breaks. Innomat provides both technical and organizational support to efficiently roll out the standard to additional areas.
A look into the future: Going forward, the process-step status from weighing and production will be automatically transferred to the cloud ERP, making order progress visible in real time.