iCap™ plant floor control software

As a carton/combo weighing station, the operator presses the "hot key" on the touchscreen to select the product. The weight is read from the scale, and a label is printed, which the operator affixes to the carton/combo. After a pallet is filled, a pallet label is automatically printed. For standard weight (fixed weight) products, the fill-to-weight application prints a label automatically when the weight is between the product-specific tolerances. Supervisors can report the amount of "give-away" (cumulative amount by which the standard weight was exceeded). For rapidly labeling standard weight cartons, the batch printing application prints and tracks serialized labels Label formats can be unique to a product (or use the default), and iCap supports ingredient labels or database-filled nutritional labels printing on a secondary label.

• product "hot keys" configurable by operator
• tare weights can be specific to a product
•  offline graphical label design (optional). Alternatively, Carlisle provides standard GS1 label formats for cartons and pallets
• local reports : product totals, giveaway
• multiple printers : can have a separate printer connected for pallet label, or for backup purposes

• Protector 3800 workstation, Datamax-O'Neil I-class printer with Protector Printer enclosure, food industry stand, scale with roller-top

For larger facilities, iCap can integrate with high-volume production lines for in-motion weighing and labeling. iCap has the advanced connectivity and error handling required to co-ordinate scales, photo-eyes, conveyors (via PLC integration), alarms, and reject mechanisms. If you are running mixed products on the same line, iCap can use an in-bound scanner to determine the product and apply the right labels.

• advanced applicator handling to monitor faults
• failover mode can use backup printer while changing media
• control of conveyors to optimize product spacing, line speed

• Protector 5800 workstation, in-feed conveyor (for product spacing), in-bound scanner, in-motion scale, Panther P8 label applicator, pallet label printer (also serves as backup for applicator)

Customers are often demanding fixed weight products. Unfortunately, this means there is product in excess of the "label weight" that you're not getting paid for.  Reducing this "give‑away" can save you a ton of money. iCap help you statistically prove that you're not illegally short‑changing your customer, while helping you keep the give-away to a minimum The iCap Net Weight Management application ensures compliance by requiring operators to sample a specific number of products to ensure that weights are statistically within tolerances. It then prints a pass/fail label, and a compliance report.

• Rules are pre-configured according to regulations
• In-line or off-line sampling modes
• Supports one or two scales simultaneously
• Schedule sampling by number of pieces, cartons, or pallets, and iCap will calculate when to sample and will instruct operator
• Capture reasons and corrective actions for issues
• Print Pass/Fail label with statistics for affixing to shipment
• Save .PDF report for recordkeeping

• Protector 3800 workstation, Datamax-O'Neil M-class printer in Protector printer enclosure, food industry stand, scale, handheld scanner

Multiple iCap stations can be integrated via Carlisle's Symphony MES (Informer). This provides central control of the product information, tare weights and labels, while collecting the data from each station for centralized reporting and traceability. Gain visibility of your production efficiency via the web-based KPI Dashboard, which shows top products, error conditions, yields, giveaways, and more…

• label design and deployment: ensure your approved labels are active on your iCap workstations
• Manage stations individually, or as part of a workgroup
• reporting via web browser - many standard reports for production, yield, efficiency, traceability
• event alerting with escalation paths, to minimize downtime
• partials support : operator with insufficient product can mark the box as a "partial", and complete filling it later
• production goal setting and monitoring: Monitor your progress towards production targets, and alert operators when the target is reached
• integrates with  inventory (Symphony WMS), so that all your production is automatically in inventory, and available to pick and ship

When you need an expanded level of traceability through complicated recipes and WIP processes, iCap/PTM can help. iCap/PTM is part of the Symphony Process Traceability Manager solution ("PTM"), which connects and co-ordinates the various production stations on your plant floor. Rather than being point solutions for weighing, labeling, and WIP tracking, these stations are part of a unified "Recipe Execution" system. A Recipe is more than a list of ingredients to Symphony. It is a series of steps that are taken to ensure that your product is built with consistent quality, including HACCP & GMP data collection. iCap/PTM is the plant floor software that follows these process steps, from mixing ingredients, taking temperatures, weighing, and even prompting operators to verify that the equipment has been cleaned. And most importantly, every process and ingredient is linked together with automatically-generated lot numbers, so you'll have full traceability. These steps can be executed on particular stations, in a prescribed order. Quality control steps can be added, such as checking temperatures, recording operator feedback, and of course measuring weights.

• automatically generate lot codes at Critical Control Points (CCPs)
• assign specific processes to an iCap station or group of iCap stations
• create and schedule batches of production that follows a specific recipe of processes and ingredients
• ensure recipes are followed within specified tolerances, or leave open for simplicity/discretion of operator
• track exceptions to the recipe (e.g. substitutions, recipe development, or approved quantity changes)
•  integrates with inventory (Symphony WMS) to deplete ingredients, packaging, add finished goods ready for shipping
• track stations, operators, process steps, inputs, output

In some scenarios, food processors need to package products according to orders (customer sales order or work orders). Using the Symphony Order Filling module, orders are co­ordinated with one or more iCap stations for fulfillment. When an order is complete, iCap notifies the operator, so that they can quickly change to another order

• Orders can be filled on one or more iCap stations simultaneously
• Labels can automatically contain order information
• Orders can originate from your external ERP system (optional)