Chemical companies often strive to earn profits due to increased competition from international players and stringent government norms due to environmental issues. Companies need to get the best out of their processes with least investment to maintain profitability and market share.
For this many companies resort to Enterprise Applications which integrate and automate their processes thus reducing the cost and increasing the efficiency manifold. The problems faced by chemical companies are similar to any other process manufacturers but in addition to that chemical manufacturing software have some unique requirements like
They involve only mixing of certain chemicals in as per formulae. There is no reaction, no change in quantity and generally there is no by-product. This is comparatively simple production process.
Here the chemicals put together in a given ratio and pre-defined processes actually go through certain reactions which change the character of the output totally. e.g. from liquids to solids. The final manufactured quantity may not simply be a total of two or three ingredients but may be less or may increase in volume, though not in weight. There would be by-products too. The reaction being complex, the output may not be as per inputs and as the batch goes through series of QC tests, certain chemicals may be added during process to get the right output. Batch yield reports are typically a critical requirement in this type of production. The change in yield during chemical process can result in change in batch cost significantly.
ebizframe chemical erp software handles batch production based discreet manufacturing chemical industry successfully. It can also handle continuous process industry that produces in batches but process in continuous, i.e. input from one end of the production line comes out directly as a finished production, with no work in process separation or recording possible in between various processes e.g. Plastic Sheets Production.
There is a mix of continuous process and batch production also, like in Milk powder and Edible oils. These can be handled in with a little customization in ebizframe. In such processes, the data is generally captured through PLC machines and this can be imported into erp system easily.
One can define the Bill of Materials (generally called ‘recipe’ in chemical pharmacy parlance) for a production batch. But, the input quantities can change based on potency or purity of the raw materials. Thus, input of an acid in a batch of 10kg may be 200 ml for 98% purity. If the available stock is of 96%, this quantity will change to, say 210 ml. Therefore, the issue slip needs to be flexible to allow this.
Critical features of ebizframe ERP Software for Chemical Industry are listed below: