Process Control System

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Process Control System

Process Automation

in manageable stages

Become faster, increase quality and still remain flexible. Process automation in manageable, perfectly coordinated stages.
Achieve a substantial increase in your productivity!

ESAweight is our modularly structured process control system, which has been developed precisely to meet the needs of production facilities in the bulk materials industry. ESAweight is configured for the processes of your production facility and your entire flow of goods. It can be extended modularly at any time in line with your growth. Furthermore, we cover many elements of a traditional Manufacturing Execution System (MES), such as production management - also across different locations - or comprehensive recording of operating data. This means that you only need ESAweight as a single system between the plant controller and your ERP system. This reduces the complexity of your systems many times over.

Control and monitoring of batch processes (batch control)
Processing of solid and liquid substances
Data exchange with ERP system
Integration of automated storage systems and driverless transport systems
Overall Equipment Effectiveness - OEE figures for increasing overall efficiency

Why ESAweight?

This is why!

Transparent

Do you want to control your production and flow of goods efficiently and successfully? Then you need transparency and control in all process steps, evaluations as a basis for decision-making, reports, batch logs, OEE (overall equipment efficiency) figures, etc.

Traceable

Traceability as per EU regulation 178/2002: ESAweight ensures efficient and unbroken tracing of all product flows within the whole automated system.
Legal security, cost savings through avoided recall campaigns and quality assurance are individually calculable benefits you can count on!

Sustainable

Benefit from our growth and our continuously updated products. With a software maintenance contract, we keep your system up to date.

Free-of-charge use of our technical support hotline is also included.

user-friendly

Easy-to-operate user interface, intuitive user guidance, cohesive, modern look & feel, and individual work instructions.

All this guarantees straightforward production control.

Tailor-made

Thanks to its modular structure, ESAweight can be extended at any time, growing with your system at a reasonable, predictable cost.
Many different requirements - we supply you with tailor-made, optimised solutions for your company.

Innovative

Provision of innovative solutions is our highest priority and the main driving force behind our everyday actions. We embrace the responsibility and supply innovative products.

Industry 4.0 with ESA, cutting-edge technology!

ESAweight MANAGER

THE ADMINISTRATOR OF ALL DATA

ESAweight Manager is used for defining and managing all data as well as for preparing the entire configuration of the ESAweight process control system. All system-specific parameters, such as lines, stations, scales/weighing machines, storage locations, etc., are freely configurable.

Based on an MS SQL database and MS Windows, the data is managed centrally.All the production data is fed back from individual stations to the ESAweight database, from where it can be retrieved, appropriately prepared. By means of the integrated report editor incl. client administration, evaluations and declarations can be created and adapted to meet your needs.

Based on concrete requirements, ESAweight Manager has been continuously updated, thereby providing a selection of comprehensive functions for production, merchandise management, logistics, maintenance and management, including:

Master data management (components, orders/jobs, stock levels, etc.)
RFID user administration featuring RFID with integrated language changeover
Column and table views are freely configurable
Client administration with integrated report generator
Standard interface to recipe optimisation programs, such as Bestmix, Hybrimin, etc.
Bar code support as per EAN 128
Contamination matrix based on units
Storable work instructions
Warehouse management with integrated inventory function
Historical stock levels
Traceability as per EU regulation 178/2002
Connection to common ERP systems (SAP, Navision, Adifo, etc.)

ESAweight MODULES

ESA covers all production and storage processes from inbound delivery to production through to stock removal.
The following list of modules is supplemented by additional sector-specific production modules.

Inbound Delivery
ESAtrade

Acceptance of your delivered raw materials takes place reliably and efficiently. Whether it be loose or bagged goods, with or without sampling - no matter how complex the delivery of your goods may be - ESAtrade meets your requirements.

Traceability thanks to unique transaction numbers, data exchange with the ERP system for purchase orders/deliveries and stocks, weight checking, connection to weighbridges, sampling with data acquisition, label printing for reference samples, fully automatic batch code generation, delivery documents, hazardous goods certificates - An excerpt from the list of inbound delivery tasks - We take care of everything!

Fully automatic batch code generation
Transaction-guided or manual first/second weighing
Article inspection before the acceptance process
Truck image storage from WebCAM during weighing

OUTBOUND DELIVERY
ESAtrade

ESAtrade supports you in all the processes for delivering your finished products. In ESAtrade, customer orders are accepted, picking and loading are controlled by user guidance, and finally the dispatch notes are generated.

Traceability thanks to unique transaction numbers, data exchange with the ERP system for deliveries, weight checking, connection to weighbridges, delivery documents, hazardous goods certificates - An excerpt from the list of outbound delivery tasks - We take care of everything!

Logical weight checking for bagged goods
Weighing slip printing - multi-client capability (various logos)
Weighing scale drivers available for all conventional weighing terminals
Data archiving of all weight measurements with calibration memory number

WAREHOUSE MANAGEMENT
ESAlogistics

The warehouse management module enables perfect control of your materials and merchandise management for loose and bagged goods. ESAlogistics supports the management of your goods from goods acceptance to stock transfer, processing, storage and picking through to loading. Particular attention is paid here to simple user guidance and manageability.

User-guided goods receipt and goods issue
User guidance via handheld or stacker terminals
Inventory management at batch level
Pallet management with incoming/outgoing ledger for suppliers, forwarding agents or hauliers

BAGGING MODULE
ESApack

For filling and bagging, ESApack and ESAbigbag can meet all your needs. Specification and securing of packaging, labelling, bag-bottom inscription, declaration, weight checking - everything that you need for this purpose. The flexible design of interfaces provides a wide variety of options - from the mere displaying of bagging data through to full integration of downstream systems.

Automatic transfer of bagging orders
Complete integration of check weighers
Automatic or manual data transfer
Full traceability as per EU regulation no. 178/2002

PRESS MODULE
ESApress

Expertise is also called for in pellet production. With ESApress, pellet presses are controlled flexibly and the settings made for e.g. expanders, hygienisation, liquid or steam supply. All data is visualised online and logged on a lot and batch-specific basis for traceability.

Recipe-controlled liquid addition
Order-related trend recording
Batch-specific traceability
Automatic press start-up

MIXING TECHNOLOGY
ESAmix

ESAmix controls the mixing process according to the production recipe, takes care of fluid additives and requests the addition of components. Mixer data, such as speed or processing temperature, is displayed using trends and recorded for traceability.

Mixer weight checking
Batch-specific trend recording of temperatures,
mixing times and speeds
Connection of metal separators and detectors
Traceability as per EU regulation no. 178/2002

MANUAL DOSING
ESAcom

Efficient and precise dosiing by hand with ESAcom. The components are taken either from bags/containers or from automatically delivered crates and weighed manually. Bar code-assisted product identification and "pick to light" systems provide traceable reliability.

Article identification using bar code scanner EAN 128
Automatic batch code transfer on article scanning
Container management with label printing
Order-related or chaotic pre-production

AUTOMATIC DOSING
ESAweight runtime

ESAweight runtime provides for fully automatic dosing of solid and liquid substances in conjunction with the PLC. The required amounts of raw materials or semi-finished products to be delivered are calculated from the recipes and orders, then dosed. Lines can be configured flexibly and changed over conveniently. The central system visualisation allows the front end to be started and hence current lines to be monitored and controlled.

Automatic overrun optimisation
Self-optimising metering curve function
Fully automatic metering with visualisation
Contamination and material availability check

STOCK TRANSFER
ESAtrans

Flexible silo provisioning and efficient stock transfer options are a basic prerequisite for the smooth transfer of goods to the production processes. The ESAtrans - stock transfer module is a professional system for placing goods in storage and transferring them. First-in/first-out principle, activation of production preparation processes, such as cleaning, automated stock transfer processes triggered by time or event (e.g. by temperature), minimum stock warnings, requirement messages from production. Quality and process-oriented procedures - tailored precisely to your needs.

First-in/first-out principle
Point of origin and destination checking
Carrying of the batch code
Quality assurance

Screenshots

ESA Process Control System

ESAlogistics

PERFECT CONTROL OF YOUR MATERIALS MANAGEMENT

The warehouse management software enables perfect control of your material flows. ESAlogistics supports the management of your raw materials and finished products from goods acceptance to production replenishment, storage and picking through to loading. Special attention is paid here to batch traceability and the shelf life of goods.

MATERIAL FLOW MANAGEMENT

ESAmfm

Integrated in ESAweight Manager, the material flow manager is the central control element for all transport tasks. It allows logistical goods movements to be controlled and monitored transparently from the point of origin to the destination.

transfer orders are triggered by freely definable strategies and control:

Driverless transport systems (FTS/APM)
High-bay warehouses (HLR)
Automatic conveyor systems for small-parts warehouses
User-guided stock movements via handheld or stacker terminals

Further Functionalities

Discover the multitude of possibilities

Maintenance Manager
ESAmaint

Management of the defined maintenance and servicing work for individual units or for an entire system:

straightforward and well organised! The ESAmaint maintenance manager thinks for itself, creating the freedom you need for important things. ESAmaint is the perfect package for your maintenance tasks - whether it be simple unit servicing or maintenance of an entire industrial plant.

The various maintenance tasks for entire systems or individual units are defined in the maintenance plan. This definition includes the necessary activities in a maintenance process and the frequency at which servicing must be performed.

Functions:

Maintenance planning for individual units or entire systems
Freely definable configuration of systems/units
Grouping of system parts using leading units
Service interval definable in terms of hours run, switching cycles or a fixed time frame
Storable descriptions of the maintenance activities to be performed.
Linking via Windows file path: PDF, text file, etc.
Work due is indicated as standard four weeks in advance, although this is freely configurable.
A report function allows a list of the overdue maintenance tasks to be printed.
Excel import function (optional)

TRACEABILITY
ESAtrace

Efficient and seamless traceability of all raw materials and finished products as per EU regulation no. 178/2002

ESAtrace ensures unbroken tracing of all product flows within the whole production process. This development is based on EU regulation 178/2002. Furthermore, ESAtrace scores highly with additional features. Batch-specific traceability reduces the scope of any necessary recalls to a minimum.

Functions:

Seamless, clear traceability from the inbound delivery of raw materials to the outbound delivery of finished products
Various search criteria, including batch code as well as suppliers, customers, lots, etc.
Provision of samples
Convenient tree views with a direct link to the process log

ESAweight
DATA EXCHANGE

The standardized software solution. For connection ERP systems to the ESAweight process control system

In order to reduce the expenditure for duplicate data entry and master data maintenance, data is exchanged between the ERP system and our process control system. The lead system is defined in the respective data area. Our data import checks the data contained therein for completeness and correctness.

Functions:

master data: articles, customers, supplier, declarations
Various search criteria, including batch code as well as suppliers, customers, lots, etc.
recipes from Bestmix or Hybrimin
raw material acceptance
production, inward stock movements
stock movement / inventory postings
outgoing goods

Here is an excerpt from the list of ERP systems already connected: SAP, Microsoft Dynamics AX, Microsoft Dynamics Nav (Navision), BioStockManager, AdifoSoftware, Orlando, Business Software, CWG Business Software, ABAS, AS400, Proalpha.

Process Automation