Case Studies
Results from four decades of batch control and process automation work.
Our Work
Proof on the Plant Floor
The case studies below highlight projects across the industries we serve. Each one covers the challenge the customer brought us, the system BCI delivered and the results they measured afterward.
Featured Projects
Alcohol & EthanolWild Turkey Bourbon
Real estate constraints ruled out expanding the plant, so BCI mirrored the entire production process in a new, purpose-built distillery — protecting the taste profile while automating sequences.
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Food & BeverageContinental Mills
A plantwide conversion — iBatch to RSBatch, iFix to RSView SE, Sybase to SQL Server — executed during a single weekend shutdown with no lost production and two small punch list items.
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Food & BeverageKing's Hawaiian
One technology standard for 11 OEM machine builders on a 125,000-square-foot greenfield site. The bakery opened a week early and doubled bread production.
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Alcohol & EthanolGTEC Beverage Grade Ethanol
Retrofitting an obsolete control system in two phases, retaining all field wiring and devices and containing the major installation to five days during a scheduled shut-down.
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Pet FoodNatura Pet Food
A new Fremont, Nebraska plant automated from the ground up — batching, packaging and MES integration tracking ingredients from grain truck to grocery store delivery truck.
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PharmaceuticalVitamin Production
A validated ingredient automation system for a full vitamin line, built on a Master Recipe concept that executes Shop Floor Orders without an intermediate recipe management system.
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Pet FoodDAD'S Pet Food
Automating extruder ingredient delivery raised yields 10 percent and production more than 40 percent, and cut change-over times from 90 minutes to 30.
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Pet FoodWilliams-Carver
Partnering with an OEM to automate a formerly manual meat processing operation, replacing circular chart recorders with a SQL data logger that retains temperature records for five years.
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