Cerexio ProcessOne

Cerexio ProcessOne is an AI-optimised food and beverage manufacturing platform that connects production planning, production scheduling, recipes and BOMs, electronic batch records, machine management, quality assurance, HACCP, CCP monitoring, traceability, FEFO, cold storage, NCR/CAPA and industrial IoT connectivity in one manufacturing environment. Designed for food and beverage manufacturers, ProcessOne provides connected visibility from ingredients and batch planning through production, quality inspection, food safety controls, traceability, QA release and finished-goods storage. It supports recipe-driven batch and discrete production across operations such as mixing, cooking, filling and packing while providing manufacturing data for OEE, downtime and operational decision-making.

Food manufacturing software is a digital manufacturing system used to manage, monitor and optimise food production processes, from production planning and recipes to batch execution, quality, food safety, traceability and inventory. Modern food manufacturing software can connect production orders, bills of materials, recipes, machines, operators, ingredients, quality checks, HACCP critical control points, lot genealogy and finished goods. Cerexio ProcessOne extends these capabilities through production scheduling, electronic batch records, OEE monitoring, FEFO inventory control, cold-store monitoring, quality management, CAPA and Industrial IoT connectivity.

Cerexio ProcessOne manages food production by connecting production orders, recipes, bills of materials, material issues, production operations, machine status, labour assignments, quality checks and batch execution. Production teams can plan and schedule manufacturing activities while monitoring production progress and shop-floor conditions. ProcessOne supports recipe-driven batch and discrete production, including mixing, cooking, filling and packing lines. Its production management capabilities provide visibility across work orders, production status, machine performance, cycle counts, downtime, OEE and active manufacturing issues, helping teams coordinate production from planning through completion.

Yes. Cerexio ProcessOne provides recipe and Bill of Materials (BOM) management for food and beverage manufacturing, including version-controlled recipes, ingredient requirements and approval workflows. Recipes and BOMs can incorporate allergen declarations, Halal declarations, Critical Control Point (CCP) definitions and OEM or customer-specific product variants where configured. Version control helps ensure that approved production teams work with the intended recipe or BOM rather than obsolete manufacturing instructions. This connects formulation management with production planning, batch execution, material traceability and quality control.

Cerexio ProcessOne supports Digital Batch Records for electronic batch execution, material verification, production activities, HACCP/CCP capture, in-process quality checks, label verification and QA release workflows. Operators can scan and verify material lots, including FEFO, expiry and Halal-related requirements where configured, while manufacturing information is captured digitally against the relevant batch. Configured CCP controls can block progression when critical limits are breached. Digital batch records create a structured manufacturing history that can connect production, quality, material lots and batch genealogy, reducing dependence on fragmented paper-based records.

ProcessOne supports HACCP and Critical Control Point (CCP) monitoring by providing live visibility into configured food-safety control points across active production batches. Depending on the manufacturing process, monitored parameters can include cooking, cooling and freezing temperatures, metal detection and cold-chain conditions. Critical limits can be configured so that a deviation can trigger appropriate blocking or escalation workflows. By connecting HACCP monitoring with digital batch records, quality processes and traceability, ProcessOne helps food manufacturers capture food-safety information within the production workflow rather than managing HACCP checks as a disconnected activity.

Cerexio ProcessOne provides food manufacturing traceability by connecting material lots, ingredients, batches, production processes, equipment and finished goods into a structured genealogy. Its Traceability capabilities support forward and backward lot genealogy, material lot registration and batch history. This allows authorised teams to understand relationships between incoming materials and manufactured products and to investigate affected batches when a quality, food-safety or customer issue occurs. Connected batch traceability helps food manufacturers strengthen ingredient traceability, lot traceability, production genealogy and end-to-end manufacturing visibility.

Yes. ProcessOne supports food recall analysis through forward and backward lot genealogy and recall impact simulation. Manufacturers can use connected material, batch and production information to identify relationships between ingredient lots, production batches and affected finished goods. This is particularly valuable during a potential food recall, customer complaint, quality event or food-safety investigation because teams can work from structured genealogy rather than manually reconstructing relationships across disconnected records. ProcessOne therefore connects lot traceability, batch genealogy, material genealogy and recall-impact analysis within the broader food manufacturing workflow.

Cerexio ProcessOne supports First-Expired-First-Out (FEFO) inventory control for ingredients, packaging materials and frozen finished goods, together with cold-store and temperature monitoring. FEFO helps manufacturers prioritise inventory based on expiry requirements rather than simply receiving date. ProcessOne can also support cold-room temperature monitoring and blocked-stock enforcement, helping teams identify inventory that should not be issued or released according to configured controls. These capabilities connect food inventory management, expiry management, cold storage, cold-chain monitoring and production material control.

Cerexio ProcessOne helps manufacturers improve Overall Equipment Effectiveness (OEE) by connecting production output, machine performance, downtime, cycle counts, machine status and operational data. The platform's Executive Dashboard can provide plant-level visibility into OEE, production output, quality yield and downtime, while Machine Management provides machine status, OEE trends, parameters, downtime and maintenance history. This helps teams identify equipment availability issues, downtime events, performance losses and utilisation problems that can affect production efficiency and OEE. OEE improvement should be evaluated against each plant's baseline, processes and operating conditions rather than assumed as a guaranteed percentage.

ProcessOne provides machine management and real-time shop-floor visibility for food manufacturing equipment, including machine status, OEE trends, parameters, downtime, maintenance history and active failures. Its Control Centre can display per-machine run/stop status, current production order, cycle count, OEE and active failures for control-room monitoring. ProcessOne can also connect shop-floor equipment through supported Industrial IoT protocols and connectivity technologies, enabling manufacturing teams to bring machine and production information into a common operational environment.

Yes. Cerexio ProcessOne provides finite-capacity production scheduling across departments and machines using a Gantt-based scheduling environment. Production planners can work with machine and departmental capacity, dependencies, scheduling conflicts and changeovers while coordinating production orders. Drag-and-drop scheduling and visual planning can help planners understand how changes affect the manufacturing schedule. This connects production planning with actual shop-floor capacity and machine availability instead of relying solely on static production schedules.

ProcessOne supports food quality assurance through configurable QA plans, in-process and final inspections, SPC control charts, sampling plans, CoA management and non-conformance workflows. Quality teams can capture inspection results and quality checkpoints within production processes while monitoring process variation through Statistical Process Control (SPC). Non-conformances can be investigated and connected to root-cause analysis, disposition and CAPA workflows. This creates a stronger relationship between food production, quality control, food safety, batch records and traceability.

Yes. ProcessOne provides an Integration Hub designed to connect manufacturing operations with supported enterprise and industrial systems. The supplied platform architecture includes connectors for SAP S/4HANA, Oracle NetSuite, Microsoft Dynamics 365, LIMS and historians, together with message queues, checksums and reconciliation capabilities. ProcessOne also provides Industrial IoT connectivity for supported shop-floor technologies. Actual integration scope depends on the customer's existing systems, architecture, interfaces and implementation requirements, so individual ERP, LIMS, historian and automation integrations should be confirmed during technical discovery.

ProcessOne connects food manufacturing equipment and shop-floor data through Industrial IoT technologies and supported industrial communication protocols. Its IoT Connectivity module supports technologies including OPC UA, Siemens S7, Modbus, MQTT, Euromap 63/77 and FANUC FOCAS, with gateways and live tag streaming. This allows relevant machine and operational data to be brought into the manufacturing environment for machine monitoring, OEE analysis, production visibility and operational intelligence. The exact connectivity architecture depends on the equipment, PLCs, gateways, network environment and protocols deployed at the manufacturing site.

AI can improve food and beverage manufacturing by analysing production, machine, quality, batch and operational data to identify patterns, anomalies, risks and improvement opportunities. In ProcessOne, AI can support manufacturing intelligence such as predictive insights, pattern analysis, AI-assisted root-cause investigation, OEE analysis and natural-language reporting where configured. For example, teams can use manufacturing data to investigate recurring machine failures, production losses, quality deviations, downtime patterns and batch issues. This helps production, quality, engineering and management teams move from manually searching through disconnected records towards more informed, data-driven operational decisions.

ProcessOne is a connected food and beverage manufacturing platform that brings together capabilities commonly associated with production management, manufacturing execution, quality, traceability, food safety, inventory control, machine monitoring and manufacturing intelligence. An MES generally focuses on manufacturing execution and shop-floor operations, while an ERP generally manages broader enterprise processes such as finance, procurement, inventory and supply chain. ProcessOne is specifically structured around food and beverage manufacturing workflows, including recipes and BOMs, batch execution, HACCP/CCP monitoring, traceability, FEFO, quality, OEE, machine connectivity and production scheduling. Its relationship with an organisation's existing MES or ERP should be determined according to the required architecture and integration scope.

Cerexio ProcessOne supports Industry 4.0 food manufacturing by connecting production systems, machines, Industrial IoT data, recipes, electronic batch records, quality controls, traceability and manufacturing analytics. Supported technologies such as OPC UA, Siemens S7, Modbus and MQTT can connect relevant shop-floor data, while machine monitoring, OEE analytics, digital batch execution and real-time operational dashboards provide greater manufacturing visibility. This creates a foundation for smart food factories where production, equipment, quality and food-safety information can be connected and analysed within a unified manufacturing environment.