FeedSmart Recipe Optimizer

Capture savings hidden in your current recipes now and base any future feeding solution purchase on factual data

The Total Savings Solution

The FeedSmart™ Recipe Optimizer is a powerful tool developed by Coperion K-Tron that adds a new level of functionality for processors wishing to minimize ingredient costs and evaluate options. It is complemented by the TruCost™ Savings Comparator, a tool to support you in making the best possible decision when it comes time to purchase a new feeding system. These two essential tools are combined in an easy-to-use Microsoft® Excel® Workbook which Coperion K-Tron is offering free of charge as a download from this website.

The FeedSmart™ Recipe Optimizer tool exploits permitted variations in a recipe’s ingredient proportions to engineer maximum savings and determine the lowest possible cost for every blend, formulation or compound you process. Based on the costs, proportions, tolerances and feeding accuracies entered, the Recipe Optimizer minimizes total ingredient cost by strategically replacing expensive ingredients with less costly recipe components, all without violating quality limits.

When it comes to performing financial analyses, predicting long-term project savings and identifying your favored supplier for feeder systems, the TruCost™ Savings Comparator is the tool called for. TruCost combines data from as many as twenty FeedSmart Recipes with acquisition and support cost data you enter, and then compares supplier offerings and projects costs and savings over process lifetimes of up to twenty years.

Benefits & Features

  • Key in your own recipe application data and let FeedSmart do the rest
  • See how to cut costs today with your current feeding system, and plan the most cost-efficient recipes and feeding systems for tomorrow's applications
  • Calculate savings, payback time and return on investment on a new feeder or an entire feeding system
  • Simplify the feeder purchase decision using FeedSmart's Total Cost Worksheet to combine ingredient savings with total acquisition costs
  • Experiment with What if? questions to see their effects on savings
  • Conform to all ingredient tolerances and quality standards
  • System Optimization feature assures that acceptable variations in one ingredient won't cause other recipe components to violate their allowable proportion limits
  • See why it pays to feed even low-cost ingredients more accurately
  • Instantly compute the efficiency of current or prospective feeding systems
  • Compute cost efficiency ratings and blend uniformity indices for your current recipe and FeedSmart's cost minimized solutions
  • FeedSmart's Efficiency Grid dynamically illustrates the savings you'll realize from optimizing your current recipes, and the added savings gained through improved blend uniformity made possible by better feeder performance
  • Identify the feeders that are most critical to saving you money
  • Helps you make the 'volumetric or gravimetric' feeder investment decision
  • Quickly perform sensitivity analyses on the cost, tolerances and feeder accuracy of any ingredient
  • Use FeedSmart's QuiCalc function to instantly see the savings associated with any degree of systemwide improvement to feeder accuracy
  • FeedSmart's Savings Builder worksheet lets you combine up to 20 recipe solutions to calculate total ingredient savings available with your current or prospective feeding systems
  • FeedSmart's Recipe Log lets you save and retrieve up to 50 recipe solutions
  • Tips and Techniques section provides practical hints to help you get the most out of FeedSmart. Tech Talk section profiles the innovative concepts behind FeedSmart
  • Work in any currency or weight unit for recipes of up to 6 ingredients in any continuous process feeding application
  • Export results to other programs

Cutting Costs with Coperion K-Tron


FeedSmart Recipe Optimizer

Based on the recipe entered into the feeder operator interface, and other application data, FeedSmart identifies the recipe’s most expensive ingredient and minimizes its presence according to the application’s quality tolerances. Once minimized, FeedSmart 'freezes' the ingredient’s proportion and recalculates the remaining ingredients according to their relative proportions in the original recipe. FeedSmart then moves on to the next-most-expensive ingredient to repeat the process until the recipe is fully optimized.

Constrained by the upper and lower tolerance limits set for each ingredient being fed, expensive components are progressively replaced with lower-cost ingredients, minimizing total ingredient cost without violating established tolerances.

After computing the lowest-cost recipe, FeedSmart's integrated System Optimization feature automatically adjusts the formulation to assure that allowable variations in one ingredient will not cause other ingredients to violate their specified proportions in the final blend.


FeedSmart’s Worksheets

To optimize a recipe, users go to the Main Worksheet and enter the application’s original data (costs, targeted proportions, and upper and lower tolerance limits) along with each feeder’s expected repeatability/accuracy performance. FeedSmart instantly generates the optimized recipe and calculates hourly, weekly and yearly savings. Savings are immediately available for existing installations. Other worksheets let you see the effects of varying feeder accuracies and ingredient tolerances.

For new feeding systems, or to compare the savings between alternative systems, FeedSmart’s Feeder Performance Comparison (FPC) Worksheet permits the entry of a second set of feeder performance data. With the Main Worksheet containing the original application along with one set of feeder performance data, a second data set is entered on the FPC Worksheet. The resulting optimized recipes and their associated savings are displayed and compared. Payback time and return on investment are also calculated for each scenario.

A third form, the Ingredient Tolerance Comparison (ITC) Worksheet, allows processors to quickly see the effect any change in ingredient tolerance has on total recipe cost. The fourth and last worksheet, FeedSmart’s Total Cost Worksheet, enables users to combine recipe savings with total feeder system acquisition cost, and compare the result among alternative systems with differing performance levels.

Once users familiarize themselves with FeedSmart’s basic functions, they will see it is also possible to easily pose ‘what if?’ questions, perform sensitivity analyses, and identify cost-critical ingredients and performance-critical feeders.


The Efficiency Grid

In addition to its cost-saving potential, FeedSmart’s tolerance-based recipe model also suggests two useful measures of process efficiency:

  • Recipe Efficiency and
  • Feeding Efficiency.

FeedSmart’s Efficiency Grid, presented on the FPC Worksheet, combines these two efficiency measures in an integrated graphic to provide a compelling snapshot of current and potential savings. It provides a clear and dynamically changing visualization of the improvement in recipe efficiency enabled in a tolerance-based approach, as well as the added savings realized through improved feeder performance.



Recipe Efficiency

With FeedSmart’s ability to operate anywhere within a band of acceptable proportions for each ingredient based on product quality standards, total recipe cost can vary over a defined range, depending on the chosen proportions for each ingredient. This suggests the concept of Recipe Efficiency, a measure of where a given recipe exists on its cost spectrum. 0% efficiency represents the recipe's maximum theoretical cost, and 100% represents its minimum theoretical cost. Where a given recipe lies on this spectrum provides a measure of the potential for further cost reduction through improved feeding performance.

Working behind the scenes on a separate worksheet, FeedSmart computes the minimum theoretical cost for the currently entered recipe by replacing user-entered feeder accuracy values with an ideal 'zero-error' feeding system, and then applying its standard cost-minimization procedure. The maximum theoretical cost is computed on another hidden worksheet that has been modified to determine the highest, not lowest possible recipe cost. With these cost limits calculated, FeedSmart displays the efficiencies of the original and optimized recipes.


Feeding Efficiency

But how can feeder performance-related efficiencies be quantified and captured? While improved feeding accuracy has long been employed to reduce costs by avoiding the need to overfeed critical or expensive ingredients, many processors following the traditional definition of a recipe find it difficult to justify the added investment typically associated with improved levels of feeding performance.

According to a traditional “target-value” recipe where ingredient setpoints are fixed, as long as established quality limits are not violated, no specific material savings can be realized, regardless of the feeding system employed. In addition, the ongoing variability of the final product being produced when using a less accurate feeding system will be higher. However, by using the FeedSmart™ Recipe Optimizer to convert to a “tolerance-based” recipe where ingredient setpoints are adjusted to their optimum level without violating established product quality standards, and by employing a more accurate feeding system, processors can realize maximum savings. FeedSmart’s tolerance-based optimization changes the logic, and each improvement in feeding accuracy reduces recipe cost by a specific, calculable and achievable amount. It turns any improvement in feeding accuracy, no matter how small, into a lower cost recipe.

To gauge how well a feeding system exploits the potential savings implicit in the recipe tolerance model, a new term, Feeding Efficiency, is introduced. Like Recipe Efficiency, Feeding Efficiency spans a scale from 0 to 100%. But unlike Recipe Efficiency (that only has significance in the context of the total recipe), Feeding Efficiency can be applied equally to a single feeder or an entire feeding system. 100% Feeding Efficiency is defined as a hypothetical 'zero-error' feeder, and 0% Feeding Efficiency is defined as the poorest feeder performance level that would not violate either quality assurance boundary for a given ingredient (any performance worse than that would be irrelevant to the application). To compose a single measure of Feeding Efficiency for the total recipe, FeedSmart displays a weighted average of individual ingredient Feeding Efficiencies based on their relative ingredient proportions.


TruCost Savings Comparator

Coperion K-Tron’s TruCost™ Savings Comparator combines the recipe profile you build in FeedSmart with acquisition cost data and estimated support costs to produce a Total Savings Solution customized to your specific process operation.

TruCost enables you to:

  • Identify favored supplier in areas of acquisition cost, total ingredient savings, support cost, and total comparative savings.
  • Evaluate offerings from any number of feeder system suppliers.
  • Compute the savings achievable with improved feeder performance.
  • Calculate project savings over process lifetimes up to 20 years.

TruCost is fully supplier-independent and results depend only on user data. It calculates and compares feeding system return on investment and payback time for each supplier. Furthermore it charts comparative total savings over the process lifetime and hourly comparative savings in each cost area. TruCost allows user entry of inflation and interest rates for accurate net present value (NPV) analysis.

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