Lighthouse ERP for the biofuels industry is designed to streamline all the operations and processes. Our ERP software is constantly upgrading and evolving for 35+ years to meet modern industry requirements. Lighthouse Info Systems provides cost-effective ERP software for Ethanol Manufacturing. Lighthouse Biofuel ERP delivers outstanding performance and impeccable services to improve the efficiency of operations in ethanol manufacturing.
To achieve energy security and to transition to a low-carbon economy, the Government of India brought a National Policy on Biofuels in 2018 under the Ethanol Blended Petrol (EBP) program and set a target of 20% blending of ethanol in petrol by 2030.
Several Industry Players have set up grain or molasses-based bio-ethanol plants to cater to this demand for ethanol blending in petrol arising from government regulations.
The grain-based ethanol plant process will have the following steps, namely - Grain Receipt and Storage, Grain Handling and Milling, Slurry Preparation/Liquefaction, Saccharification and Fermentation, Multi-Pressure Distillation, MSDH, Decantation, Multi-Effect Evaporation, DDGS Dryer &Product Storage.
Biofuel manufacturing plants also utilize raw water, steam, power, plant air, instrument air, and nitrogen.
The industry uses grains such as damaged food grains, such as broken rice & maize as basic raw materials.
Besides this, processing chemicals are used for the production of Ethanol. Along with Ethanol, Biofuel plants also produce byproducts such as CO2, Fusel Oil, DDGS, Corn Oil.
Ethanol production relies on key raw materials like grains, sugarcane, and coal. Due to their seasonal nature, the prices of these materials fluctuate significantly, impacting overall production costs.
The quality and purity of ethanol is a major criterion for passing clients material acceptability. Hence tracking of Ethanol batches during storage and transportation solutions is crucial.
Energy consumption tracking is a crucial factor in production costing, which involves various factors including coal, water and other utilities usage.
Maximizing yield is essential for productivity and cost-effectiveness. Tracking of Production recovery at each process stage is a challenging task.
ERP for ethanol industry helps monitor raw material supply chain requirements considering in stock and pipeline stock. This helps in planning for price fluctuations.
Manufacturers can streamline logistics by tracking vehicle movement from plant to customer improving overall supply chain efficiency. It also tracks and controls logistics costs associated with material delivery.
Lighthouse Erp software tracks energy and water consumption at every stage. The Plant maintenance system helps in proper equipment reliability management to increase up-time.
ERP software monitors essential metrics like yield, fermentation efficiency, and downtime, enabling plants to track bottlenecks and optimize output.
Plan production with detailed item BOMs, monthly production schedules, and precise control over process parameters like temperature and pressure.
Manage Production in each batch with Lot & Godown Control enabling tracking of inventory with efficient workflow throughout production.
Standard to actual yield calculations to manage variance analysis
Comprehensive Quality Control with Accurate MIS Reporting on Inventory, Raw Material Quality, Production Costs, and Plant Performance.
PLC & DCS Integration with ERP Software
Quality Labs Integration for raw material & finished product testing, useful to maintain consistent quality standards and compliance.
Calculate precise raw material costs based on rates of various types of Grain/Molasses & expected recovery rates.
All inward and outward movement is tracked at Security Gate, Weighbridge, Quality lab and store/ yard locations.
Control of Material Stock at Raw material Stock Yard, Crusher, discharge area, and bagging area.
Plant movement tracking across various scenarios, including Inward, Outward, Stores Related, Purchase or Sales Return, Inter-Yard Transfers, Waste, or Scrap movement.
Carry out Batch-wise semi-finished and WIP pricing through ERP for manufacturing and getting accurate cost visibility across manufacturing stages.
Production cost analysis with Per-ton costing based on raw materials, consumables, fuel, and electricity.
Manage Division-wise & consolidated finance books Costing/ efficiency, Ledgers & Profitability. Inter-division Sales & Purchases on a real-time basis.
Manage Accounts approval and bill passing for Purchases, Services (job work/contractors), or Freight scenarios with Lighthouse ERP.
Various Stock MIS with 10-level drill down: Group -> Entity -> Division -> Plant -> Dept -> Cost Center -> Equipment -> Item Group -> Item -> Issue Slip.
Multi-level order cycle at Contract and Sales Order levels to meet tender-based delivery schedules.
Delivery orders can be made based on Sales Orders with the details of the actual product to be dispatched to a specific location- depot (with Grade-wise product details).
Sales Invoicing is generated instantly, by linking to Weighslips and Delivery Orders
Complete Control of Freight orders and Freight Costs.