Precision Process MRP for Chemicals & Pharma
Eliminate active ingredient variance, enforce strict QC quarantine gates, and automate Certificate of Analysis (COA) generation across complex multi-stage batch reactions.
What is Included in the Process MRP Suite
Engineered specifically for formulation chemistry where raw material purity fluctuations dictate dynamic shop-floor recipe execution.
Potency Auto-Adjustment
Automatic Formula Balancing: The system automatically calculates exact raw material quantities based on supplier purity percentages to ensure exact batch strength without scrap.
Virtual Quarantine Gates
Automatic stock isolation upon gate entry. Work orders cannot consume raw lots until lab chemists record approved test parameters.
Multi-Stage Reaction BoM
Multi-level bill of materials modeling temperature phases, catalyst additions, reflux durations, and condensation losses.
Automated Digital COA
One-click Quality Test Certificates (COA): Automatically generates client-ready Certificates of Analysis compiling lab test results once approved.
Live Tank Monitoring & FEFO Expiry Dispatch
Strict First-Expiry-First-Out barcode allocation prevents expired chemical stock and alerts supervisors on retest intervals.
Schedule M Audit Dossier
Complete Electronic Batch Records (eBMR) with user timestamps, change histories, and tamper-proof compliance logs.
Active Ingredient Potency & Overdosing Simulator
Discover how much working capital your plant leaks each year by formulating with static Bills of Materials instead of dynamic assay compensation.
Why Generic ERPs & Tally Fail in Chemical Manufacturing
See how Arihant AI eliminates the dangerous offline Excel spreadsheets and manual batch records that generic ERPs force upon chemical plants.
| Capability / Shop-Floor Reality | Arihant AI Chemical MRP | Tally Prime / Busy | Excel Spreadsheets | Legacy SAP / MS Dynamics |
|---|---|---|---|---|
| Dynamic Active Potency Auto-Adjustment |
Native Algorithm
Automatically recalculates active vs solvent charge based on specific incoming lot HPLC assay %.
|
Static BOM Only
Assumes 100% purity; leads to batch failure or severe overdosing.
|
High Risk
Formulas easily overwritten or corrupted by shift operators.
|
High Custom Code
Requires expensive ABAP custom programming & consulting.
|
| Virtual Quarantine & Lab QC Lockdown |
Automated 2-Step Gate
Stock auto-locks upon gate inward; cannot be consumed until QA signs off test parameters.
|
No Gate Control
Uninspected material freely issued to production orders.
|
No Enforcement
Paper tags only; zero digital barrier preventing consumption.
|
SAP QM Module
Rigid, complex navigation with steep operator training curve.
|
| Schedule M & 21 CFR Part 11 Electronic BMR |
Tamper-Proof Audit Trail
Immutable digital batch records with operator timestamps, electronic signatures, and change logs.
|
Manual Paper Only
Physical paper BMR binders filled after shift; high regulatory risk.
|
Fails Audits
No immutable log or signature verification; fails FDA inspections.
|
Available via MES
Requires expensive third-party MES add-on licensing.
|
| 1-Click Cryptographic Digital COA |
Automated with QR
Pulls live batch QC test results directly into customer-ready Certificate of Analysis in 5 seconds.
|
Not Supported
Manually retyped into Word/Excel; takes 40+ mins per dispatch.
|
High Typo Rate
Prone to copy-paste errors across customer specification limits.
|
Complex Setup
Requires Crystal Reports / Adobe Document Services developer.
|
| By-Product, Co-Product & Solvent Recovery |
Multi-Tier Yield Costing
Recovers distilled solvents with secondary batch costing credits and environmental reporting.
|
Single SKU Focus
Forces manual journal entries and guesswork unit costs.
|
Untracked Leakage
Distillation loss is rarely reconciled with financial books.
|
Complex Co-Product BoM
High overhead configuring joint production cost apportionment.
|
5-Stage Chemical Reaction Lifecycle
From tanker weighbridge inward to lab assay compensation, reactor phase execution, and customer COA dispatch.
Tanker Inward
Weighbridge gross/tare capture. Solvents discharge directly to virtual quarantine storage.
Lab Assay Gate
Chemists record HPLC assay, moisture, and density. Pass status unfreezes raw material lots.
Potency Recipe
ERP recalculates required solvent and active weights based on the specific lot assay percentage.
Reactor Phases
Operators log temperature stages, catalyst charging, and reflux durations on floor tablets.
COA & Packing
GHS barcode labeling for drums, automatic digital COA generation, and FEFO allocation.
Shop-Floor Hardware & Analytical IoT Pipeline
Arihant AI connects directly with your physical plant instrumentation over industrial IoT protocols: eliminating manual terminal data re-entry.
Executive Controls & Daily Operational Telemetry
Arihant AI equips your plant managers and quality controllers with standardized, tamper-proof operational outputs that eliminate manual spreadsheet reconciliations.
Case Study: How a 50-Ton Specialty Polymer & Resin Unit Eliminated Batch Rework
Facing a 4.2% batch failure rate due to raw monomer assay fluctuations from domestic and overseas chemical vendors, this Ankleshwar plant implemented Arihant AI's dynamic potency engine, virtual quarantine gates, and 1-click digital COAs.
Frequently Asked Questions
Concrete answers to technical and operational questions asked by plant directors and CFOs.
Pairs Well With Other Arihant AI Solutions
Ready to Eliminate Chemical Batch Variance?
Consult directly with our senior process MRP architects for custom recipe modeling, reactor phase mapping, and zero-downtime Tally migration.