I-Control 7 – A Future-Ready MES Solution

For more than 25 years, Interstates has been at the forefront of control and manufacturing execution system (MES) technology, delivering innovative solutions tailored to the feed, flour, and pet food industries. With the release of Interstates’ I-Control 7 (IC7), manufacturers now have access to a future-ready, highly configurable MES and control system that enhances efficiency, compliance, and scalability. 

A Step Forward in MES Technology 

Manufacturers can now reduce maintenance time, improve system reliability, and keep production running smoothly—all thanks to IC7’s new web-based architecture. "This upgrade significantly reduces the time it takes to maintain and support the system, improves system reliability, and allows for seamless updates without disrupting production," says Jeremy Van Den Berg, Product Manager at Interstates. The new architecture also supports real-time inventory tracking, providing plant operators with immediate visibility into material availability and production progress. 

Meeting strict regulatory requirements is now simpler with IC7, as it streamlines compliance reporting and ensures full traceability of materials. The system’s lot-controlled item reconciliation helps manufacturers adhere to FDA regulations with ease. "With IC7, compliance reporting and audits become much simpler, reducing the burden on internal teams," says Bryan Monroe, Automation Manager at Interstates. 

Customizable Features for Operational Flexibility 

With IC7’s modular design, manufacturers can optimize production without a full system overhaul. Some key optional features include: 

• HandAdd – Ensures precise manual addition of small ingredients through guided workflows.
• BlendIQ – Minimizes waste and maintains product quality by optimizing item use based on moisture and protein content.
• Free-Fall Optimization and Pellet Mill Tuning – Improves feed production efficiency.
• Bin Inspection – Helps track material storage conditions to prevent quality degradation. 

"Our clients now have the flexibility to integrate additional modules that improve their operations while maintaining system continuity," says Van Den Berg. IC7 integrates seamlessly with existing ERP solutions, such as SAP and JD Edwards, and formulation software for importing recipes, such as Feed Mill Manager, through secure data transfer protocols and API interfaces, ensuring data consistency across business functions.  

Competitive Advantages in the Market 

You can take advantage of tailored functionality, scalability, and robust compliance features with IC7, including: 

• Industry-Specific Customization – Designed for feed, flour, and pet food manufacturers.
• Scalability – Expands with business growth, ensuring long-term usability.
• Compliance Readiness – Built-in FDA traceability and audit-friendly reporting reduce compliance risks.
• 24/7 USA-Based Support – Expert support teams minimize downtime.
• Ease of Integration – Secure API and data exchange options work seamlessly with major ERP, formulation, and quality management systems. 

"IC7 is more than just a software upgrade – it’s a strategic investment in future-proofing manufacturing operations," Monroe emphasizes. 

A Smarter Future for Manufacturing 

Maximizing productivity while maintaining high-quality standards is now easier with IC7. By incorporating automation and AI-driven insights, the system optimizes production processes and reduces manual errors. "With intuitive interfaces, guided workflows, and real-time analytics, operators can make better decisions and prevent costly mistakes," says Van Den Berg. 

Location-wide access further enhances efficiency by helping manufacturers identify and resolve bottlenecks proactively. "Clients can now access I-Control software from any device on the network, allowing them to optimize operations and boost production," says Monroe. 

Beyond efficiency, IC7 supports long-term growth by enabling facilities to adapt to industry changes. Its future-ready architecture will allow for future enhancements like AI-driven analytics, predictive maintenance, and smart automation. "We designed IC7 with scalability in mind, ensuring our clients have a solution that grows with them," Van Den Berg adds. 

The Financial and Operational Impact 

Manufacturers implementing IC7 can reduce manual interventions, automate reporting, and minimize downtime, resulting in significant cost savings and operational efficiencies. "IC7 enables operators to respond faster to changing conditions, reducing waste and maximizing production," says Monroe. 

Compliance management also becomes more efficient, lowering the risk of violations. "The built-in traceability and reporting functions take the guesswork out of compliance, making it easier to maintain industry standards," Van Den Berg adds. 

Looking Ahead: The Future of I-Control 

Early adopters of IC7 are already experiencing its benefits, appreciating the system’s intuitive design and advanced automation capabilities. "Many of our clients have been looking for an MES solution that evolves with their operations, and IC7 is designed to do just that," says Monroe. 

Interstates is continuously enhancing IC7 with planned updates that include AI-driven analytics, deeper IoT integrations, and predictive maintenance to prevent system failures before they happen. "We’re committed to continuous innovation, ensuring IC7 remains at the forefront of MES and control technology for years to come," says Van Den Berg. 

For manufacturers looking to enhance their MES and control capabilities, I-Control 7 offers an adaptable, compliance-ready, and future-proof solution. Contact Interstates today to learn how IC7 can transform your operations.