Yogurt & Ice Cream Factory

This cookbook walks you through setting up TilliT for a yogurt and ice cream manufacturing facility. By the end, you will have a fully configured multi-site operation with mix rooms, ageing tanks, filling lines, packing rooms, and a scheduler that can plan and optimise production runs.

The setup is based on a real-world ice cream and frozen yogurt factory that receives bulk milk and cream, blends ice cream mixes, ages them in tanks, fills into tubs (from 125 mL to 16 L), and packs finished goods for distribution. The plant operates across two sites with day and night shifts and uses TilliT for quality checks, CIP cleaning logs, consumption tracking, and production scheduling.

All names used in this guide are generic examples. Replace them with your own site, line, and product names.

Prerequisites

Before you begin, ensure you have:

• A TilliT tenant provisioned for your organisation

• An administrator account with access to Settings

• The Excel Add-in installed (recommended for bulk data loading)

For a general introduction to TilliT setup concepts, see Introduction for New TilliT Customers.

1

Create Sites

An ice cream factory may operate across more than one physical location. Each location becomes a site in TilliT.

Go to Settings -> Asset Hierarchy -> Sites -> Create

Field	Example Value
Name	Main Plant
Timezone	Pacific/Auckland
Location Code	MP

Field	Example Value
Name	Secondary Plant
Timezone	Pacific/Auckland
Location Code	SP

For more detail, see Site.

2

Define Asset Classes

Asset classes group similar types of equipment. A yogurt and ice cream factory typically has the following asset classes:

Asset Class	Description
Room	Logical groupings of equipment (mix room, production room, packing room)
Receiving Tank	Tanks for incoming bulk milk, cream, and liquid sugar
Mix Plant	Mixing and pasteurising equipment
Ageing Tank	Tanks where ice cream mix ages before filling
Filling Line	Tub filling and extrusion lines
Freezer	Spiral freezers and blast freezers
Packing Room	Packing areas including cartoning and palletising
Packing Line	Robotic packing lines
Lab	Laboratory for quality and micro testing
CIP	Clean-in-place systems
Tanker Arrival	Tanker receiving bays for bulk liquid

Go to Settings -> Asset Hierarchy -> Asset Class -> Create

Create one asset class for each type listed above. See Asset Class for details.

3

Build the Asset Hierarchy

Assets represent the individual equipment and areas at each site. In an ice cream factory the hierarchy follows the production flow: receiving -> mixing -> ageing -> filling -> freezing -> packing.

Main Plant Site

Main Plant
├── MP Mix Room (class: Room)
│   ├── MP Receiving Tanks (class: Room)
│   │   ├── W3 (class: Receiving Tank)     ← milk
│   │   ├── W2 (class: Receiving Tank)     ← milk
│   │   ├── C1 (class: Receiving Tank)     ← cream
│   │   ├── C2 (class: Receiving Tank)     ← cream
│   │   └── Liquid Sugar (class: Receiving Tank)
│   ├── MP Tanker Arrival (class: Tanker Arrival)
│   └── MP Mix Plant (class: Mix Plant)
├── MP Ageing Tanks (class: Room)
│   ├── A1 through A10 (class: Ageing Tank)   ← 10 tanks
├── MP Production Room (class: Room)
│   ├── MP Spiral Line (class: Filling Line)    ← small tub line
│   ├── MP 2L Line (class: Filling Line)        ← 2-litre tub line
│   ├── MP 5L Line (class: Filling Line)        ← 5-litre tub line
│   ├── MP Bulk Line (class: Filling Line)      ← bulk (16L, 5L)
│   ├── MP Bulk Blast Line (class: Filling Line) ← blast-frozen bulk
│   └── MP Specialty Filler (class: Filling Line)       ← specialty filler
├── MP Packing Area (class: Packing Room)
│   ├── MP Packing Room (class: Packing Room)
│   └── MP Pack Unload (class: Packing Room)
├── MP Freezer (class: Freezer)
├── MP Laboratory (class: Lab)
└── MP CIP (class: CIP)

Secondary Plant Site

Secondary Plant
├── SP Mix Room (class: Room)
│   ├── SP Receiving Tanks (class: Room)
│   │   ├── SP Silo 4 through Silo 7 (class: Receiving Tank)
│   │   └── SP Tanker Arrival (class: Tanker Arrival)
│   ├── SP Mix Plant (class: Mix Plant)
│   └── SP Ageing Tanks (class: Room)
│       └── SP A1 through A6 (class: Ageing Tank)   ← 6 tanks
├── SP Production Room (class: Room)
│   ├── SP Line One (class: Filling Line)
│   ├── SP Line Two (class: Filling Line)
│   ├── SP Line Three (class: Filling Line)
│   └── SP Bulk Line (class: Filling Line)
├── SP Packing Room (class: Room)
│   ├── SP Spiral Lane One (class: Freezer)
│   ├── SP Spiral Lane Two (class: Freezer)
│   ├── SP Robot 1 (class: Packing Line)
│   └── SP Robot 2 (class: Packing Line)
└── SP Laboratory (class: Lab)

Key points

• Receiving tanks hold incoming bulk milk, cream, and liquid sugar from tankers.

• Mix plant blends and pasteurises the ice cream base mix.

• Ageing tanks store the blended mix for 4-24 hours at controlled temperature before filling.

• Filling lines vary by tub size - spiral lines handle small tubs (125 mL - 1 L), dedicated lines handle 2 L, 5 L, and bulk (16 L) formats.

• Freezers (spiral and blast) harden the product after filling.

• Packing lines include robotic cartoning, labelling, and palletising.

• Shared assets like the Laboratory and CIP systems sit at the top level.

• Use Display Order to control the sequence assets appear in the UI (e.g. 1000, 2000, 3000).

Go to Settings -> Asset Hierarchy -> Assets -> Create

Create each asset, assign it to the correct asset class, and set the parent asset for child equipment. See Asset for details.

For sites with many assets, use the Excel Add-in to create assets in bulk.

4

Configure Shifts

Shift templates define the working hours for each site. An ice cream factory typically uses day and night shifts:

Shift Template	Site	Description
Day Shift	Main Plant	Standard day shift (e.g. 06:00 - 18:00)
Night Shift	Main Plant	Night shift (e.g. 18:00 - 06:00)
Day Shift	Secondary Plant	Standard day shift (e.g. 06:00 - 18:00)

The Main Plant site runs two shifts to cover 24-hour production during busy periods, while the Secondary Plant site may operate day shift only.

Creating shift schedules

Setting up shifts is a two-step process: first, you define the overall shift pattern (Shift Template and its Items); then, you link that pattern to your equipment using a Shift Calendar.

1

Create and Configure the Shift Template

1. Go to: Settings -> Asset Hierarchy -> Shift Templates -> Create.

2. Create the required shift templates.

3. Within each created template, go to: Items

4. Define the specific shift periods, including their start times and durations.

See Creating a Shift Template for details.

2

Assign Shifts to Assets

Once your templates and items are ready, create calendars to map these schedules to the correct assets.

Since not every line runs the same schedule (e.g., high-volume lines may run 24 hours while specialty lines run day shift only), calendars ensure each asset accurately reflects its real-world operating schedule.

1. Go to: Settings -> Asset Hierarchy -> Calendars -> Create.

2. Add your Shift Template as a calendar Item.

3. Select the relevant asset and apply the template.

5

Set Up Units of Measure

Before creating materials and process variables, define the units of measure your site will use.

Unit	Description
Kilogram	Primary weight unit for ingredients and mixes
Gram	Smaller weight measurements (inclusions, flavourings)
Litre	Volume for liquid ingredients and tank levels
Tub	Individual tub count
Carton	Cartons of finished goods
Each	Individual items
Degree Celsius	Temperature measurements
%	Percentage (fat content, overrun, giveaway)
Bar / Pa / kPa	Pressure measurements (homogeniser, pasteuriser)
Kg/hr	Flow rates (churn speed)
L/hr	Liquid flow rates
g/L	Concentration measurements

Go to Settings -> Configuration -> Unit of Measure -> Create

See Unit of Measure for details.

6

Create Material Groups

Material groups categorise your raw materials, semi-finished goods, and finished products. For an ice cream factory:

Group	Description
Raw Materials	Bulk milk, cream, liquid sugar, water
Ingredients	Flavourings, colours, stabilisers, emulsifiers, cultures, inclusions (cookies, nuts, ripples)
Ingredients-PRE	Pre-aeration stage ingredients (added before freezing)
Ingredients-POST	Post-aeration stage ingredients (added after freezing - ripples, inclusions)
Semi-Finished Goods	Ice cream base mixes (plain, chocolate, premium, etc.)
Packaging	Tubs, lids, labels, cartons, pallets, shrink wrap
Finished Goods	Packaged ice cream, frozen yogurt, and sorbet products

Go to Settings -> Material Definition -> Material Groups -> Create

See Material Group for details.

Splitting ingredients into PRE and POST groups helps track consumption at the correct stage of the filling process - pre-aeration (into the mix) vs post-aeration (injected after the freezer barrel).

7

Add Materials

Materials represent the specific items consumed or produced during ice cream manufacturing. An ice cream factory typically has hundreds of materials across groups.

Raw Materials

• Fresh Bulk Milk - incoming tanker milk

• Fresh Bulk Cream - incoming tanker cream

• Liquid Sugar - bulk liquid sugar

• Water - process water

• Frozen Milk Concentrate - concentrated milk solids

• Whole Milk Powder - dry milk powder

Ingredients (sample)

• Stabilisers and emulsifiers - xanthan gum, guar gum, emulsifier blends

• Colours - Beta-Carotene, Red Beet, Tartrazine

• Flavourings - Vanilla, Strawberry, Coffee, Banana, Toffee, Maple

• Inclusions - Cookie crumbs, chocolate chips, brownie pieces, nuts, marshmallows

• Ripples - Strawberry ripple, Chocolate ripple, Caramel ripple, Toffee ripple

• Cultures - yogurt starter culture (for frozen yogurt products)

• Cocoa and chocolate - Cocoa powder, chocolate flakes

• Dry goods - Sugar, Salt, Skim Milk Powder, Maltodextrin

Semi-Finished Goods (ice cream base mixes)

These are the pasteurised and aged mixes, typically categorised by brand and fat content:

• Plain mix - e.g. "Brand IC Mix Plain 10%", "Brand IC Mix Plain 14%"

• Chocolate mix - e.g. "Brand IC Mix Chocolate"

• Specialty mixes - e.g. "Green Tea 14%", "Burnt Butter 10%"

• Shake/Soft serve mixes - lower overrun mixes for milkshake and soft-serve products

Finished Goods

Packaged products by brand, flavour, and pack size:

• Ice cream tubs - e.g. "Vanilla 6x2L", "Chocolate 2x5L", "Cookies & Cream 1x16L"

• Frozen yogurt - e.g. "Frozen Yoghurt Plain 2x5L", "Frozen Yoghurt Forestberry 2x5L"

• Sorbet - e.g. "Sorbet Berry Burst 2x5L", "Sorbet Mango 2x5L"

• Specialty/Export - e.g. export markets, premium ranges

Go to Settings -> Material Definition -> Materials -> Create

For bulk loading, use the Excel Add-in to import materials from a spreadsheet.

See Material for details.

8

Define Attributes

Attributes store metadata against orders, materials, and assets. In an ice cream plant, think of them as the product's digital "Product Specification Sheet" or identity card. They hold specific details about a work order (such as flavour, allergen status, recipe type, packaging format, etc), which TilliT uses to automatically show or hide relevant fields based on that specific product type, as well as to help the Scheduler calculate changeover times.

Order Number Attributes

These attach to all work orders that share the same Order Number. They are particularly useful when production orders are split into multiple operations but still need to share common information. When orders are loaded via the API, these attribute values can be provided in the payload (see Step 14). Group them by purpose:

Product & Recipe

Attribute	Data Type	Purpose
Base Flavour	STRING	Base flavour of the mix (Vanilla, Chocolate, Plain, etc.)
Mix Code	STRING	Recipe/mix code identifier
Mix Flavour	STRING	Flavour name for the mix
Mix Type	STRING	Mix classification (e.g. plain, chocolate, premium)
Yoghurt Mix Type	STRING	Yoghurt-specific mix classification
Species	STRING	Milk source species (cow, goat, etc.)
Brand	STRING	Product brand name
Product Format	STRING	Format description (tub, bulk, soft-serve)
Pack Size	STRING	Pack size configuration
Shelf Life	NUMBER	Shelf life in days

Production Parameters

Attribute	Data Type	Purpose
Tub Per Minute Target	NUMBER	Line speed target
Cartons On Pallet	NUMBER	Cartons per pallet configuration
TubsPerCarton	NUMBER	Tubs per carton count
Ageing Tank Count	NUMBER	Number of ageing tanks allocated
Current Ageing Tank	STRING	Currently active ageing tank
First Ageing Tank	STRING	First tank in the sequence
Ageing Tanks Used	STRING	List of all tanks used for this order
Receiving Tank	STRING	Assigned receiving tank
Churn Volume	NUMBER	Churn/freezer barrel volume

Temperature & Processing

Attribute	Data Type	Purpose
First Divert Temp	NUMBER	First divert temperature threshold
Second Divert Temp	NUMBER	Second divert temperature threshold
Homogenisation First Stage Pressure	NUMBER	Homogeniser first-stage pressure
Homogenisation Second Stage Pressure	NUMBER	Homogeniser second-stage pressure

Quality & Testing

Attribute	Data Type	Purpose
Fat Results	NUMBER	Fat content test result
Protein Results	NUMBER	Protein content test result
Total Solids result	NUMBER	Total solids test result
pH results	NUMBER	pH measurement
Overrun Result	NUMBER	Overrun percentage result
Number of Sensory Testers	STRING	How many sensory testers are required
Sample Collection Count	NUMBER	Number of samples to collect
Pathogen Collection Count	NUMBER	Number of pathogen samples required

Allergen Flags

Attribute	Data Type	Purpose
ContainsMilk	BOOLEAN	Product contains milk
ContainsEgg	BOOLEAN	Product contains egg
ContainsSoy	BOOLEAN	Product contains soy
ContainsGluten	BOOLEAN	Product contains gluten
ContainsTreeNuts	BOOLEAN	Product contains tree nuts
ContainsInclusion	BOOLEAN	Product has solid inclusions
ContainsRipple	BOOLEAN	Product has a ripple/swirl
AllergenicIngredient	STRING	Description of allergens present
FormofAllergen	STRING	Form of allergen (powder, liquid, etc.)
AllergenTest	BOOLEAN	Allergen testing required

Market & Compliance

Attribute	Data Type	Purpose
isHalal	BOOLEAN	Halal-certified product
IsChinaMarket	BOOLEAN	Destined for China market
IsExportCustomerA	BOOLEAN	Export customer A flag
IsExportCustomerB	BOOLEAN	Export customer B flag
isYoghurt	BOOLEAN	Product is a yoghurt
Batch	STRING	Batch number
Best Before Date	STRING	Best-before date
Purchase Order	STRING	ERP purchase order reference

Mix & Ingredient Control

Attribute	Data Type	Purpose
FlavouringRequired	BOOLEAN	Whether flavouring is needed
HasMembrane	BOOLEAN	Membrane filtration used
Carbonator	BOOLEAN	Carbonation used
WaterAddition	NUMBER	Amount of water to add
Ingredient Feeder	STRING	Which ingredient feeder to use
Aeration Stage	STRING	Aeration stage configuration
Fermentation	STRING	Fermentation instructions (for yoghurt)

Go to Settings -> Configuration -> Attributes -> Create

See Attribute for details.

You do not need to create all attributes manually before loading orders. When you use the order upsert API (see Step 14), any attribute that does not already exist will be created automatically.

9

Set Up Process Variables

Process variables define the measurements and checks that operators capture. They can reference attributes to pull specs from the work order.

Tank Monitoring

Process Variable	UoM	Purpose
MP Ageing Tank 1-10 Level	Litre	Tank fill level
MP Ageing Tank 1-10 Temperature	Degree Celsius	Tank temperature
SP Ageing Tank 1-6 Level	Litre	Tank fill level
SP Ageing Tank 1-6 Temperature	Degree Celsius	Tank temperature
Receiving Tank Levels (W2, W3, C1, C2)	Litre	Milk and cream tank levels
Receiving Tank Temperatures	Degree Celsius	Incoming liquid temperatures
Liquid Sugar Tank Level	Litre	Sugar tank level
SP Silo 4-7 Level / Temperature	Litre / Degree Celsius	Secondary Plant silo monitoring
Mix Tank 1 & 2 Level	Litre	Mix room tank levels

Quality Measurements

Process Variable	UoM	Purpose
Fat	%	Fat content of mix or finished product
Protein	%	Protein content
Total Solids	%	Total solids content
pH	--	Acidity measurement
Overrun	%	Air incorporation percentage
Tub Weight	Gram	Individual tub weight
Tub Inclusion Weight	Gram	Weight of inclusions per tub

Production Metrics

Process Variable	UoM	Purpose
Giveaway %	%	Product giveaway percentage
2L Giveaway	%	Giveaway specific to 2L line
Bulk Giveaway	%	Giveaway specific to bulk line
Checkweigher results (per line)	Gram	Inline weight check data

Pasteuriser / Processing (Secondary Plant)

Process Variable	UoM	Purpose
SP Holding Tube Temperature	Degree Celsius	CCP pasteurisation temperature
SP Final Product Temperature	Degree Celsius	Product temperature post-pasteuriser
SP Raw Product Pressure	kPa	Raw product pressure
SP Regeneration Section Pressure	kPa	Regen section pressure
SP Chilled Mix Pressure	kPa	Chilled mix pressure
SP Chilled Water Pressure	kPa	Chilled water pressure
SP Spiral Freezer Temperature	Degree Celsius	Spiral freezer temperature

Go to Settings -> Configuration -> Process Variable -> Create

See Process Variable for details.

Process variables that reference attributes (like ageing tank assignments) will automatically pull the correct spec from the current work order.

10

Create Activity Classes

Activity classes group related activity templates in the UI. For an ice cream factory:

Activity Class	Purpose
Tanker Checks	Incoming bulk liquid inspection, milkoscan, unloading
Mix Checks	Mixing room startup, ingredient issuance, transfers, CCP pasteuriser checks
Flavour Team Checks	Ageing tank startup, sample collection, flavouring, water specification
Production Checks	Filling line startup, weight checks, overrun, packaging checks, downtime
Production Sample Collections	Micro samples, pathogen samples, retention samples, per-tank samples
Quality Checks	Sensory testing, metal detector tests, QC sign-offs
Packing Room Checks	Pack room startup, packaging quality, robotic packer checks, metal detection
Lab Checks	pH calibration, fridge temperature, allergen tests, hygiene swabs, pathogen checks
CIP	Cleaning logs, pre-clean checklists, weekly cleaning, machinery inspection
Consumption	Ingredient consumption tracking (flavouring, packaging, returns)
General Checks	Safety equipment, fridge temperature, daily tools check
Order Management	Cancel order, changeover reason, suspended order reason
Supervisors	Staff rostering, head counts, order quantity updates
Yoghurt Checks	Yoghurt-specific activities (culture addition, pH testing, fermentation monitoring)

Go to Settings -> Activity Template -> Activity Classes -> Create

See Activity Class for details.

11

Build Activity Templates

Activity templates are the digital forms that operators interact with. An ice cream factory has a large number of templates covering every stage from tanker arrival through to packed goods.

Core Activity Categories

Tanker & Receiving

Activity	Triggered by	Purpose
Incoming Bulk Liquid Inspection	Tanker order start	Visual and documentation checks on incoming tanker
Incoming Bulk Liquid Milkoscan	Tanker order running	Lab analysis of incoming milk/cream
Incoming Bulk Liquid Unloaded	Tanker order end	Confirm tanker unloaded, record volumes
Incoming Bulk Liquid Variance	Tanker order end	Record variance between delivery docket and received volume
Incoming Bulk Liquid Corrective Actions	Event-based	Handle out-of-spec incoming liquid
Receiving Tank Record	Manual	Log receiving tank levels and temperatures
Receiving Tank Reconciliation Record	Manual	Reconcile tank volumes against deliveries

Mix Room

Activity	Triggered by	Purpose
Mix Start-up CCP Checks	Mix order start	Critical control point checks for pasteuriser
Mix Started	Mix order start	Confirm mix has started, record parameters
Mix Temperature Checks	Interval	Monitor pasteurisation temperatures
Mix Homogeniser Pressure Check	Interval	Check homogeniser pressures
Mix Ingredient Issuance	Mix order start	Issue ingredients from store to mix room
Mix Ingredient Consumption	Mix order end	Record actual ingredient quantities consumed
Mix Ingredient Dump Confirmation	Event-based	Confirm ingredient additions
Ingredient Consumption Raw	Mix order end	Record raw material consumption (milk, cream, sugar)
Mix Transfer	Mix order end	Transfer completed mix to ageing tank
Halal Mix Pre-Start Checks	Mix order start	Additional checks for Halal-certified products
Mixing Room Daily Checks Sheet	Shift start	Daily housekeeping and readiness checks
Mix Room Temperature Checks	Interval	Ambient temperature monitoring
Milk And Cream EOS Calculation	End of shift	End-of-shift milk and cream reconciliation

Ageing Tanks & Flavouring

Activity	Triggered by	Purpose
Ageing Tank Start-up Checks	Ageing order start	Confirm tank readiness, record initial conditions
Ageing Tank Process Checks	Interval	Monitor temperature and level during ageing
Ageing Tank Level Record	Interval	Record tank level at regular intervals
Ageing Tank Sample Collection	Event-based	Collect samples for lab testing
Ageing Tank Sample Quality Signoff	Event-based	QC sign-off on ageing tank sample results
Tank Flavour Sheet	Order start	Record flavouring additions to aged mix
Multistream Tank Flavour Sheet	Order start	Flavouring for multi-stream (blended) products
Flavour Ingredient Issuance	Order start	Issue flavouring ingredients
Ageing Tank Water Addition	Event-based	Record water addition adjustments
Ageing Tank Order Complete	Ageing order end	Close out ageing tank order
Water Specification Sheet	Order start	Record water quality specs for the mix

Production / Filling

Activity	Triggered by	Purpose
Production Start-up Checks	Filling order start	Line readiness, equipment checks
Production Line Setup	Filling order start	Record line configuration and settings
Label and Inkjet Information Check	Filling order start	Verify correct labels and inkjet codes
Lid & Tub Information Record	Filling order start	Verify correct tub and lid for the product
Weight Check	Interval	Tub weight checks against target
Check Weigher Result	Interval	Inline checkweigher data capture
Overrun	Interval	Overrun (air incorporation) measurement
Overrun Cup Test Start of Run	Filling order start	Initial overrun verification
Product Taste and Appearance	Interval	Sensory check during production
Inclusion Dosing	Filling order running	Record inclusion dosing rates
Inclusion Monitoring	Interval	Monitor inclusion distribution
Churn and Filler Information	Filling order start	Record churn/filler setup parameters
Churn Breakdown	Event-based	Record and log churn equipment failures
Production Downtime	Event-based	Capture and categorise downtime events
Post Production Check	Filling order end	End-of-run line checks and reconciliation
Retention Sample	Filling order start	Collect and log retention samples
Barcode Label Scanner Check	Filling order start	Verify barcode scannability

Yoghurt-Specific

Activity	Triggered by	Purpose
Yoghurt Culture Addition	Order start	Record culture addition to yoghurt mix
Yoghurt Mix pH Testing	Interval	Monitor pH during fermentation
Yoghurt Temperature Monitoring	Interval	Monitor fermentation temperature
Yoghurt Mix Lactic Acid Addition	Event-based	Record lactic acid additions
Yoghurt Sample Collection	Event-based	Collect samples for lab testing
Yoghurt Sample Corrective Actions	Event-based	Handle out-of-spec yoghurt samples
Cultured Yoghurt Sampling	Event-based	Specific sampling for cultured products
Yoghurt Blended Mix Transfer	Order end	Transfer blended yoghurt to ageing/filling

Packing Room

Activity	Triggered by	Purpose
Pack Room Order Received	Order start	Confirm packing room ready for incoming product
Pack Room Packaging and Quality Checks	Interval	Ongoing quality checks during packing
Metal Detection Activated	Event-based	Record and investigate metal detector activations
Pack Room Daily Cleaning Checks	Shift start	Daily cleaning verification
Pack Room Chiller Inspection	Shift start	Check chiller temperatures
Pack Room Drain Inspection	Shift start	Check floor drains
Pack Room Post Production	Order end	End-of-order packing room checks
Pack Room Unload Confirmation	Order end	Confirm product unloaded from freezer

Quality & Lab

Activity	Triggered by	Purpose
Finished Product Sensory Check	Order running	Formal sensory panel testing
Sensory Tub Check (Testers 1-5)	Order running	Individual tester scorecards
Upper/Lower Belt CCP2 Metal Detector Test	Shift start	Metal detector verification
Lab Allergen Test Record	Event-based	Record allergen testing results
Lab Hygiene Swab Results	Scheduled	Environmental monitoring results
Lab pH Calibration	Shift start	Calibrate pH meters
Lab Fridge Temperature Check	Shift start	Lab fridge temperature logs
Pathogen Swabbing Check	Scheduled	Pathogen environmental monitoring
Lab Retention Sample Checks	Scheduled	Inspect stored retention samples

CIP & Cleaning

Activity	Triggered by	Purpose
Pre-Clean Checklist (Daily)	Shift start	Pre-production cleaning checks
Production Cleaning Area (Daily)	Shift end	End-of-day production area cleaning
Mix Room Cleaning Log	Event-based	Record mix room CIP cycles
Weekly Cleaning	Scheduled	Thorough weekly deep clean
Machinery Parts And O-Rings Inspection	Scheduled	Inspect and record condition of seals and parts
Ageing Tank Acid Wash	Scheduled	Periodic acid wash of ageing tanks
Chemicals Check	Shift start	Verify CIP chemical concentrations

Consumption Tracking

Activity	Triggered by	Purpose
Flavour Ingredient Consumption	Order end	Record flavouring ingredients consumed
Pack Room Goods Consumption	Order end	Record packaging materials consumed
Ingredient Consumption Semi-Finished	Order end	Record semi-finished goods consumed
Mix Dry Goods Consumption	Order end	Record dry goods consumed in mix room
Pack Room Return Consumption	Order end	Record packaging returns/waste
Final Pack Room Carton Count	Order end	Final carton count reconciliation

Building an activity template

For each activity, you need to:

1. Create the template with a name and activity key

2. Assign it to an activity class

3. Set the "Claimable By" field to define who can see and claim the activity

4. Configure the trigger (when it fires - see next section)

5. Build the form items (the fields operators fill in)

Go to Settings -> Activity Template -> Activity Template -> Create

See Creating an Activity for a complete walkthrough.

For understanding trigger types, see When and Where.

Start with a small set of critical activities (e.g. mix startup CCP checks, weight checks, metal detector tests, production startup) and expand once the team is comfortable.

12

Configure Order Templates

Order templates define how a work order is executed across a line. They specify which machines (child assets) within the line (parent asset) participate in the order, as well as the operation type for each stage.

Main Plant - Spiral Line (small tub line)

Order Template	Operation	From Asset	To Asset
Spiral Line	Filling	MP Spiral Line	MP Spiral Line
SpiralLAB	Lab	MP Spiral Line	MP Laboratory
SpiralPack	Pack	MP Spiral Line	MP Packing Room
SpiralUnpack	Unpack	MP Spiral Line	MP Pack Unload

Main Plant - 2L Line

Order Template	Operation	From Asset	To Asset
2L Line	Filling	MP 2L Line	MP 2L Line
2LPack	Pack	MP 2L Line	MP Packing Room
2LUnpack	Unpack	MP 2L Line	MP Pack Unload
2L Lab	Lab	MP 2L Line	MP Laboratory

Main Plant - 5L Line

Order Template	Operation	From Asset	To Asset
5L Line	Filling	MP 5L Line	MP 5L Line
5LPack	Pack	MP 5L Line	MP Packing Room
5LUnpack	Unpack	MP 5L Line	MP Pack Unload
5L Lab	Lab	MP 5L Line	MP Laboratory

Main Plant - Bulk Line

Order Template	Operation	From Asset	To Asset
Bulk Line	Filling	MP Bulk Line	MP Bulk Line
BulkPack	Pack	MP Bulk Line	MP Packing Room
BulkUnload	Unpack	MP Bulk Line	MP Pack Unload
Bulk Lab	Lab	MP Bulk Line	MP Laboratory

Main Plant - Supporting Operations

Order Template	Operation	From Asset	To Asset
MP Mix Room	Mix Room	MP Mix Room	MP Mix Plant
MP Tanker Arrival	Tanker	MP Tanker Arrival	MP Tanker Arrival
Yoghurt Blend	Ageing	MP Ageing Tanks	MP Ageing Tanks

Secondary Plant - Filling Lines

Order Template	Operation	From Asset	To Asset
SP Line One	Filling	SP Line One	SP Line One
SP Line Two	Filling	SP Line Two	SP Line Two
SP Line Three	Filling	SP Line Three	SP Line Three
SP Bulk Line	Filling	SP Bulk Line	SP Bulk Line

Secondary Plant - Supporting Operations

Order Template	Operation	From Asset	To Asset
SP Mix Room	Mix	SP Mix Room	SP Mix Plant
SP Tanker Arrival	Tanker	SP Tanker Arrival	SP Tanker Arrival
SP Tanker Arrival Lab	Lab	SP Tanker Arrival	SP Laboratory

Key points

• Filling lines are the primary work order assets - the order is created against the line and cascades to child operations (Lab, Pack, Unpack).

• Mix Room orders track the mixing and pasteurising process separately from filling.

• Tanker Arrival orders track incoming raw material deliveries.

• Yoghurt Blend uses the ageing operation type for yoghurt-specific fermentation and blending.

• Unpack operations track product leaving the freezer and entering the packing area.

Go to Settings -> Asset Hierarchy -> Order Templates -> Create

See Order Template for details.

13

Set Up the Scheduler

Once Digital Operations is configured, you can set up the Scheduler to plan and optimise production runs.

1

Create the Data Template

The Default Data Template links the Scheduler to the Digital Operations site and connects scheduler equipment to live production data.

In newly provisioned environments, sections such as Equipment, Availability, Optimisation, and Changeovers may not be available until a Data Template has been created.

Go to Scheduler -> Data Templates -> Create

Create the Default Data Template.

See Data Templates for details.

2

Create Scheduler Equipment

Each key asset becomes a piece of equipment in the Scheduler. The full list for a two-site ice cream operation:

Equipment (Name)	External ID (Code)	Display Order
SP Tanker Arrival	SP Tanker Arrival	1
SP Mix Room	SP Mix Room	5
MP Tanker Arrival	MP Tanker Arrival	5
SP Line One	SP Line One	10
MP Mix Room	MP Mix Room	11
MP Ageing Tanks	MP Ageing Tanks	12
MP Spiral Line	MP Spiral Line	13
MP Specialty Filler	MP Specialty Filler	14
MP 2L Line	MP 2L Line	15
MP 5L Line	MP 5L Line	17
MP Bulk Line	MP Bulk Line	18
SP Line Two	SP Line Two	20
MP Bulk Blast Line	MP Bulk Blast Line	20
SP Line Three	SP Line Three	30
SP Bulk Line	SP Bulk Line	40

See Equipment for details.

3

Create Availability Templates

Availability templates define when each line is available for production. Typical patterns for an ice cream factory:

Template (Code)	Description	Hours
Day Shift	Standard day shift, Mon-Fri	06:00 - 18:00
Day & Night (24hr)	Two-shift 24-hour coverage, Mon-Fri	06:00 - 06:00
Day Only (Secondary Plant)	Single day shift for smaller site	06:00 - 18:00

Assign each availability template to the appropriate equipment using the Calendarised Availability Template Set.

See Availability for details.

4

Define Optimisation Properties

Optimisation properties are the characteristics the scheduler uses to sequence orders and calculate changeover times. For ice cream manufacturing:

Property (Name)	Example Values	Purpose
Base Flavour	Plain, Chocolate, Strawberry, Coffee, Yoghurt...	Flavour drives cleaning requirements between runs
Mix Type	Standard, Premium, Organic, Halal, Sorbet	Mix type affects tank and line compatibility
Allergen Profile	Contains Egg, Contains Nuts, Contains Gluten	Allergen changes require thorough cleaning
Pack Size	125mL, 470mL, 1L, 2L, 5L, 16L	Pack size determines which line the order runs on
Brand	Brand A, Brand B, Brand C, Brand D	Brand-specific packaging and settings

See Optimisation for details.

5

Configure Changeover Rules

Changeovers define the downtime required to clean or mechanically reconfigure a line when switching between products. They are based on the optimisation properties above.

Key changeover rules for ice cream:

• Same flavour to same flavour - 0 minutes (no changeover needed)

• Light to dark colour - shorter changeover (e.g. vanilla to chocolate: 30 minutes)

• Dark to light colour - longer changeover requiring rinse (e.g. chocolate to vanilla: 60 minutes)

• Non-allergen to allergen - standard changeover

• Allergen to non-allergen - full CIP required (e.g. 90-120 minutes)

• Halal to non-Halal or vice versa - full CIP required

• Inclusion change - moderate changeover for hopper cleanout (e.g. 30-45 minutes)

• Pack size change - line adjustment time varies by format

Changeover times are entered as a matrix of from-value to to-value for each optimisation property.

See Changeovers for details.

6

Define Operations and Production Routes

Equipment, availability, and changeovers tell the scheduler where and when it can work. Operations tell it what the work is and how long it takes.

The model is a small hierarchy:

Operation (one per finished good -- code = the product's material code)
  └── Route
        └── Segment "Fill and Pack"
              ├── Consumed materials  -- the bill of materials (milk, cream, sugar, cultures)
              ├── Produced material   -- the one finished good this operation makes
              └── Run rate            -- throughput in units per second

For each finished good, create an operation with a single Fill and Pack segment that:

• consumes its components - e.g., Vanilla 6x2L consumes the aged plain ice cream mix, vanilla flavouring, 2L tubs, lids, and outer cartons;

• produces the one finished good (the SKU);

• declares a run rate in units (tubs) per second. The scheduler derives an order's duration from quantity ÷ run rate (e.g., 5,000 tubs at 1.4 tubs/s ≈ 1 hour of run time, before changeovers). Smaller retail formats (e.g., 125mL) typically run at a faster rate than larger bulk formats (e.g., 2L or 5L); and

• declares an equipment requirement. Match the segment to an equipment class (e.g., Filling Lines) rather than a single line, so the scheduler can place the order on any compatible line in that class. Without an equipment requirement, the scheduler has nowhere to run the order.

The run rate replaces a fixed duration: a segment is timed either by a fixed duration or by a throughput rate. For filling lines, the per-product run rate is what you want, since duration then scales with order quantity.

See Operations for details.

7

Load Scheduler Data

For bulk loading of scheduler master data (equipment properties, availability calendars, changeover matrices), use the Excel Add-in:

See Loading data with Excel Add-in for details.

14

Integrate Order Loading from ERP

In most ice cream factories, work orders originate in an ERP system (SAP, Microsoft NAV/BC, etc.) and need to flow into TilliT automatically. Use the POST:/core/order-instances/upsert endpoint to load orders with all their attributes, tolerances, and components.

Order Payload Structure

The upsert endpoint accepts an array of orders. Each order carries the core fields plus arrays for attributes, tolerances, and components:

[
  {
    "orderNumber": "WO-20260101-001",
    "orderDate": "2026-01-01",
    "dueDate": "2026-01-03",
    "scheduledStart": "2026-01-02T06:00:00",
    "scheduledEnd": "2026-01-02T14:00:00",
    "quantityTarget": 5000,
    "defaultRunRate": 80,
    "status": "NEW",
    "name": "Vanilla 6x2L",
    "asset": "MP 2L Line",
    "material": {
      "externalId": "FG-VAN-2L-6PK",
      "name": "Vanilla Ice Cream 6x2L"
    },
    "attributes": [
      { "attributeName": "Base Flavour", "value": "Vanilla" },
      { "attributeName": "Brand", "value": "Brand A" },
      { "attributeName": "Mix Code", "value": "MIX-PLAIN-10" },
      { "attributeName": "Mix Type", "value": "Plain" },
      { "attributeName": "Pack Size", "value": "6x2L" },
      { "attributeName": "TubsPerCarton", "value": "6" },
      { "attributeName": "Cartons On Pallet", "value": "60" },
      { "attributeName": "Tub Per Minute Target", "value": "40" },
      { "attributeName": "Shelf Life", "value": "365" },
      { "attributeName": "ContainsMilk", "value": "true" },
      { "attributeName": "ContainsEgg", "value": "true" },
      { "attributeName": "ContainsSoy", "value": "false" },
      { "attributeName": "ContainsGluten", "value": "false" },
      { "attributeName": "ContainsTreeNuts", "value": "false" },
      { "attributeName": "ContainsInclusion", "value": "false" },
      { "attributeName": "ContainsRipple", "value": "false" },
      { "attributeName": "isHalal", "value": "false" },
      { "attributeName": "isYoghurt", "value": "false" },
      { "attributeName": "FlavouringRequired", "value": "true" },
      { "attributeName": "Ageing Tank Count", "value": "2" },
      { "attributeName": "First Ageing Tank", "value": "A1" },
      { "attributeName": "Current Ageing Tank", "value": "A1" },
      { "attributeName": "Species", "value": "Cow" }
    ],
    "tolerances": [
      { "processVariableName": "Tub Weight", "target": 2050, "lowerLimit": 2030, "upperLimit": 2070 },
      { "processVariableName": "Fat", "target": 10.0, "lowerLimit": 9.5, "upperLimit": 10.5 },
      { "processVariableName": "Overrun", "target": 90, "lowerLimit": 80, "upperLimit": 100 }
    ],
    "orderComponents": [
      { "componentExternalId": "MIX-PLAIN-10", "componentGroup": "Semi-Finished Goods", "componentName": "IC Mix Plain 10%", "target": 3000 },
      { "componentExternalId": "FLV-VANILLA", "componentGroup": "Ingredients", "componentName": "Vanilla Flavour", "target": 15 },
      { "componentExternalId": "PKG-TUB-2L-VAN", "componentGroup": "Packaging", "componentName": "Vanilla 2L Tub", "target": 5100 },
      { "componentExternalId": "PKG-LID-2L-VAN", "componentGroup": "Packaging", "componentName": "Vanilla 2L Lid", "target": 5100 },
      { "componentExternalId": "PKG-CTN-6x2L", "componentGroup": "Packaging", "componentName": "Outer Carton 6x2L", "target": 850 }
    ]
  }
]

Key points

• asset - set to the filling line name. If order templates are configured (Step 12), the order will automatically cascade to child operations (Lab, Pack, Unpack).

• attributes - all values are strings, even for BOOLEAN and NUMBER types. TilliT converts them based on the attribute definition.

• tolerances - override the default process variable limits for this specific order. Only include tolerances that differ from the defaults.

• orderComponents - the bill of materials for the order. Components include the semi-finished mix, flavourings, inclusions, and packaging.

• Upsert behaviour - If you send a work order that matches an existing combination of orderNumber, operation, and asset, TilliT will simply update the details instead of creating a duplicate. This allows you to safely re-send or refresh the full schedule whenever it changes.

• Auto-creation - materials, attributes, UoMs, and tolerances that do not already exist will be created automatically.

Typical attribute categories in the payload

Category	Attributes	Purpose
Product identity	Base Flavour, Brand, Mix Code, Mix Type, Species, Pack Size	Identify the product and its recipe
Production params	Tub Per Minute Target, Cartons On Pallet, TubsPerCarton, Shelf Life	Line configuration
Tank management	Ageing Tank Count, First Ageing Tank, Current Ageing Tank, Receiving Tank	Track which tanks are allocated
Temperature	First Divert Temp, Second Divert Temp	Pasteuriser divert settings
Allergens	ContainsMilk, ContainsEgg, ContainsSoy, ContainsGluten, ContainsTreeNuts, ContainsInclusion	Allergen management and cleaning triggers
Market/Compliance	isHalal, IsChinaMarket, IsExportCustomerA, isYoghurt	Regulatory and customer requirements
Mix control	FlavouringRequired, HasMembrane, WaterAddition, Ingredient Feeder	Mix room configuration
Quality	Sample Collection Count, Pathogen Collection Count, Number of Sensory Testers	Testing requirements

For the full API reference, see Upload Production Schedule.

15

Create Your First Work Order

With all master data in place, you can test by creating a work order manually:

1. Navigate to the filling line where you want to run the order (e.g. MP Spiral Line)

2. Click Create Order

3. Select the material (finished good) to produce (e.g. Vanilla Ice Cream 6x2L)

4. Enter the quantity (e.g. 5000 tubs)

5. Fill in the order number attributes (ageing tank, allergens, Halal status, flavouring)

6. Start the order

When the order starts, TilliT will automatically trigger the configured activities (production startup checks, weight checks, sensory samples, etc.) and the order will flow through each operation according to the order template.

See Create adhoc Order and Start an Order for details.

16

Schedule Production (Scheduler)

With the scheduler configured, you can now plan production:

1. Open the Scheduler

2. Import orders from your ERP or create them manually

3. Assign orders to lines

4. Let the scheduler optimise the sequence based on changeover rules (flavour, allergen, pack size)

5. Publish the schedule to Digital Operations

See How to Schedule and Scheduler to Digital Operations integration for details.

Summary Checklist

Use this checklist to track your progress:

• Sites created (Main Plant, Secondary Plant) with correct timezone

• Asset classes defined (Room, Receiving Tank, Mix Plant, Ageing Tank, Filling Line, Freezer, Packing Room, Packing Line, Lab, CIP, Tanker Arrival)

• Assets created with correct parent-child hierarchy across both sites

• Shift templates configured (Day Shift, Night Shift per site)

• Units of measure defined (Kilogram, Litre, Tub, Carton, Degree Celsius, %, etc.)

• Material groups created (Raw Materials, Ingredients, Ingredients-PRE, Ingredients-POST, Semi-Finished Goods, Packaging, Finished Goods)

• Materials loaded (milk, cream, flavourings, inclusions, mixes, packaging, finished goods)

• Attributes defined (product, allergen, production, temperature, market/compliance)

• Process variables configured (tank levels, temperatures, fat, protein, pH, overrun, weight)

• Activity classes created

• Activity templates built and triggers configured (tanker, mix, ageing, production, packing, quality, CIP, yoghurt)

• Order templates mapped for each line (Filling, Lab, Pack, Unpack operations)

• Scheduler equipment created for both sites

• Availability templates configured and assigned

• Optimisation properties defined (Base Flavour, Mix Type, Allergen, Pack Size, Brand)

• Changeover rules entered (flavour, allergen, inclusion, pack size)

• Order integration configured and payload tested

• First work order tested end-to-end

Related Articles

• Planning Overview

• Data Gathering Checklist

• Upload Production Schedule (API)

• Entity Data Source