IT Infrastructure Update

Rewiring the Future: How Formulated Solutions Is Powering a Smarter, AI-Driven Operation

At Formulated Solutions, innovation doesn’t stop at the lab. It pulses through every layer of our business, including the way we power our operations. Over the past several months, our IT department has quietly led one of the most transformational initiatives in company history, laying the groundwork for a smarter, more connected, and AI-enhanced future.

Apprentice: A Platform for Smart Manufacturing

One of the most exciting advancements has been the rollout of the Apprentice platform, a modern Manufacturing Execution System (MES) driven by AI. This system replaces physical binders and paper forms with intelligent, automated digital workflows. Batch records, cleaning logs, and compliance documentation are now managed through sleek, user-friendly interfaces that reduce human error and provide real-time visibility.

This shift doesn’t just streamline tasks, it unlocks the foundation for a larger digital transformation across our manufacturing environment.

“Formulated Solutions’ investment in digital transformation is the largest in the company’s history and will drive us to the next level in efficiency, compliance, and quality,” said Scott Rogers, Vice President of Information Technology. “We’re building systems that will not only streamline how we work but set new standards for how a CDMO can operate.”

Scott Rogers, VP Information Technology

Automation: Expanding Intelligent Workflows

We’ve already introduced automation in our pre-weigh processes, with plans underway to expand into weight filling, mixing, and other production activities. These smarter workflows eliminate manual inputs and introduce tolerance tracking, automatic alerts, and error-proofed processes that help us:

• Eliminate unnecessary manual steps
• Improve precision and reduce risk
• Automate calculations and adherence
• Increase speed while maintaining product quality

IoT Integration: Real-Time, Connected Operations

By integrating Internet of Things (IoT) capabilities into our equipment and systems, we’re connecting operations in real time and unlocking powerful new insights. IoT integration enables:

• Live data capture and production visibility
• Seamless communication between digital and physical systems
• On-the-fly process adjustments to keep lines moving efficiently

When combined with MES and AI, this connected environment empowers us to operate with agility and act on data trends in ways that were previously impossible.

Custom OEE Tracking: Built by Us, for Us

One of the standout achievements in this transformation has been the creation of a custom-built Overall Equipment Effectiveness (OEE) tracking tool—designed entirely in-house by our IT team. This proprietary tool offers real-time visibility into:

• Which lines are running or idle
• Current production throughput
• Operational inefficiencies that need attention

And because it was developed internally, there are no subscription costs, making it a sustainable, high-value asset in our performance strategy.

A Connected Future: Building a Smarter CDMO

Apprentice. Automation. IoT. OEE. These are more than just technologies—they’re interconnected components of a smarter, more agile CDMO. By embedding intelligence into our workflows, we’re reducing bottlenecks, increasing transparency, and delivering outstanding results to the brands we serve.

We’re not just modernizing how we operate. We’re building a scalable platform for innovation, performance, and long-term success.

And this is just the beginning. The future of manufacturing is digital, data-driven, and intelligently automated. With each smart solution, we’re moving closer to that future, one innovation at a time.