Prodooo solves syrup, blending and filling as one problem — every tank, every line, every SKU, every constraint. The schedule your team spends a day building, in ninety seconds.
Built for beverage. Runs alongside SAP, Blue Yonder and Kinaxis — no replacement required.
Capex is committed. Labour is fixed. Formulations are locked. The schedule is rebuilt from scratch every week — and it decides how much of your capacity you actually get to sell.
Most bottlers hand that decision to one experienced planner and a spreadsheet. The planner is very good. The problem is simply larger than any person.
A syrup batch has a shelf clock. A blend tank feeds a specific filler. A filler has a bottle-size constraint. Optimize any one stage and you push the cost into the next.
Flavour-to-flavour changeovers, allergen and sugar-free ordering rules, CIP windows, minimum run lengths. The feasible sequence space is larger than a person can search.
A filler goes down. A promo lands early. A resin delivery slips. Rebuilding takes hours, so the plant runs a patched version of last week's plan instead.
Your best scheduler knows which sequences actually work on the floor. None of it is written down, and they retire eventually.
Generic advanced planning tools treat filling as the schedule and everything upstream as a constraint to satisfy afterwards. That's backwards for beverage. The upstream tanks are where the changeover cost actually lives.
Prodooo optimizes all three stages simultaneously, so a sequencing decision on Line 2 is evaluated against what it does to syrup tank availability sixteen hours earlier.
Batch sizing, tank assignment, shelf-life clock, sugar and concentrate availability.
Blend tank allocation, CIP windows, allergen and diet sequencing rules, brix targets.
Bottle and can format changeovers, line speeds, crew coverage, packaging supply.
Your planners don't lose their view. Prodooo produces a conventional schedule board across all three stages, editable by hand, with every changeover and CIP window shown where it actually falls.
Prodooo doesn't hand you a Gantt chart and leave you to defend it. Each plan is costed — changeover hours, expected shorts, inventory position, overtime — against the plan you'd otherwise have run.
That gives your planners something to show a plant manager, and gives you something to take to a business review.
| Driver | Current | Prodooo | Δ |
|---|---|---|---|
| Changeover & CIP hrs | 412 | 171 | −241 |
| Forecast short cases | 38,400 | 4,100 | −34,300 |
| Finished goods days | 11.4 | 8.9 | −2.5 |
| Overtime shifts | 14 | 6 | −8 |
| Contribution impact | — | $418k | +$418k |
A filler failure at 02:00 shouldn't cost you a day of planning. Prodooo re-solves the remaining horizon in seconds and shows you the trade-off between recovering service and containing cost, so the call gets made by the person accountable for it.
Each option carries its own numbers. Nobody has to guess which one protects the customer.
Adds 2 changeovers, 3.5 hrs overtime. Protects the two national-account SKUs.
No added cost. 8,600 cases land two days late; one promo commitment at risk.
Requires format change and crew move. Pushes water SKUs into next week.
Every scheduling tool makes this trade-off. Most of them make it for you, buried in a solver weight nobody in the plant can see or change.
Prodooo puts it in front of you. Move toward service and the solver protects fill rate at the cost of more changeovers. Move toward efficiency and it consolidates runs. The same setting can differ by plant, by season, or by week — and every position shows you what it costs before you commit.
| Setting | Fill rate | Changeover hrs | FG days |
|---|---|---|---|
| Protect service | 99.6% | 248 | 10.8 |
| Current | 99.1% | 171 | 8.9 |
| Maximize efficiency | 97.4% | 124 | 7.6 |
The sequencing knowledge your team carries — which flavour follows which, which line really handles 2L in summer, which changeover always takes longer than the standard — gets captured as explicit constraints.
Prodooo won't propose a schedule the floor can't run. And when someone retires, the knowledge stays.
| Rule | Scope | Type |
|---|---|---|
| Diet before full-sugar in any tank run | All blend tanks | Hard |
| Cola → citrus requires full CIP | Syrup A, B | Hard |
| Min run 4 hrs on Line 3 | Line 3 | Hard |
| Format change only at shift boundary | Lines 1–2 | Soft |
| Avoid 2L on Line 2 above 30 °C | Line 2 | Soft |
Scheduling is usually pitched as a cost story. In beverage it isn't — the bigger number is almost always the sales you didn't make because the right SKU wasn't on the right line in the right week.
Fill rate is a scheduling outcome, not a forecasting one. When the sequence is right, the cases exist when the order lands.
Every avoided changeover is production hours back, plus the water, chemicals, syrup and labour that went with it.
These aren't a separate sustainability feature. They're the same avoided changeovers, counted in the units your CSRD and Scope 1 reporting already asks for — which means the efficiency case and the environmental case are the same submission.
It reads your master data and demand plan, solves the production schedule, and writes orders back. Your ERP stays the system of record. Nobody has to rebuild an integration landscape to run a pilot.
Schedules reveal capacity, cost structure and customer commitments. We treat that accordingly, and we'll go through your security review before we ask for a purchase order.
Your data is never pooled with another bottler's, and never used to train models for anyone else.
Certification in progress. Current controls, penetration test results and architecture available under NDA.
Cloud, your own cloud tenancy, or on-premise for plants with restricted network policies.
SAP is where your orders, materials and demand plan live, and it should stay there. What it doesn't do is search the sequence space for a multi-stage beverage plant — it validates a schedule someone else has already decided on. Prodooo makes that decision and hands the result back to SAP as process orders. Most of our conversations start with a planning team who are already exporting to Excel to build the actual sequence.
Those are horizontal platforms configured per industry. A beverage implementation means a long modelling project to describe your syrup and blend constraints in a generic framework, and the result is only as good as that configuration.
Prodooo ships with the three-stage beverage model already built. We're narrow on purpose: we only do production scheduling, and only for beverage. That's why implementation is measured in weeks rather than quarters.
No — it gives them a bigger search. Their rules become explicit constraints in the model, and every proposed schedule is editable. If a planner overrides a sequence, Prodooo re-solves around the change instead of discarding the plan.
In practice the role shifts from building the schedule to reviewing and approving it, which is where the judgement was always most valuable.
Twelve months of historical demand, your SKU and routing master data, changeover matrices, tank and line capacities, and whatever sequencing rules exist in writing. If the changeover matrix is incomplete — it usually is — we reconstruct it from historian data during onboarding.
We start in shadow mode. Prodooo generates a schedule alongside the one your team builds, for four to six weeks, with no operational risk. You compare changeover hours, service and cost on real weeks before anything is executed on the floor.
A pilot on one plant runs six to eight weeks: two weeks to model the plant, four to six weeks in shadow mode. You end with a costed comparison across real weeks, not a demo. If the number isn't there, you have a defensible answer and we haven't touched your operation.
Prodooo compares planned to actual every shift using historian and MES data. Persistent deviations — a line that never hits its rated speed on 2L, a changeover that always runs 40 minutes long — get surfaced for your team to confirm, then folded into the model.
We'll model it, run it in shadow mode against your own schedulers, and show you what the difference is worth. Thirty minutes to see whether it's worth trying.