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BURA industrial system
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One system that carries material from the scale to Navision

BURA is an industrial ERP system, built by the Bayer Construct SRL group's own team together with ExarLabs and Sonrisa Technologies. Warehouse management, production, quality assurance, maintenance, fleet management and inter-site order flow all run on one database.

It runs in four deployments, across twenty-two sites, in live production since 2022. This page is not a sales page for BURA: it shows what the team that built it can build.

Get in touch Full module specification
Deployments4
Sites22
Modules6
Integrations18
Permissions50+
In productionsince 2022

The path of material: from LOT to traceback

A LOT moves through eight stations in the same system: from goods receipt, through quality inspection, put-away and the production order, to the material balance, picking and traceback. Every station writes to the same database, so a finished product can be traced backward to the raw-material batch it was made from.

Traceability rail The path of material from LOT opening to traceback, across eight stations. 01 Goods receipt (LOT opened) 02 Quality inspection 03 Put-away (3D cell) 04 Production order 05 Processing 06 Material balance 07 Picking 08 Traceback
  1. Goods receipt (LOT opened)
  2. Quality inspection
  3. Put-away (3D cell)
  4. Production order
  5. Processing
  6. Material balance
  7. Picking
  8. Traceback
FIGURE 01 All eight stations of a LOT are tracked in the same database, from receipt to traceback.

Six modules, one database

01

WMS

Warehouse stock, weighing and slotting in one system.

Scale integration Automatic slotting Custody storage
02

Production and MES

Production lines and recipes, from planning to execution.

Configurable steps Continuous processing Material balance
03

QMS

Quality parameters and traceability for every batch.

Versioned QA IFS, GGN Quarantine and release
04

CMMS

Assets and maintenance tasks, synced with Navision.

Navision sync Preventive maintenance Resource booking
05

Fleet

Vehicle and equipment records with document expiry.

Mileage and fuel log Document expiry Excel export
06

Orders

Orders and material movement between sites.

Navision sync Intercompany billing Automatic job chaining

All six modules, in detail

Screenshot of the BURA interface: a table of jobs across multiple sites and companies, with filters and status indicators.
FIGURE 02 The same interface switches between the group's entities and carries a job through its full chain: receiving, updating, processing, dispatch, inbound, quality.

Connected to the machines and to Navision

BURA is connected to 18 named external systems: scales (Elicom, KERN, ScaleIT), label printers (Zebra, Markem-Imaje), SCADA systems (WinCC, Ignition), the MES layer (Kastor), and Navision as the ERP backend. Data moves over whatever protocol the machine supports.

TCP/IP Web API database-level connection OPC UA MQTT
Integration map BURA's machine and enterprise connections: nine field-level sources, the BURA core, eight enterprise systems. Elicom / KERN / ScaleITscales Zebra Markem-Imaje WinCC Ignition KobFlex OPC UA sensors SCOTT palletizer Schneider PAS600 Navision (ERP) Kastor (MES) Azure AD Azure Blob SMTP Grafana Smagria MOL BURA WMS · MES · QMS · CMMS TCP/IP DB to DB OPC UA MQTT Web API
Integration links: field side, enterprise side, protocol
Machine / plant sideEnterprise sideProtocol
Scales: Elicom / KERN / ScaleITNavision (ERP)TCP/IP
WinCC, Ignition, OPC UA sensorsKastor (MES)OPC UA
User access across all sitesAzure ADWeb API
Labeling: Zebra, Markem-ImajeAzure BlobMQTT
Alerts and notificationsSMTPWeb API
KobFlexGrafanaDB to DB
SCOTT palletizer, Schneider PAS600SmagriaMQTT
Fleet and fuel dataMOLWeb API
FIGURE 03 Field-level machines and enterprise systems connect through the same integration layer.
Screenshot of the BURA master-data view: an article master list in columns, with a Navision sync status column.
FIGURE 04 759 master-data article rows, continuously synced with Navision.

Traceback: what it was made from, where it went

Traceability works in both directions: forward, from raw material to finished product, and backward, from a shipped batch to the original raw-material LOT. The system handles IFS and GGN certification requirements, quarantine and release, and attaches a certificate to every quality event.

Screenshot of the BURA genealogy view: a branching tree structure linking a batch to its related work steps.
FIGURE 05 A batch traced through about 45 linked work steps, from raw material to finished product and back.
Screenshot of the BURA material-balance table: input and output line items with calculated yield and loss columns.
FIGURE 06 A closed material balance in a single calculated table: input, output, yield percentage, process loss, by-products.

Four deployments, twenty-two sites

  • POWA: potato warehouses and factories, 7 sites.
  • LYO: freeze-drying (lyophilization), 1 site.
  • MIPO: milk powder and infant-formula production, 3 sites.
  • CMMS: maintenance and fleet, 11 sites.
Deployment matrix Four BURA deployments, twenty-two sites in total, from one shared codebase. POWA 7 LYO 1 MIPO 3 CMMS 11 01 02 03 04 05 06 07 01 01 02 03 01 02 03 04 05 06 07 08 09 10 11 22 SITES · 4 DEPLOYMENTS · 1 CODEBASE
Deployment matrix: instance, scope, site count, modules
InstanceWhat it runsSite countModules
POWAPotato warehousing and processing deployment7WMS, Production and MES, QMS
LYOFreeze-drying line supervision1Production and MES, QMS
MIPOMilk powder and infant-formula production3WMS, Production and MES, QMS, CMMS
CMMSMaintenance management only11CMMS
FIGURE 07 POWA, LYO, MIPO and CMMS are configuration variants of the same codebase, not four separately built systems.

Built with

Stack

FrontendReactJS
Backend.NET Core
DatabaseMongoDB
MonitoringGrafana
Real-time pushSignalR

Security

AuthenticationAzure AD
Permission managementRole by site
Number of permissions50+
Data isolationMulti-tenant isolation, 22 sites

Operations

AlertsStock shortage, overfill, expiry, integration event
ReportsWarehouse, receiving, production and dispatch statistics
Regulatory reportingYes
Energy consumptionTracked

Who built it

The Bayer Construct SRL group started BURA with its own in-house development team, aiming for one shared system across the group's factories. Because of the size of the job, the group brought in outside development capacity: ExarLabs and its strategic partner Sonrisa Technologies.

For two and a half years the three sides worked as one team of roughly twenty people, not three teams side by side. Project management stayed with Bayer Construct throughout, and the group's own developers ended up writing code as well. ExarLabs and Sonrisa supplied development capacity, plus design and decision advice where needed.

The collaboration has ended. The system is today operated and further developed by the group's own ten-person team. That handover was the goal, not an afterthought: the point was to leave behind a system and a team that keep running smoothly without us.

exarlabs.com · sonrisa.hu

Let's build one for your plant too

If building a system like this for your plant is something you are considering, this email address is where to start. There is no form, and no mandatory introductory call: one sentence about what you want to solve is enough.

Email us

ExarGroups SRL · Odorheiu Secuiesc · RO41839221