Control Systems Upgrade Maximizes Efficiency for Dessert Packaging Line
Challenge
In the fast-paced world of food manufacturing, efficiency and precision are paramount for maintaining a competitive edge. When a major player in the food industry wanted to upgrade their packaging controls for flan and pudding products, they turned to the trusted engineering team at Automation Group. The packaging process required precise control and synchronization to maintain product quality and optimize packaging speed. However, the client’s outdated controls system hindered their ability to meet growing production demands. The challenge was to develop an efficient controls solution that could be executed within a tight one-weekend timeframe and with minimal downtime. The project encompassed addressing outdated PLC and HMI systems, aging control panel hardware, and the need for improved networking communications.
Solution
Recognizing the tight project timeline, Automation Group leveraged their expertise to create the best solution. Through planning and collaboration, they formulated a comprehensive approach that began with a thorough evaluation of the existing control panel and its components, and identified which areas required improvement and retrofitting. Automation Group consulted with trusted vendors to assist in the retrofitting process for servo drives, motors, and gear boxes, and strategized the most effective approach to implement the necessary program changes. Once these enhancements were identified and received, the project team utilized a planned shutdown period to validate the functionality of the retrofitted products.
Over the course of the weekend, Automation Group put the project plan into action. The team disassembled the customer’s control panels and installed new components, migrated existing PLC code to the new controllers, and converted the customer’s existing HMI screens to a new PanelView HMI application. They utilized Studio 5000 for retrofitting PLC programs, FactoryTalk View software to make required alterations to the customer’s HMI programs, in addition to command line programing to support network segregation for the new Stratix 5700s.
Results
The controls upgrade was achieved swiftly and effectively, all thanks to the unwavering dedication and collaborative efforts of Automation Group’s engineering team. The customer experienced minimal interruptions and downtime, enabling enhanced production and operational efficiency. The upgraded PLC and HMI systems brought improved functionality, while the new control panel hardware simplified system maintenance and reduced costs. Furthermore, the enhanced networking communications facilitated seamless data transfer and real-time monitoring, empowering the client to make informed decisions and uncover possibilities for further optimization. Automation Group’s collaboration, expertise, and determination to overcome project challenges demonstrates their commitment to customer satisfaction and their ability to deliver successful project outcomes under time-sensitive circumstances, solidifying their reputation as one of America’s fastest-growing system integrators.