Production Controls Modernization for Food Manufacturing Company

Background

A food manufacturer initiated a comprehensive project to upgrade their technology-related equipment across multiple plants. This effort was part of a corporate-wide program aimed at modernizing outdated hardware and software to meet current industry standards and ensure the availability of spare parts, software, and support systems in the future.

Approach

This multi-phase project included all phases from the initial thorough evaluation / investigation of all production controls equipment through the final implementation and start-up of the proposed changes. These upgrades elevated the process and packaging systems to current technology in a standardized condition. This standardization allowed for easier troubleshooting and increased visibility, enabling issues to be resolved quickly, often virtually, rather than requiring on-site intervention.

The initial scope included reviewing / evaluating all existing machine controls, networking and drives, identifying and proposing the most effective controls architecture (hardware & Software) to support the upgrades. The subsequent phase of completing the engineering design effort to properly select and implement the newer technology controls hardware (PLC, I/O, HMI, VFD and Servo Drives, Safety and Industry 5.0 / Connected Shop floor Networking hardware, etc.) including design reviews to discuss operational and safety impacts were completed across numerous production lines and support assets and required both electrical and mechanical changes to support safety guarding as well as retrofitting newer servo motors and pneumatic system upgrades. In addition to replacement / upgrading of obsolete components, the team was also responsible for panel procurement, installation, start-up and training of operators and technicians on updated controls, new HMI screens as well as operational and safety improvements. The team managed overall schedule, parts procurement, provided and coordinated the installation efforts. The team also managed / coordinated all startup and commissioning activities with OEM’s as well as plant operations and maintenance to allow minimal disruption to production through complex phased shutdowns.

Several innovations were introduced, including technical upgrades for energy savings, control architecture improvements using newer distributed control technologies, transitioned from timers and dedicated pattern controllers to a flexible PLC Automation & Safety controller. These upgrades improved safety, reliability, line flexibility / change over capability, consistency, and compliance with industry standards, ensuring quicker operational readiness.

Results

The project provided enhanced efficiency and performance, safety, maintainability, ease of troubleshooting, ensured future readiness, as well as compliance with industry and client standards.  This comprehensive upgrade not only streamlined production processes but also positioned the manufacturer for sustained success and growth.