Utilizing Ignition Platform to Provide Organization-Wide Access to Quality Data
E Tech Group helped Prima Frutta increase productivity by 50% without hiring extra personnel by using the Ignition platform, which allowed remote operation of the production line and real-time data access from any smart device.
The Project: Ignite Increased Productivity with the Right Automation Platform
Manufacturers are facing costly workforce challenges. Between the labor shortage and the costs associated with employee turnover, companies are finding it difficult to increase productivity on their current automation system designs.
Prima Frutta, a cherry packaging facility in Linden, California, was struggling to maintain its production levels, but did not have the scope to add a lot of extra personnel to reach those levels. E Tech Group was called to help overhaul their control system, and under a tight timeline.
The Solution: Divide & Conquer Material Handling Automation
This control system upgrade was divided into three phases:
- Phase One: Project Planning and Documentation
- In the project’s first phase, the E Tech Group and Prima Frutta teams collaborated on planning, budgeting and documentation. They used CSIA methodologies and standards, created a detailed budget, and documented all OEM hardware into schematics that were approved before proceeding to Phase 2. This ensured the project remained on track and within budget.
- Phase Two: Wireless Network Set-Up
- The E Tech Group team successfully established a wireless network, which enabled ten tablets to remotely operate the production line through the Ignition industrial application platform from Inductive Automation. Ignition was chosen because of its flexibility, affordability and fast setup. The applications can be entirely customized quickly and easily, and data can be accessed from any smart device, including tablets, desktops, or any other smart device to allow real-time data access from anywhere the user is located.
In this project, the tablets enabled a change in process flow from anywhere in the plant, providing full SCADA control, unlike a static location. The installation process of Ignition on the tablets was seamless and took less than two hours. The Ignition software also ran on more than 120 screens throughout the plant, providing real-time data and color-coded information to employees for quick and efficient reactions.
- Phase Three: Development, Testing and Implementation
- E Tech Group used Prima Frutta’s existing server to develop modular software and PLC codes, allowing for quick deployment through component, template and user-defined type reuse.
The Result: Reaping the Fruits of a Well-Designed, Fully-Integrated Control System
The project resulted in a 50% increase in production with no additional personnel, helping Prima Frutta become the world’s largest cherry production line. The Ignition platform reduced downtime and enabled the facility to respond to changing conditions.
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Winery Begins Digital Transformation with Automated Brix Monitoring & IFM Integration
A leading California winery was facing manual sampling inefficiencies. E Tech Group implemented an IFM Integration project, achieving fully-automated in-tank brix monitoring with our IO link platform expertise.
The Project: Transition Manual Brix Monitoring to an Automated System
A California winery faced operational inefficiencies with manual wine sampling and turned to E Tech Group for an IFM integration project. The goal was a seamless transition to fully automated brix monitoring. Our proposed solution involved IO Link Masters for Modbus TCP data retrieval and two durable NEMA 4x stainless steel enclosures. The client chose to contract E Tech Group as their integration partner because of our proven expertise in IO Link Platform, and our proven track record of providing reliable process automation solutions.
The Solution: Leverage Expertise & Cooperation for a Custom Automation Solution
The project team partnered with IFM and a research university to verify the precision of a new pressure transmitter for accurate brix measurements. Our team worked with the winery’s maintenance team to secure space for control panels, and collaborated with Tanknet for the system integration. An IO Link Master was set up for communication through Modbus, leading to successful implementation of the automated brix monitoring system.
The Results: Process Automation Optimizes the Sampling Process
We successfully acquired brix measurements within the tanks and integrated Modbus IO Link Masters into the control system, meeting the client’s goals for automated brix monitoring. Our automation team’s expertise and collaboration resulted in a positive outcome, moving this leading winery forward into their digital transformation.
Rockwell Automation Solutions Improve Spice Company’s Production Capabilities
When a major spice producer decided it was time to convert key manual processes to automation in order to improve efficiency, E Tech Group leveraged Rockwell Automation solutions that supported increased throughput and cost reductions.
The Project: Design a Custom Automation System for a Spice Supplier
A supplier of culinary spices needed to automate their receiving and washing areas to improve efficiency and visibility. The existing manual approach caused bottlenecks and hindered production potential, making automation crucial for optimizing processes, streamlining workflows and gaining the ability to scale.
The Solution: Utilize Rockwell Automation Technology for Seamless Transition
E Tech Group used a range of Rockwell Automation hardware and technologies to align with the customer’s objectives, resulting in a more streamlined and responsive control system. They also upgraded the hot wash hardware using a suite of Rockwell Automation components, improving efficiency, reliability, and safety. Rockwell Automation’s Studio 5000 v33 and Factory Talk View Studio Machine Edition provided a user-friendly control system interface for the spice supplier.
The Results: A Cost-Effective Automation Solution with Real-Time ROI
Our automation and engineering firm provided dedicated support to the project, which resulted in increased throughput and reduced production costs. The expected return on investment will materialize in three years, showcasing the cost-effectiveness of the Rockwell-based automation solution. This transformation optimized operations and paved the way for future improvements, highlighting the effectiveness of our collaboration and Rockwell Automation’s process control solutions.
An efficient PLC and SCADA upgrade successfully minimized downtime, reduced costs, and improved the operational control of a tomato peeler system, enhancing product quality and competitiveness for a food manufacturer.
Challenge:
A prominent food manufacturing company specializing in tomato processing faced a significant challenge with their existing peeler system. The controls hardware was outdated, causing a higher risk of downtime, limited maintenance support, and poor controls performance and control network communications. The company needed to resolve these challenges and sought the support of E Tech Group. The food manufacturer chose E Tech Group for their proven track record and expertise in control systems, supporting a swift and successful automation project.
Solution:
The customer needed to upgrade their existing panel hardware for a modern EtherNet/IP control system. E Tech Group analyzed the customer’s existing system and provided the customer with a detailed plan to meet their specific needs of an upgraded system. This upgrade involved converting their existing Allen-Bradley PLC5 to the Rockwell Automation ControlLogix platform using the RSLogix 5000 programming environment. The customer also needed support connecting the ControlLogix platfrom to a new EtherNet/IP control network, converting several Powerflex VFDs with EtherNet/IP communications, and programming AVEVA HMIs and SCADA software for improved system visibility and real-time data monitoring. E Tech Group supported the system upgrade, retagging and remapping the existing logic to the new EtherNet/IP controlled hardware. The AVEVA HMIs and SCADA system were redesigned and programmed to provide the customer’s operators with better usability and improved access to critical data, ultimately enhancing their operational efficiency.
Results:
The project was completed on schedule, minimizing downtime. This led to significant cost savings as system failures were reduced. Improved control performance ensured smoother tomato peeler operations, enhancing the customer’s product quality. The enhanced system visibility enabled data-driven decisions and proactive issue resolution, reducing operational risks, and improving efficiency. Ultimately, this project supported the food manufacturer’s competitiveness in the market with a more modern control system.