Updating Label Detection System for Automated Beverage Production
Quality assurance issues were plaguing a bottling facility, as their current label detection system wasn’t catching missing or misapplied labels. E Tech Group was able to integrate three systems into one, allowing for more accurate detection and less missed bottles.
The Project: Remedy the Output Bottleneck Caused by Missed Bottles
An internationally-distributed beverage production company wanted to upgrade their facility’s inspection station to check for missing body, back and neck labels on their bottles before shipping. Quality control was a growing concern and ensuring consistency in each shipment was a must.
Their current label inspecting system wasn’t meeting expectations; imperfectly applied or missing labels were making their way through. This cost the client in time, waste and slowed-output, not to mention threatened consistency assurance in their packaging.
The Challenge: Integrating Three Systems into One on a Tight Timeline
Our team started with a site visit to walk through the customer’s existing control system solution, helping them better understand current challenges and working to define the desired end result and deliverables.
This exploratory review would uncover that we would not be implementing a single system, as was originally outlined in the proposal, but the integration of a new system while simultaneously supplementing the existing system and upgrading the PLC to tie everything together.
The rigid production schedule standard in food and beverage automation would only allow for two days of downtime, each only 12 hours. This required all panels and hardware to be prefabricated before installation and perfect execution on a very truncated timetable.
The numerous moving pieces would dictate the need for strict project management, frequent and open communication, and detailed documentation for any changes in schedule or equipment that might happen throughout the project. Without effective coordination between our automation team and the client, implementation of the new control systems could end up problematic.
The Solution: Build a Robust, Integrated Label Detection System
Coordination between teams translated to coordination between automation products as we pivoted from the original plan of single-system implementation. Instead, we brought together the existing Allen Bradley PLC (existing main panel), repurposed the Teledyne Taptone system that wasn’t providing the results they would like, and integrated the new Keyence label detection system to create one cohesive solution was a large undertaking.
Once the decision was made to implement a Keyence label detection system, the E Tech Group team designed, built and oversaw the installation of the two control system panels that would house the Keyence systems. Both panels were installed close to the reject area after the automated labelers.
Our team actively troubleshot the installation as they went because nothing like this had ever been attempted with the Teledyne product, and between the client and component manufacturers, there were differing opinions on how this should be set up.
E Tech’s automation specialists were able to get the cameras working quickly, but getting them to interface with the Teledyne system wasn’t as easy. A missing trigger signal that would initiate a bottle with a bad label to be diverted was the culprit. Our team moved and reordered some components while repurposing Teledyne photo eyes that weren’t being used, tying them back into the Teledyne system at the same point the Keyence system was being tied in, providing the supplementary signal needed to get the desired results.
Once the system was functioning properly, it was a matter of fine tuning. Our team would be on site, making sure any adjustments were made during planned downtime to not disrupt the client’s production schedule.
Understanding the Scope of Work on this Process Integration Project
The nature of this project required multiple efforts:
ELECTRICAL DESIGN
One generic drawing package was created that detailed the vision systems. An Engineering Information (EI) document package was provided, sufficient to allow for review of the proposed updates, installation by a qualified electrical contractor, and continued maintenance and support, by plant personnel, of the updated equipment, hardware, electrical panels, or controls.
PLC ENGINEERING
E Tech Group integrated the Taptone divert into the Keyence solution and the available PLC control system. The installation of the specified Keyence cameras and configuration was performed and tested. HMI screens were housed in one of the two panels that were supplied. This was the primary access point for the reject solution.
INTERNAL READINESS TESTING
One day for virtual readiness testing was included. A full test of the PLC and HMI was completed. Client and supplier representative(s) thoroughly reviewed the design, programming and commissioning schedule for the system being considered. A checklist was developed and used to identify the key aspects for each system that had been determined to be critical to the success of the installation and assessed the overall readiness. For programming updates, where possible, basic simulation was provided to show that the functionality of the updated system was unchanged.
ON SITE SAT
During commissioning, E Tech Group assisted in on site testing to prove the functionality of the reject system. The testing protocol matched the testing effort from the internal readiness testing. All test scenarios were communicated by Boston Beer prior to start of development. This testing was expected to be performed within one single downtime window.
ELECTRICAL INSTALLATION
Electrical installation will be provided by a third party. The internal controller of the Taptone system and Keyence system controller will get tied back into the pre-existing PLC. Wiring for IO and power is included.
ENGINEERING SUPPORT
One engineer was on site for installation and commissioning, which took one day for setup and commissioning took multiple part-days over the span of a week during planned downtime.
- Infrastructure/communication checks (PLC, HMI)
- Checking of all equipment IO (equipment level check only)
- Parameter/timing adjustments
- Operational checks of all system functions
- Keyence configurations
- Verify any old programs for each updated system are properly archived per site standards
The Results: Adaptation and Communication Made for Smooth Execution
Our team quickly adapted to the change in project parameters and developed, tested and implemented a prototype solution utilizing the selected technology.
Originally planning to implement and test over two twelve-hour days, the team once again pivoted, this time to accommodate the facility’s bottling schedule. Our control system integrators were able to complete the implementation over several days while stopping the line for only brief periods.
The onsite team ensured proper operation while the line was running, confirming the Keyence cameras rendered the correct decision and then had the reject signal sent to the Taptone system, verifying both systems were working properly together.
Through open and clear communication, changes in equipment and time frame were received well by the client and the overall project was a good experience for all involved. The relationship between E Tech Group and the client was strengthened, providing future opportunities to work together.
E Tech Group is a leading control system integrator serving clients across North America with customized automation systems that optimize the vital processes of their facility. Our engineers utilize their expertise, cutting-edge automation products, and a client-centered approach to help them optimize their operations now and in the future.
Challenge
Integrating additional cooling towers in milk production can support a plant’s processing capacity and quality control. These results were desired by a leading American dairy producer who faced challenges with their milk production process. The dairy producer wanted to integrate two additional cooling towers with their existing system to improve production efficiency and support the increased demand for their milk products. The company engaged E Tech Group for this project as the system integrator developed their existing system and had the integration expertise to successfully deploy this project on-time and within budget.
Solution
The project required comprehensive control engineering support. This included system design and development, input/output validation, system functionality testing, and custom control panel design and fabrication based on the customer’s requirements. PLC, HMI, and SCADA programing were also needed to control and monitor the new equipment as well as balance the water flow between the customer’s cooling towers. E Tech Group engaged the engineering team to create the best controls strategy for the customer.
First, the project team verified the project scope with the customer and collaborated on proactive solutions to potential installation and integration challenges. Next, the project team developed the control system design including Rockwell Automation CompactLogix PLCs and PanelView Plus HMI, and Inductive Automation Ignition SCADA programing. New IFM I/O Link modules, PowerFlex drives and Soft Starters were also integrated to monitor new instruments and control new motors for pumps and fans added to the system. The project team integrated these components with the customer’s custom UL 508A control panel build, keeping safety, functionality, and durability of the design top-of-mind.
Results
The panel construction was executed in eight weeks and site commissioning was completed in three days including a few days planned for fine tuning. The integration and installation of additional cooling towers helped increase the customer’s milk processing capacity, supporting greater production efficiency and quality control. By investing in modern technology and upgrading their infrastructure, the plant was able to meet the growing and quality demand for their milk products and support its competitive edge in the market.
Challenge
Fires are a devastating event for any business. It can result in the loss of equipment, inventory, and even the facility itself. The aftermath of a fire can be challenging for any company as it seeks to rebuild and return to business as usual. This case study highlights how E Tech Group collaborated with an architectural engineering company to support an international almond supplier after a fire destroyed their roasting line. The project team worked together on a tight schedule to replace and upgrade the almond supplier’s roasting system, leveraging PLC, HMI, networking, and control panel expertise.
Solution
The almond supplier needed to replace their out of commission roasters with a new, modernized system. On the old line, the operators had to walk between two floors to start and monitor production. The customer needed a solution that simplified the almond roasting process while providing more visibility from beginning to end. The first step was forming a strong communication strategy between the customer and the project team. This consisted of daily progress meetings about the project’s developments and potential challenges such as equipment procurement, control panel design, and PLC and HMI programing to control the roasting systems. One of the biggest challenges was the “design-build” method to execute the control panel build. This meant the control panel design had to be open to changes while it was still being built in the shop. The project team relied on their strong collaboration skills to successfully merge these steps to support the tight project timeline.
E Tech Group’s principal engineers leveraged their expertise to develop the control modules in CompactLogix PLCs and PanelView Plus HMI for the customer’s various devices as well as configured Moxa managed switches for multi-level network topology. The engineering team also worked closely onsite with electricians to change the control panel design as needed, which included designing auxiliary panels and ordering time sensitive parts for safety and air handling operations. The onsite team also focused on configuring network controls as well as fan VFD motor controllers and burners for the new roasting line. The project manager maintained timely communications with the project team and the customer, securing engineering resources to help with the PLC and HMI code design and managed the team’s progress toward the finish line.
Results
With everything in place, the project team was able to successfully execute the project and trained the customer’s operators and maintenance staff on their new and improved roasting system. The project took about four months to complete from the design phase to site acceptance testing. Rather than walking between two floors to start and monitor the roasting process, the customer’s operators could now start the entire line with the push of a button on the HMI and have production visibility from start to finish. Also, the added controls to the plant network, such as Rockwell Automation’s FactoryTalk AssetCenter, supported the management and protection of the customer’s automation-related asset information. With the project complete, the customer was able to resume production with a more intelligent, modernized roasting line.
Building a PlantPAx 5.0 System for a Pilot Cultivated Meat Plant
A cultivated meat production facility needed to scale up from lab production so they could refine their process of growing cells at bench-top scale to a pilot scale. E Tech Group helped them to replicate their lab-driven results in an increased-volume setting, setting them up for large-scale production and distribution.
The Project: Innovate a Facility-Wide Control System for a Pilot Alternative Protein Plant
Alternative proteins, including lab-grown meats, are the new horizon of ethical, sustainable meat production. Specifically, cultivated meats are just emerging, with the first expected to be available within a few years. Cultivated meat production plants are a new frontier as far as food and beverage automation goes.
A client leading the way in this vein of alternative protein was scaling up from lab production, where they were able to refine their process of growing cells at benchtop scale to a pilot scale. Proving it was possible to replicate their lab driven results in an increased volume setting, if successful, would help move into large-scale production and distribution once necessary approvals came through.
Previously having worked with E Tech Group as an automation partner that helped guide and coach them through thoughtfully identifying their needs for their first automation project, they were confident in our ability to help plan, design, implement, test and support an end-to-end, turnkey automation solution for this new facility.
The Challenges: A New Type of Food Production Requires New Automation Tech
Because this was a new installation of cutting-edge technology, there was no lack of presented challenges on this project. We were all in uncharted waters.
Understanding that nothing in this industry had yet been designed and executed on this scale, the entire process would remain fluid. Change and adaptation would be a constant theme throughout the planning and implementation.
Knowing what was being produced was designed for human consumption, ensuring the developed solution exceeded industry and federal guidelines and standards was non-negotiable. E Tech Group needed to ensure this facility’s automation system took all of the unknown out of the cultivated meat production process.
The Solution: Utilize Rockwell’s PlantPAx 5.0 to Support the Automated Systems
The design of this project needed to be just as creative as the client’s endeavors in this new field of meat production. Communication and flexibility was key in pulling off this leading-edge, facility-wide automation system integration.
Process Design
The plant being a pilot and the organization essentially a start-up, the process engineering environment was naturally ever-evolving and dynamic. The E Tech Group team kept up with the constant changing strategies, provided technical guidance in streamlining the design to a point where it could be automated, and clearly communicated changes to the process design as they went live. This helped maintain open lines of communication with stake holders and create realistic expectations for delivery.
Process Outline
- Media Prep – Media Transfer, CIP of the Media Prep suite, SIP of the Media Prep Suite
- Clean In Place (CIP) – CIP of the Bioreactors and the transfer lines
- Steam in Place (SIP) – SIP of the Bioreactors and the transfer lines
- Inoculation
- Media Filtration
- Cell Growth
- Seeding/Circulation
As part of the design effort, Pin Charts were developed and maintained. These defined the valve alignment and various schemes for Equipment Modules corresponding to each phase step, covering a matrix of over 100 phase steps and over 300 devices, over 200 valves, and a gamut of control modules.
The team also worked to design customized control loops (involving Cascade methodology) for pH, Dissolved Oxygen (DO) and Temperature Control (both Vessel and Jacket) of the Bioreactors. These complex algorithms use shared equipment and phase-specific control strategies.
The process design also involved deciphering functionality of specialized equipment such as Mix Proof Valves – the Equipment Module developed for this valve comprises of 9 schemes in its operation.
Electrical Design
- Panel Layout
- Network Layout
Automation Products
Our process automation team had a daunting task at hand – to synthesize the enormous design and get the system ready for production in less than 6 months. The automation effort included the following tasks:
- PLC Program Design: Rockwell Automation PlantPAx 5.0, ControlLogix L85 EP, Studio 5000 v33
- Mix of 4.x and embedded 5.0 process objects
- Function Block and Ladder Logic used to program Control and Equipment Modules
- Structured Text programming for Phases
- Phase Parameter definitions
- Hold, Abort and Stop Logic
- Operator Prompts and Reporting Logic
- Linking/Messaging with Parallel Phases
- Equipment Module Programming
- Scheme Propagation
- State Model
- Permissive
- Interlocks
- Valve Supervisor Equipment Modules
- Online Configuration Tool – development and maintenance for bulk import of IO
- Handshaking with External Skids (Sanimatic CIP, Alfa Laval Centrifuge)
- Message Instruction programming
- Produce, Consume Tags
- Batch Programming: FactoryTalk Batch
- Area Model Configuration – S88 standardized
- Recipe development – Unit Operations and Unit Procedures
- Handshaking with External Skids (Sanimatic CIP, Alfa Laval Centrifuge)
DCS Design & Implementation
A new DCS System was implemented in a virtualized environment using the FactoryTalk View SE, PlantPAx system. The system is scalable and sustainable, as the infrastructure supports future growth for the pilot plant. The HMS, Historian and Win-911 systems were integrated and deployed.
Components
- SCADA Server: hosts the HMI server, Data server, Alarm and Event server
- ThinManager and Terminal Server: host thin client sessions for HMI operations on the plant floor
- Batch Server: ISA -88 standard Batch engine for Recipe development
- Network Directory Server
- SQL Server
- Win-911: Remote alarm notification to pre-configured user groups via FactoryTalk Alarm and Events
- FactoryTalk Historian SE Server
- Engineering Workstation – hosts the Rockwell Development suite
Features
- Graphics are developed based on the ISA 101 standard.
- Alarms are based on ISA 18.2 standard.
- Node security implemented
- Scope for external Skid Integration
- Custom graphics developed for external skid integration
- Sanimatic CIP Skid
- Centrifuge
Onsite Support & Equipment Testing
In addition to the unparalleled in-house development effort, E Tech Group has provided over 600 hours of hands-on onsite support to the client – starting from instrument checks to Recipe Testing. From beginning to end, our team kept up with dynamic changes happening during the Wet Runs, adjusting the design accordingly and re-integrating the changes into the active system.
E Tech Group’s ability to adapt, adjust, and overcome was critical in the final testing and rollout of this solution. Vital processes we monitored, tested and facilitated included:
- Loop Checks
- Loop Tuning
- Equipment Module Testing
- Phase Testing
- Recipe Testing
- Troubleshooting
- Operator Training
Documentation
Documentation is key in an effective facility-wide automation system, as it allows the users to analyze and identify everything that happens within the system. This has implications for standards, quality control and troubleshooting.
E Tech Group developed the Functional Design Specifications for the entire process – starting from ground zero and then updating all the specs based on the As Built system. Throughout the entirety of the project, our team consolidated information from various vendors – Standalone Skids, construction management and piping and instrumentation vendors – trying our very best to not let any details slip through the cracks.
We also helped develop SOPs to meet the client’s production and compliance requirements. This gives the owner the ability to better support their own system, since it is well-documented. They can find information easily and without having to bring in a control system expert. This reduces downtime, which is inevitable in a development process for cutting-edge products like cultivated meat.
The Results: A Positive Learning Experience for All Involved
After a successful completion of this EPIC project, E Tech Group is fueled with stronger skillsets and hungry for more. We are proud to be part of this journey with the client and extremely thankful to them for trusting and partnering with us in designing and creating the automation solution.
E Tech Group is a Rockwell Automation partner, supporting manufacturers across industries with a unique brand of innovative, adaptable, robust control systems. We design and implement building-wide automation systems that are secure, user-friendly, and sustainable long-term, so you can focus on maximizing quality, capacity and the ability to scale.