PLC-5 to ControlLogix Migration Supports Greater Uptime for Global Spice Supplier
A global supplier of spice ingredients needed to upgrade their Allen Bradley PLC-5 system. E Tech Group was recruited to modernize their obsolete PLC system to a more IIOT-friendly platform.
The Project: Remove Production Constraints with Complete Control System Upgrade
A global supplier of spice ingredients needed to upgrade their 25-year-old Allen Bradley PLC-5 system. The outdated platform was experiencing constraints and was limiting network connections. The client was seeking a system integrator that could provide timely PLC migration support using the latest technology available.
Automation Group, an E Tech Group Company was recruited to modernize their obsolete PLC system to a more IIOT-friendly platform. Automation Group, E Tech Group’s most recent acquisition, is a leading provider of automation services. They’ve worked with over 1000 clients across North America, implementing advanced control system solutions tailored to each facility’s unique challenges.
The Solution: Implement an Integrated, IIoT-Compatible Control System
E Tech Group automation professionals reverse-engineered the customer’s legacy system and analyzed existing diagrams to identify potential risks to obtain detailed information on device and wiring configurations. This step was crucial to improve control system performance and understand their control environment before moving to the design phase.
As a leading Rockwell Automation system integrator and CSIA-certified automation company, we developed a simplified migration plan using the latest technologies. We converted all networks to Ethernet/IP communications, upgraded the client’s PLC-5 system to ControlLogix and consolidated FactoryTalk View SE screens, making it easier for plant personnel to operate the system.
The Results: The First Step in a Digital Transformation
The global spice supplier’s upgrade from PLC-5 to ControlLogix was completed on schedule and improved performance, greater uptime, and a more user-friendly interface for the client’s PLC system. This upgrade project was a crucial step in the client’s digital transformation journey.
Our recent addition, Automation Group, an E Tech Group Company, designed and implemented this creative automation system solution. For more information on this control system upgrade, visit their website to read the complete case study.
Major SCADA & PLC Upgrade Increases Uptime, Lowers Maintenance Costs for Rice Milling Company
A rice milling company needed a new PLC in a truncated timeline. Automation Group, an E Tech Group Company’s team inventoried equipment and upgraded the facility’s automation system to Ignition SCADA software, setting the client up to meet goals and be prepared for growth.
The Project: Upgrade a Facility’s Control System in 2 Days with No Downtime
A rice milling company was facing operational constraints of a legacy SCADA system. The system was costly to maintain, and the control system design caused frequent communication problems between different production areas.
The client needed a new PLC program to be installed within a 48-hour timeframe to minimize production impacts, and the existing SCADA system needed to remain operational during the migration to Inductive Automation’s Ignition platform.
The client contracted Automation Group, an E Tech Group Company as their choice system integrator given their advanced expertise in system migration and the successful execution of projects at the client’s other facilities.
The Challenge: Tread Softly with Time & Operation Constraints
There were a few obstacles to this control system upgrade that required one of the unique proficiencies of E Tech Group’s brand of automation system integration:
- An obsolete PLC controlled their rice finishing line.
- An obsolete SCADA automation application controlled the entire facility.
- The client had a strict 48-hour timeline to the upgrade implementation.
- The new SCADA needed to be implemented without disrupting the existing one.
- The new SCADA needed to be able to work alongside the legacy control system.
E Tech Group’s team knew this diverse set of obstacles would affect the course of the project, end-to-end. Our control system integrators had to find a creative way to work quickly without sacrificing our detailed approach or the quality of the upgraded automation system.
The Solution: Modular Migration Solves Everything
The project team created a site inventory of the customer’s existing PLCs, network, computers, and applications. The project included upgrades to servers, computers, and network switches in collaboration with the customer’s IT department, the upgrade to Ignition SCADA software across six applications with approximately 500 screens, and the upgrade to two ControlLogix PLC chassis.
The SCADA upgrade was completed in several phases and each application was upgraded individually. This helped minimize impacts on the customer’s production efforts and enabled the legacy and new SCADA applications to run simultaneously so the customer’s personnel could learn the new SCADA software.
The Results: Short-Term Success for Long-Term Growth
This approach to updating the facility’s control system allowed the client to improve operations and network communications at once while giving their operators time to learn the new system before getting rid of the old. Automation Group, an E Tech Group Company leverages this distinct diverse, multidisciplinary engineering approach to create intelligent automation solutions for the customer’s long-term success and the opportunity to support their operations in the years to come.
The talented automation engineers at our most recent acquisition, Automation Group, an E Tech Group Company, managed this particularly tricky project. For more information on this system upgrade, visit their website for the complete case study.
The benefits of hiring a system integrator with robust project management methodology for high-speed execution and high-quality solutions
Challenge
A major food manufacturer needed a system integrator to design and fabricate six control panels for their new production line. They chose E Tech Group because of their expertise in building UL 508A control panels, ability to source hard-to-find parts, and capability to create alternative solutions to meet tight project deadlines. The customer needed a fast project execution and a customized solution with E Tech Group’s streamlined panel build process leveraging AG5 project management methodology. E Tech Group rose to the challenge, constructing six UL508A control panels with speed, quality, and engineering integrity to support the customer’s new production line.
Solution
A main challenge was to ensure the project remained on schedule due to long lead items to PLC components, such as safety PLC modules, VFDs, and other control components. E Tech Group leveraged their efficient panel build process and AG5 project methodology to create a viable solution for the customer across five key phases:
Phase 1 – Collaborate
Following a technical Q&A with the customer and creating a bill of materials, E Tech Group’s project manager collaborated internally with their purchasing department to review project materials and potential long lead items. Long lead items were ordered to ensure the project timeline was not impacted.
Step 2 – Design
Next, E Tech Group’s engineering team created the control panel design, defining the system requirements, developing a device and I/O list, and creating the panel schematics. Every detail is considered and carefully planned to support proper functionality when the control panels are later assembled. E Tech Group’s engineers and drafting team approved the panel design with engineering leadership as part of the system integrator’s internal quality control procedures before it proceeded for customer approval. E Tech Group’s purchasing department then ordered all parts to support the multiple control panel builds and quickly informed the project team of unavailable materials to discuss possible alternatives with the customer. E Tech Group’s project manager and engineering team worked with the customer to create a viable solution with compatible alternatives and then the team regrouped internally to source those alternative hardware options with the purchasing department.
E Tech Group understands that the collaboration and design stages can impact the next phase of a project – building the control panels. Attention to detail and quality control measures lead to faster and higher-quality project outcomes, which is why the first two phases act as a foundation to deploying a well-executed project.
Phase 3 – Build
Once the schematics were completed and the components were received, E Tech Group began building the control panels at their large-scale panel shop in Modesto, California. The panel shop team assembled the six control panels to the customer’s specifications and to comply with UL 508A standards. The panels integrated CompactLogix 5380 Controllers with POINT I/O Safety I/O Modules, PowerFlex 525 AC drives, and Panel View Graphic Terminals for visualization.
Phase 4 – Test
E Tech Group’s panel shop team carefully evaluated each aspect of the assembly process to ensure it complied with safety requirements and functions as intended. The panel shop team performed several evaluations, including point-to-point testing, and produced documentation for the customer of how the control panels were built in collaboration with E Tech Group’s drafting team.
Phase 5 – Deploy
With the control panels thoroughly tested for complete functionality, E Tech Group prepared and shipped the control panels to the customer’s site for installation.
Results
E Tech Group’s multidisciplinary team showcased exceptional results in their project execution, completing the project 4 weeks ahead of schedule. Through seamless collaboration and leveraging diverse expertise, the team achieved high-speed project completion without compromising quality. Their coordinated efforts expedited the timelines, resulting in significant time and cost savings for the customer. The emphasis on maintaining high standards throughout the project lifecycle ensured the delivery of quality solutions, ultimately leaving the customer highly satisfied with the outcomes achieved for their new production line.
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 E Tech 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, E Tech 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. E Tech 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, E Tech 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 E Tech 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. E Tech 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.