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Food and beverage automation is undergoing a series of transformations, from more ethical livestock treatment to eliminating artificial ingredients and processes to improving the hygiene of irrigation systems in agriculture. But perhaps the most impactful and paradigm-shifting development in this industry is the emergence of lab-grown meat, which is changing not only how we view meat production and consumption, but also how we view the nature of food automation. Understanding the Cultivated Meat Movement Cultivated meat, also called lab-grown or cultured meat, grows mammalian and fish cells for human consumption in a process similar to biotech drug substance manufacturing. Cultured meat is real meat that is grown from a cell bank of a small number of real animal cells. It doesn’t require animals to be raised, fed, and slaughtered as traditional meat does. In theory, cultured meat should be more sustainable than traditional animal-slaughtered meat. Bio-cultured meat requires significantly less land and water, has a better yield per pound of feedstock, and produces pure meat protein and/or fat that creates minimal waste and byproducts. A single batch can grow 350 pounds of pure meat protein in less than two weeks with no feathers, beaks, claws, blood, bones, or excrement to dispose of. Traditional meat raises the animals where few people live and must be transported to a slaughter facility, processed and further transported to market. Cultured meat plants can be built much closer to population centers, reducing travel time and expense. Additionally, because it is grown in a sterile environment, it is cleaner and has a shelf life that is significantly longer than slaughtered meat – as most contaminants that spoil meat are introduced during slaughter processing. Cultured Meat Automation Intersects with Biotech Automation Growing cultivated meat is a relatively new concept in the biotech marketplace. Although this new industry is … Continued
Overhauling a Botched Control System Upgrade for Warehouse Client
A fulfillment center needed to upgrade its obsolete system which was no longer operational. E Tech Group traveled onsite and overcame a multitude of challenges to get the client operational in their allotted timeframe.
The Project: Restructure a Down System Causing Delays & Disrupting Operations
An order fulfillment and warehousing client was facing significant challenges with an antiquated control system that was no longer operational causing them to fall behind schedule.
In an effort to bring it back online, they had previously engaged another automation services vendor, who had been working on the system for months without success. The client required the system to become operational urgently; further delays would keep them from meeting deadlines and impacting profitability. They turned to E Tech Group to expedite the commissioning process.
The Challenge: Limited Information & a Tight Timeline Leave No Room for Error
Attempting to pick up where another control system integrator left off isn’t the easiest, especially when any number of unknown variables can rear their heads at any time, as they did here. If not for the adaptability and diverse skill set of our automation team, they may not have been able to address and overcome those challenges.
Limited Information and Timeframe: We were provided with only one week to study the current automation system, and the information available was limited, including the system’s description of operations and system rate.
Lack of Equipment Design Information: No information regarding equipment design was presented, which made it challenging to understand all of the control system’s components.
Limited Documentation: We were given some sample codes with minimal documentation, which made it difficult to understand and modify the existing codebase.
Complex System Components: The system consisted of merges and a Print and Apply unit, adding complexity to the commissioning process.
Absence of a System Checklist: There was no existing system checklist to guide the commissioning process.
The Solution: A Hands-On Approach Was Critical in Project Execution
Given the tight project timeline and the client’s immediate need, the engineering team decided to go onsite and commence development work directly at the location. This hands-on approach allowed us to overcome various challenges that could have manifested as delays:
Addressing System Inconsistencies:
Mechanical systems were found to be designed differently at different locations, requiring additional coding.
The team needed to use the existing template, necessitating on-the-fly learning and adaptation.
Inaccurate electrical wiring and layouts posed challenges that the team successfully addressed and resolved.
Identifying Mechanical Inaccuracies:
Correcting the placement of guard rails at scan points to ensure safety and functionality.
Addressing issues related to non-uniform product conveyance within the system.
Collaboration with Scanner Technicians: The team worked closely with scanner technicians, as the work they had performed previously was suboptimal. Multiple interactions were needed to resolve issues and ensure proper scanner functionality.
Interconnections: Establishing interconnections with the upstream and downstream conveyors to ensure seamless material flow within the system.
Checklist development: Due to the absence of an existing system checklist, the team created their own tailored checklist. This served as a fundamental tool in guiding their efforts during the system startup. It allowed them to break down the complex system into smaller, manageable sub-systems, ensuring a structured and efficient approach to the project.
The Results: Adapt, Overcome & Leave the Client With An Operational System:
Through the automation team’s presence onsite, expedited learning and development efforts, they successfully addressed the project challenges and got the upgraded control system up and running within the given timeframe. This achievement was a testament to the team’s adaptability, problem-solving skills and commitment to meeting the client’s urgent needs.
The client’s system is now and remains operational, meeting their immediate requirements and helping them avoid further delays. This project showcases E Tech Group’s ability to navigate complex and challenging scenarios to deliver results effectively and efficiently.
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.
Just because a product still functions doesn’t mean it couldn’t benefit from an update, especially when we’re talking automation technology and control system integration – fields that are anything but static. The old “If it’s not broken, don’t fix it” philosophy with the AVEVA PI System has proven not only a security risk but also results in the user’s inability to leverage the full functionality of the latest PI Software capabilities, especially where the older versions of the software are installed and presently in use. 6 Reasons to Upgrade to the Latest Versions of AVEVA PI System The AVEVA PI System has evolved considerably over time with a focus on security, customer feedback, and market requirements. With the integration of OSIsoft’s IP, the new capabilities of the AVEVA PI have a lot to offer: 1. Heightened Security By upgrading to the latest versions of the PI Software Suite can help ensure the application of the latest necessary security fixes to the core software, enabling active threat deterrence. In addition, the latest version of the PI software suite enables industries to leverage the most current Windows and network security features while providing access to their users based on current standards, best practices, and industry guidelines. When upgraded, your automation system has reduced potential cyber and internal threats while preserving the integrity of your data in the PI System. 2. AVEVA PI Technical Support AVEVA has transformed its skill set to align with the latest versions of the PI Software. With older versions, one can anticipate delayed response time on “time and data-sensitive” issues due to a lack of on-hand technical expertise and solutions to resolve those technical issues. Furthermore, with changes in user requirements and technological development, many of the current PI tools are either no longer available, supported or are in the … Continued
