Challenge
Olive oil production relies on robust storage systems. Storage systems that have inadequate controls against light, heat, and oxygen exposure can compromise the freshness of olive oil products and result in considerable production loss for olive oil manufacturers. To combat this, olive oil companies commonly use temperature controlled and light-protected stainless steel tanks to safely store the olive oil until it’s ready to be bottled. Any mismatch in storage capacity to olive oil production presents a manufacturing bottleneck and loss of profits. For one of the largest olive oil producers in California, the ability to scale their business relied on a robust storage system to expand their olive oil processing capabilities. Industry partner Barnum Mechanical Inc. teamed up with E Tech Group to support the company’s storage system needs.
Solution
With the desire to expand their olive oil production, the customer needed a new storage tank farm with greater capacity. The project team assessed existing equipment, current system requirements, and collaborated with various stakeholders to best plan the storage tank system, keeping safety, maintenance processes, and future expansion capabilities top-of-mind. The team interfaced Rockwell Automation ControlLogix PLCs with Wonderware software to support a high-performance control platform with intuitive process visualization. An ifm Actuator Sensor Interface (AS-i) networking solution was designed and integrated in the PLC to simplify wiring efforts with various storage system sensors and save significant time during the installation process, notably as an alternative to conventional point-to-point wiring. Additionally, at the time of this project, it was believed that the team created the largest AS-i network in North America given the extensive networking applications needed for the customer’s large industrial environment.
The team also integrated a Clean-In Place (CIP) system in the controls engineering design to better support production uptime, product quality, employee safety, and cost-effective maintenance. The CIP system provided an automated method to clean interior surfaces of the process equipment without having to disassemble the system for future cleanings. The CIP system was integrated with all storage tanks and transfers to each tank from the olive oil extraction process.
Result
The project and process were a complete success. The customer was able to sufficiently store their increased production of olive oil and then some. The project team was thrilled to have the opportunity to support the new storage tank system and optimize their process environment with a CIP system. With the greater storage capacity, the customer was able expand their product into new geographies and gain greater market share.
Director of Business Development, Laurie Cavanaugh presented a webcast for Control Engineering on Data Analysis with Matt Ruth of Avanceon. Below are a few participant questions and answers from the webcast. Who is typically the driving force to engage on analytics in a manufacturing plant? A top-down approach to data analytics is typically driven by corporate and involves corporate IT and the use of accessible data in the form of financials and some operational data that has been consolidated (transactional data) based on enterprise resource planning (ERP) and business intelligence software. A bottom-up approach is typically driven by manufacturing departments or sites and starts with granular detail (time-series data) using historian databases and extraction tools offered by automation and controls manufacturers. Where true value and insight can be experienced is in the convergence of these two analytics’ efforts to connect the corporate financial and operational data with the more granular process execution data to provide a more thorough and holistic view of key factors that drive organizational decisions from top to bottom. What do you see as the future of analytics in manufacturing? The future is now. User expectations and demand for contextualized and intelligent information, driven by the tools used outside of the workplace, are countering old excuses or reasons for the failure to deliver fact-based analytics, directed decision making, and immediate access to critical information. Technical tools and platforms are not lacking. What is lagging is the complete understanding and response to the non-technical bottlenecks and barriers. Greater awareness of how analytics applies to processes and proper context for critical decision factors produce the value that addresses those non-technical barriers. Do you realistically see the wall between information technology (IT) and OT disappearing? The IT/OT wall or divergence must be overcome for the sake of shared responsibility: the … Continued
Challenge
Distilled spirits have complex processing needs. To stay competitive, spirit producers often turn to batch processing and blending solutions to improve their operational agility; however, this can be compromised as their systems become outdated. This was the case for a global leader in the spirits industry who needed to update their existing blending system to better support recipe management, faster quality verification, and adaptive ingredient delivery. The global spirits leader engaged E Tech Group and their industry partner Barnum Mechanical Inc. to provide a turnkey solution given their collective process design and control system integration expertise.
Solution
The first step was to understand the customer’s recipes and batch execution methods. This included their ingredient applications, equipment processes, and final product expectations. The project team introduced the customer to ISA-88 batch process management; a set of standards published by the International Society of Automation (ISA) for managing batch control systems. It divides a batch process into a hierarchy of subdivisions to better optimize the utilization of assets and operational performance.
Using the ISA-88 standard, the project team divided the production environment into logical blocks to separately analyze units, equipment, and control modules. With these separated, the sequencing of the process could be well-outlined and then proven for accuracy and reliability. The project team utilized Rockwell Automation FactoryTalk Batch and View Site Edition networked software to provide seamless integration across all aspects of the system. The team also integrated electrical design and automated reporting solutions for classified areas to help safeguard assets, equipment, and people. Once completed and thoroughly tested, the project team stayed onboard to train operations staff on how to quickly adapt to the updated system and take advantage of its enhanced features.
Results
The complex project lasted eighteen months to design, develop, commission, and decommission the existing system. E Tech Group and Barnum Mechanical Inc. enjoyed the opportunity to collaboratively leverage their process knowledge to design the batching and CIP systems, as well as support PLC and HMI programming. For the global spirits leader, the updated system supported increased productivity with greater system reliability in addition to improved quality with more precise control strategies using ISA-88 standards.
We’re excited to announce we will be exhibiting at Automate 2022 with our partners at Apera AI. We hope you’ll SWING by at booth #4113 to see our ABB cobot TEEing up a golf related demonstration utilizing the latest in adaptive 4D vision technology. You wont want to miss out! Click Here to Register for Automate 2022.
