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We are partnering with Rockwell Automation on the launch of their new FactoryTalk® Optix™Portfolio: Revitalize Your HMI Operations webinar series. The third and final webinar in this series is coming up in August- the first two are available OnDemand. The series is about how the FactoryTalk® Optix™ end-to-end HMI solution can revitalize HMI operations across the equipment lifecycle.
Earlier this month, our executive team had the opportunity to visit Rockwell Automation’s Customer Experience Center. This impressive facility not only showcases the rich history of automation and technology but also serves as a platform for E Tech Group to collaborate with Rockwell in presenting tailored technology and automation solutions to our clients.
Cassy Gardner, Director of Operations at E Tech Group, recently presented “How to Get the Most Out of Your FEED Study” in an exclusive webinar. She provided a high-level overview of what a FEED study entails, explained the reasons for conducting one, and discussed various examples and challenges.
A food and beverage client was continuously struggling with scheduling production lines. E Tech Group implemented a new control system, providing the client with a dedicated packing line for their sterilizers.
A food and beverage manufacturing client required a dedicated packing line for their sterilizers that were added in 2019. They had previously been using their existing packaging lines which, due to the physical layout, were inefficient and placed continuous strain on scheduling for other production lines.
E Tech Group’s familiarity with the client’s facility, vast skillset and expertise in the design and implementation of these types of manufacturing automation solutions in the food and beverage industry made it an easy decision for the client to contract our team.
Before developing the required solution, the onsite team first had to address the challenge of determining the hardware/control system panel layouts, as well as a networking plan for what it would take to integrate the new automation system before further assessment and design could take place.
Because budgetary restrictions played a role in this project, the client’s plan was to repurpose old packaging equipment from one of their other plants and tie it all together with a new conveyor system. This involved integrating the existing equipment, which included older PLCs, with a new line control PLC and remote racks.
The most difficult part in implementing the project was commissioning the recycled equipment. E Tech Group determined that due to age and previous use, several parts were reaching end of life both mechanically and electrically, requiring the installation of replacement parts before the equipment would function as it should.
The advanced troubleshooting required to find these aging assets took the most amount of time. However, during this time the automation team was able to further investigate the client’s operation, allowing them to provide the most comprehensive solution for the client.
Once all equipment concerns were addressed, updated and operational, the new line control system could be installed and commissioned.
This system utilized a new Allen Bradley L8x series ControlLogix PLC along with recycled Allen Bradley SLC and PLC5 plcs on the repurposed OEM equipment.
As originally planned, the main networking system was ethernet/IP. However, the team did have to install a DH+ network to integrate some of the older PLCs into the new system.
The main visualization software was the Wonderware System Platform, and the individual equipment used various forms of Allen Bradley Panelviews. This created a control system that fully-integrated the new production line with transparent, user-friendly controls.
From start to finish, the project took just a few months to complete, keeping within the client’s defined time parameters and minimizing production disruption. When our team was through, the client had a dedicated packing line for their sterilizers and were no longer dependent on inefficient equipment that would interfere with the scheduling and operation of other lines.
E Tech Group’s project team also provided an extended period of 24-hour startup support once the lines were running product, making sure everything stayed operational and maintained optimal functionality and performance. Once implemented, the new automated packing line added value for the client by removing the previous physical and technological complications that prevented them from making the most of their new sterilizers.
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