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 However, the client’s outdated controls system hindered their ability to meet growing production demands.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 The project encompassed addressing outdated PLC and HMI systems, aging control panel hardware, and the need for improved networking communications.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.
Applications Engineering Manager, Jeff Allen recently co-presented a webcast for Control Engineering covering how edge computing can be used for mission-critical, high-reliability automation and control applications. Applications demonstrate how edge computing can be used for mission-critical, high-reliability automation and control applications. See how system integrators have applied edge computing and see how it integrates in automation and control applications. Challenges and benefits will be discussed. Learning objectives: Understand how edge computing is being applied to automation and controls. Explore how edge computing enables certain applications. Learn how edge computing integrates with cloud resources. Review application benefits, return on investment considerations, and other benefits for automation and controls. Presented By:Jeffrey Allen, Applications Engineering Manager, E Tech GroupNate Kay, P.E., Control Systems Engineer, MartinCSI Moderated By:David Miller, Content Manager, CFE Media and Technology Click here to view the webcast.
This article was written by engineering technician at E Tech Group- Bradly Wright and originally appeared in Automation World. Click here to view the original post. To maintain uptime, ensure compliance, and maximize the use of skilled labor, more facilities than ever are centralizing production control and monitoring. There’s a reason more and more facilities are changing the way their production floor has been operating for decades: the current labor shortage. When production floors were fully staffed, it wasn’t uncommon to find a worker stationed at each point in the manufacturing process, monitoring the HMI (human-machine interface) as the PLC (programmable logic controller) repeated its programmed task, ensuring consistency and efficiency at each step. PLCs were designed to function optimally by executing one line of code at a time—with nothing else running in the background. This was a completely viable solution when manpower was available to individually monitor each process. Even now, the PLC remains in wide use because of its flexibility and ease of programming. It’s still incredibly reliable, allowing the operator to make on-the-fly adjustments thanks to real-time information transmission. The big difference now is in how PLCs are being used as more manufacturers are forced to implement a control system that will help centralize production control and monitoring. The use of a distributed control system (DCS) allows a central point of monitoring and operation that coordinates and supervises an entire plant completing a variety of processes and can be scaled facility wide. A PLC, however, is isolated in its control and monitoring. Because the DCS allows full visibility and control into a plant’s production, it helps make it possible to run at full capacity with a limited staff. What does the future look like? If the current trend continues, the production and manufacturing industry will likely take … Continued
Challenge
Acting as the brain behind industrial operations, PLCs are designed to perform logical decision making for control applications. But, what should be done when a PLC system reaches the end of its life cycle? This case study explores how E Tech Group supported the PLC upgrade for a carbon fiber manufacturer. The customer faced the challenge of modernizing their outdated control system which included control panels operating with an Allen-Bradley PLC-5 controller and other legacy hardware. This system was used to control their traction drive process which included VFD controls for multiple motors. The customer wanted to improve their process by upgrading their control, visualization, and machine safety systems, and sought E Tech Group’s expertise to navigate the complexities of this upgrade and seamlessly transform their outdated system with a modern solution.
Solution
E Tech Group designed a plan that fulfilled the customer’s specific requirements and adhered to a tight completion timeline. The customer needed upgraded control panels with new PLC, HMI, and VFD components, alongside a modernization of their existing machine safety system to align with the latest industry standards. The project team carefully assessed each system slated for enhancement, gaining a comprehensive understanding of the customer’s existing system and their other production lines. This supported the factory acceptance testing phase, ensuring the components and controls worked properly according to the functionality of the equipment.
With proof of functionality, quality and integrity in place, the project team swiftly deployed the required upgrades which included build-to-print control panels, an Allen-Bradley PLC-5 to Rockwell Automation Compact GuardLogix controller migration, POINT Guard safety-rated I/O module configuration, Panel View Plus programming, and PowerFlex AC Drives to improve the system’s flexibility and performance.
Results
The project was successfully completed in less than 90 days, with two months dedicated to development and two weeks allocated for commissioning. E Tech Group utilized the expertise of multiple control engineering experts for this project, and effectively leveraged their experience to meet the customer’s tight completion timeline. As a result of the upgraded system, the customer experienced substantial enhancements in productivity, increased reliability, simplified system maintenance, and a user-friendly interface. The project not only met the customer’s requirements but also delivered tangible benefits to improve overall operations.
