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Challenge
Olive oil is a multibillion-dollar market. With a projected compound annual growth rate of 6.10% by 2028, producers must find ways to keep up or get left behind.[1] Challenges in the packaging process can impact the ability to scale operations and can affect many aspects of a company’s product line such as quality, safety, product professionalism, and maintenance costs. Deploying automation solutions can help with these challenges and better streamline operations. When one of the top 4 olive oil companies in California recognized the costly operational challenges of their manual packaging process, automation was key to help them remain competitive.
Solution
The olive oil company needed to modernize and expand their packaging process, with preservation of product quality and integrity as a top priority. The customer wanted a state-of-the-art, aseptic system that would integrate well with their other existing processing lines. Certified in Ignition, an industrial application platform from Inductive Automation, and having an extensive work history at the location, E Tech Group’s Technology Solutions Manager (TSM) came up with an innovative plan for the project’s success.
E Tech Group provided design schematics, built the control panels, developed the PLC, HMI, and SCADA programs, and commissioned a new Bag-in-Box line. The controls system included several communication layers managed by a single line control AB ControlLogix gateway. The Process Level (Level 0) was composed of AB PowerFlex 525 VFDs and IFM IO-Link master blocks on an EtherNet/IP DLR network. On the Basic Control Level (Level 1), the line control ControlLogix gateway communicated with all the PLCs from the OEM equipment. Leveraging the existing Ignition SCADA system, E Tech Group developed a special project for the packaging line and installed two industrial computer clients for local monitoring and control.
Results
Using Control System Integrators Association (CSIA) methodology and best practices, our TSM coordinated with the client and the various OEM’s, keeping everything on schedule. E Tech Group has been a certified member of CSIA since 2012, which is a mark of excellence that demonstrates technical proficiency across ten key business management areas and commitment to executing the best methodology. Finally, with the ability to test and run the new system alongside the old, the olive oil company experienced no downtime or loss of production during the transition which resulted in a successful modernization of their packaging process.
[1] Geographic Scope and Forecast. (2021, August). Olive Oil Market Size and Forecast. Verified Market Research. https://www.verifiedmarketresearch.com/product/olive-oil-market/
Challenge
After producing some of the world’s most famous and flavorful confections for many years, a Northern California candy manufacturer’s aging conveyor system was becoming old, noisy, and obsolete. The existing conveyor system, which had sorted and moved large volumes of product for over a decade, was a line shaft design and was beginning to degrade. The factory was in desperate need of a conveyor system modernization which would increase efficiency, decrease noise and minimize maintenance costs.
Solution
For this project, E Tech Group (AG) used Ignition industrial application software from Inductive Automation and an Allen Bradley controller. The technology for the new conveyor was DC roller controlled. DC rollers are quieter, more energy efficient, and can be controlled more precisely with the set-up of multiple zones per conveyor. This technology allows for a variety of new features to enhance overall operations and reduce wear and tear. As an example, multiple rollers can be started and stopped in sections, and can also start and stop on demand. This enables a more efficient workflow based on capacity and need.
The addition of Ignition Software provided increased visibility to the plant floor, as well as the ability to pull more data via the new Itoh Denki controller. It also enabled AG to create templates for the DC roller controllers which included running data, alarming data and controls.
The upgrade and modernization of the candy manufacturer’s old, outdated conveyor system helped improve overall operational efficiency and enhance the automation processes. AG was able to eliminate the manufacturer’s noisy, worn-out system and modernize their entire conveyor operation with added features that created a quieter operation, extended life, and reduced wear and tear
Quieter Conveyor
Upon installation of the new system, the candy manufacturer noticed an immediate reduction in noise during the operation of the conveyor system.
More Efficiency
With a 24V DC motor nestled inside each roller’s tube, the conveyor system achieved better accumulation (a higher run rate). They also had tighter control of product placement which increased overall efficiencies.
Reduced Maintenance
The old conveyors were always running and had a lot of moving parts that would get worn out and require servicing or replacement. Since the modernization project has been completed, the manufacturer has seen a significant decrease in all service and maintenance costs.
– By Tony Schalk, Functional Safety Engineer (TÜV Rheinland), Automation Systems Engineer, E Technologies Sophisticated companies know that safety is a journey, not a destination. It is a part of their strategic and ongoing growth. As more and more companies look to implement safety programs, questions about budget, time, effort, and feasibility come into play. Larger companies may already employ a safety engineer or even a safety team, with well-established metrics and objectives each year. If you don’t fall into that category, don’t be discouraged. The most important thing you can do on any journey is to start. To begin your safety journey, you start with a risk assessment. In the United States, when an accident originates from machinery, the owner of the machine is responsible for the safety, not just the manufacturer of the machine. This means that if something happens, it’s technically your responsibility. If that doesn’t scare you, it should. The beauty of the risk assessment is that it is your education on what could happen with the machinery in your facility. What you choose to do with your newfound knowledge is up to you; however, in the immortal words of G.I. Joe, “Now you know, and knowing is half the battle.” There are a few caveats. Although companies could self-perform their risk assessments, it isn’t a job that just anyone in your plant can do. A TÜV certification is needed, as well as an understanding of ISO 13849 or IEC 62061 standards. Anyone could pick up the standard and follow the process, but it’s hard to implement a standard and its many details if you’re new to safety. This is where having a safety professional can be very beneficial for efficiency’s sake. He or she can walk into a situation and quickly identify what needs to … Continued
Returning a Roll Coater Paint Line to Maximum Profitability
Our automation engineers expanded line capabilities and upgraded to state-of-the-art Siemens digital drive systems to support a leading steel company.
Project: Bring Existing Automation Tech Back Up to Specs
A leading steel company hired E Tech Group to expand their line’s capabilities to begin production of light gage steel, as well as increase throughput on existing operations by upgrading an existing roll coater paint line to return it to the OEM specs of 1600 fpm.
Solution: Evaluate and Optimize the Automated Equipment’s Capabilities
To accomplish this, E Tech group conducted an equipment audit to determine the failure rate and root causes, and conducted a tension study to determine the equipment’s limitations. This data was then used to improve the tension control on the line by monitoring tower operations and load cell closed loop tension regulators, then tuning them accordingly.
Our engineers also analyzed cable conduit versus using remote I/O, performed a safety study and implemented the study’s recommendations, and performed startup and commissioning services of the plant.
Results: Unmatched Line Speed, Way Less Downtime
This successful project installed a state-of-the-art Siemens digital drive system with new PLC, operator stations, and HMI. The result was a 33% increase in line speed; the line was returned to the maximum OEM-spec speed of 1600 fpm from 1200 fpm prior to the upgrade. Another result of the upgrade was a 50% reduction in electrical downtime. With the hardware and software installation complete, E Tech Group expanded the line’s capabilities to include the production of light gage steel.
As one the nation’s leading control system integrators, E Tech Group is a multifaceted automation company offering the best in process automation solutions to manufacturers across industries. E Tech Group has experience in the metals, chemical, machine building/OEM, pharmaceutical industries, and more. Our turnkey factory integration services provide clients with robust, cutting-edge control systems that adapt, scale and optimize your processes.
