The Project: Streamline Rice Milling Operations with an Upgraded an Automation System

Complex upgrades require advanced expertise. Experienced system integrators will use a holistic approach to fully scope automation system upgrades, considering how the project’s complexities will impact the client’s budget, uptime, timeline, and performance requirements. A comprehensive approach to project management results in the most comprehensive control system solutions – a strategy that always benefits the client.

An example of how this plays out in an automation project is a PLC-5 and SCADA application upgrade E Tech Group implemented for a leading rice milling company. The company had an obsolete PLC-5 controlling their rice finishing line, in addition to an obsolete SCADA application controlling their entire facility. The legacy SCADA system was costly to keep operational, and the existing network caused communications issues between the client’s production areas.

The client needed a new PLC program to be installed within a 48-hour timeframe to minimize production impacts, and the existing SCADA system needed to remain operational during the migration to Inductive Automation’s Ignition platform. E Tech Group was engaged as the client’s choice system integrator for our advanced expertise in system migration and the successful execution of projects at the client’s other facilities.

The Solution: Integrating Ignition SCADA Software for Full Control

E Tech Group’s goal is to set the client up for long-term success, not just short-term gains. The project team created a site inventory of the client’s existing PLCs, network, computers, and applications. PLC specifications were quickly defined, and long lead items were ordered. The project team remained in constant communication with the customer to keep them well-informed across the different project stages and how to best utilize the new system.

The control system retrofit included upgrades to servers, computer, and network switches in collaboration with the customer’s IT department, the upgrade to Ignition SCADA software across six applications with approximately 500 screens, and the upgrade to two ControlLogix PLC chassis. By completing the automation system upgrade and integration in stages, there was minimal disruption to the client’s operations.

The Results:

The SCADA upgrade was completed in several phases and each application was upgraded individually. This helped minimize impacts to the client’s production efforts and enabled the legacy and new SCADA applications to run simultaneously so the client’s personnel could learn the new SCADA software. E Tech Group staffed the project with subject matter experts in the Ignition SCADA platform, control engineering and complex system migrations.

E Tech Group leverages this diverse, multidisciplinary engineering approach in every project to create intelligent automation solutions for the client’s long-term success, including the opportunity to support their operations in the years to come as a Main Automation Partner.