1 / 45

The Magical World of Chocolate Manufacture

The Magical World of Chocolate Manufacture. Material tracking and mass balancing in Chocolate Manufacturing. Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods). Introduction. Project Solution. Agenda. Benefits. Considerations. Summary. Chocolate manufacture. Pressure and

betty
Download Presentation

The Magical World of Chocolate Manufacture

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. The Magical World of Chocolate Manufacture

  2. Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)

  3. Introduction Project Solution Agenda Benefits Considerations Summary

  4. Chocolate manufacture Pressure and Temperature measurement

  5. Project Scope

  6. Background to the Project Seamless and transparent integration throughout the Company manufacturing systems and business system Manufacturing system designed for expandability, ease of integration and contextuality. Information that is important, relevant and contextual to be published to a portal for easy access Ability to trend and trace process issues and speed up trouble shooting.

  7. Project Goals • Traceability of fat usage and additions against works orders • Monitoring / logging of process parameters • ERP integration to Syspro • Overall system upgraded to latest technologies • Network • Windows / SQL Server environment • SCADA system • PLC system • Ingredient management of recipes • Introduction of expandable reporting infrastructure

  8. Introduction Project Solution Agenda Benefits Considerations Summary

  9. Tender process Requirements of integrator and solution Cape Town presence Instrumentation, PLC, SCADA and database development experience Previous experience in food and beverage industry Several solutions investigated Siemens Rockwell Citect

  10. Why Wonderware Proven functionality in the Food and Beverage industries Proven integration into business systems (SQL database) Well supported, widely used nationally and internationally Several solution providers / system integrators Development into the future Increased availability of resources (call-outs)

  11. Project Design Functional specification prepared Detailed design process Network topology PC/Server infrastructure PLC infrastructure Data flow

  12. Project Description Develop ArchestrA model S95 standard Model includes future upgrades Use model to define data capturing points for EOM

  13. Topology

  14. EOM

  15. Project Design Design Intouch SCADA Dual display AMR’s first project with ArchestrA 3.0 and Intouch 10.0 Converted AMR’s standard valve/motor SmartSymbols to ArchestrA graphics

  16. Project Design

  17. Project Description

  18. Project Description

  19. ERP Integration / WO Management ERP integration to Syspro via holding database WO’s pushed down from Syspro indicating Raw material, tank and equipment allocation/scheduling Operators start and complete WO’s SCADA Intouch SCADA Wonderware Historian Syspro server

  20. ERP Integration / WO Management Example of WO Management at SCADA level

  21. ERP Integration / WO Management

  22. Project Description

  23. Project Description

  24. WO – Modify execution time

  25. WO – Re-allocate

  26. WO – Remove from plan

  27. PLC Allen-Bradley Compact Logix Beckhoff Ethernet/IP remote I/O units Program designed with complete process control management in mind (for future phases) Manufacturing instructions Process parameters (Mixing times, pressure and temperature checks and operator prompts) Fat transfer route allocation Current program only handles fat transfer route allocation

  28. Reporting Wonderware Information Server MS-SQL Reporting services

  29. Reporting

  30. Reporting

  31. Reporting

  32. Introduction Project Solution Agenda Benefits Considerations Summary

  33. Benefits / Goals Achieved • Batch size consistency • No need for extensive additions to correct recipe failures • Raw material allocations tracked • What fat goes where • Better process control tracking • Alarming at SCADA level • Trouble-shooting (temperatures, pressure, grinding times) • Operators

  34. Benefits / Goals Achieved • Significant savings in fat usage • Batch processing times where standardized • Less usage of resources i.e. power • Minimised batch/formulation corrections • Savings in additional raw materials to batches.

  35. Introduction Project Solution Agenda Benefits Considerations Summary

  36. Lessons Learned (PLC) • User defined data structure always good (duplication of devices similar control) • I/O server integration with tagnames instead of address reference • Ethernet/IP needs managed switches to handle IGMP Snooping (Internet Group Management Protocol)

  37. Lessons Learned (Wonderware) Domain Security Tighter control with existing business system and network policies Client responsible for user manager/rights (IT department)

  38. Lessons Learned Understanding scope and planning vital Previous projects failures overcome Plant downtime was managed Plant process visibility greatly improved Updated P&ID Operations / process flow Increased speed of data availability

  39. Introduction Project Solution Agenda Benefits Considerations Summary

  40. Project summary / conclusions Phase I successfully completed by AMR using Wonderware technology Increased process control and shop floor visibility Phase II will further utilize the solution into other areas of the plant Future phases will allow for data to be written back to Syspro Automatically closing works orders

  41. Thank you

More Related