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the partner for the Flour Mill and Pasta Plants

SIEMENS. the partner for the Flour Mill and Pasta Plants. PRESENTATION PROGRAM Introduction Concept Requirements Solution Communications Information management Advantages Conclusions. INTRODUCTION (1) The automation of pasta plants had in these last years an important evolution.

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the partner for the Flour Mill and Pasta Plants

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  1. SIEMENS the partner for the Flour Mill and Pasta Plants

  2. PRESENTATION PROGRAM Introduction Concept Requirements Solution Communications Information management Advantages Conclusions

  3. INTRODUCTION (1) The automation of pasta plants had in these last years an important evolution. The programmable controllers are able to integrate all the process control functions into a PLC and now into PC integrating through Profibus, peripherals as inputs/outputs, drives, intelligent devices and operator panels The actual scenario is characterized by a Totally Integrated Automation Concept using a common hardware/software platform standard networking to satisfy the customers demand.

  4. INTRODUCTION (2) The Totally Integrated Automation Concept consists in integrating under a single automation system, three important areas which till now were automated separately as: Semolina silos (upstream) Pasta production (mainstream) Packaging and warehousing (downstream) Totally Integrated Automation (T.I.A.) is performing process control, recipes handling, lots scheduling, products tracing, traceability, warehousing and web connectivity.

  5. Packaging Palletizing Warehousing Milling Semolina Silos Mixing Silos Raw Material Wheat Receiving Press Extrusion Drying Cooling Utilities PLANT FLOW SCHEMATIC DIAGRAM Mainstream Downstream Upstream

  6. PCS Communication Data management HMI Configuring/Programming Controller Milling Semolina Silos Distributed I/O Packaging Palletizing Utilities Wheat Receiving Drying Cool. Press Extrus. Drives / Field devices PLANTWIDE ISSUES

  7. ARCHITECTURE STRUCTURE Enterprise Resource Planing Manufacturing Execution System Process Control System Field Automation Semolina Silos Extrusion,Drying,Cooling,Utilities Handling,Packaging Palletizing,Warehousing

  8. THE CONCEPT T.I.A. means design the plant automation introducing a new concept that has to consider the factory in its entirety. Production flexibility, costs control and total quality approach are successful key points for small and large companies. The target is to change a production process from a critical factor to a qualifying factor. To perform a complete control of all the different production phases starting from raw materials receiving and forwarding to the finished products. TIA is given an important contribution in terms of costs reduction, for revamping and new pasta plants

  9. Last floor silos Press Bridge Silos floor Press Bridge Pre dryer Pre dryer Dryer Press Foot Dryer Press Foot Spreader Cutter Ground floor Flour silos Press bridge PASTA PLANT WIDE ARCHITECTURE WinccClient WinccClient WinccClient WinccClient Engineering stations MES ERP Ethernet TCP/IP, 100 MBit WinccServer WinccServer WinccServer WinccServer Packaging Palletizing Short pasta line Long pasta line Milling Plant Flour Silos Industial Ethernet TCP/IP, 100 MBit Grain Receiving Water treatment Handling Palletizing Fieldbus system PROFIBUS AS-Interface Packaging Warehousing Waste watertreatment Milling Sieving Compessed air Grinding Wheighing Sistem Cooling Cooling Cooling/ Storage Boiler Flour silos Storage

  10. PLANT REQUIREMENTS Real time monitoring of process variables through supervisory system, and relevant corrective actions in order to guarantee high quality. Client/server technology to address information of concurrent process to Control Room and plant Information Room in order to maximize the sinergy. Communication and interoperability of production areas (orizontal way) and other plant departments (vertical way) Production data provided simply and clearly to the decision level

  11. AUTOMATION SOLUTION SIMATIC S7 controllers with distributed ET200M, drives technology and field instruments linked through Profibus. SIMATIC OP panel for distributed visualization and monitoring Drives Technology WINCC supervisory system based on client/server architecture with Industrial Ethernet networking SIMATIC Industrial Software integrated through all Project Phases

  12. SIMATIC Controllers More than just PLC's • S7 300 , S7 400 , S7 400H • I/O ET200M , ET200S • Operator Panels OP27 , OP37 • Profibus and Ethernet Cards

  13. DRIVES TECHNOLOGY

  14. WINCC SUPERVISORY SYSTEM • The Multi Client server architecture • A Multi Client provides a common view of • the process data of distributed servers in one picture • all the measured value archives, e.g. in one curve window • all the message archives • the pictures/picture windows of different servers

  15. WinCC WEB TECHNOLOGY VENEZUELA H.Q. WinCC Goes Web Operation and monitoring of the plant via the Worldwide Web INTERNET USA Plant MEXICO Plant

  16. ENGINEERING STARTS WITH TOP-DOWN DESIGN OF YOUR SYSTEM THE SIMATIC MANAGER IS THE SINGLE TOOL TO COORDINATE THE COMPLETE TIA SYSTEM CONFIGURATION • - Overall plant architectural structure • - Control strategy • - Operator visualization • - Local operator panels • - Peer communication • - Field devices, including transmitter parameteriz. • - 3rd Party PROFIBUS devices Plant / System Unit Operation Equipment Group Device / Loop

  17. AUTOMATION SYSTEM TOPOLOGY FOR LONG PASTA LINE WIN CC INDUSTRIAL ETHERNET PRESS BRIDGE PRESS FOOT S7 400 OP OP PROFIBUS-DP PRESS SPREADER DRYER/PREDRYER COOLING/STORAGE REMOTE I/0 ET200 REMOTE I/0 ET200 REMOTE I/0 ET200 EXTRUSION SCREW UP TO 4 REMOTE I/0 ET200 REMOTE I/0 ET200 FAN DOSING SYSTEM MIXER CHAINE MOTOR

  18. Savings in wiring costs 20% Cost for wiring REDUCED INVESTMENTS IN THE PASTA PLANT DISTRIBUTED I/O SAVE WIRING COSTS Distributed I/O systems save up to 20% of the wiring costs: • A family of distributed I/O systems provides the right I/O for the right application and reduces wiring costs • distributed motor starters and drives used in the pasta lines allow distributed wiring of the power bus

  19. Each supervisory station can handle supervision functions of the entire plant in addition to graphic pages, recipes handling, data archiving real time/historical trending, alarming. Comunication and interoperability are key factors for data flow from orizontal way to vertical way. To achieve production flexibility , for successful growth, of small, medium and large companies • COMMUNICATIONS (1)

  20. With T.I.A. concept and relevant networking /communications we can assure data flow from process level to supervisory and management level, from incoming raw materials to the finished products. It means : - Right info - To right people - At right time - At right place In any kind of pasta plants • COMMUNICATIONS (2)

  21. TYPICAL SYSTEM TOPOLOGY FOR PASTA PLANT WINCC Multi Client ETHERNET WINCC SERVER WINCC SERVER IND.ETHERNET LONG PASTA LINE LONG PASTA LINE SHORT PASTA LINE SHORT PASTA LINE PROFIBUS DP PROFIBUS DP PROFIBUS DP PROFIBUS DP

  22. DATA MANAGEMENT STANDARD INTERFACING APPROACH • VERTICAL INTEGRATION • TCP/IP, @aGlance, ODBC, SQL, OPC, Net DDE... • Web Browsers, intra / internet... • Gensym bridge... • SAP R/3 PP-PI… • HORIZONTAL INTEGRATION • Ethernet, PROFIBUS,, ASi-Bus

  23. INFORMATION MANAGEMENT MES and ERP Connectivity in order to have plant information and management decision support Process optimization and data analysis Web connectivity for remote information and production control Certified module for linking to SAP

  24. COMPLETE INFORMATION MANAGEMENT WITH INFOPLUS.21 MAIN FEATURES: - process data acquisition - data analysis - process optimization - certified module for linking to SAP MAIN BENEFITS: - improved production quality - improved process diagnostic Cross-Company Resource Planning Supply Chain Management & Business Systems ERP Draft Intelligent Production Systems Profound Process Knowledge Integrated Software and Services Platform Independence Model Operation Management Process Control Systems Field Instrumentation & Operating Control PCS

  25. THE ADVANTAGES It is able to satisfy adequately the requirements to operate and manage integrally the plant. It trasforms the process control into plant production control with a single system solution. It is garanted quality and HACCP certifications It can begin from a minimum architecture of one to several lines, of a small to a large plant. It reduces costs and spreads the investments according to plant growing, with an interesting pay back.

  26. INCREASING EFFICIENCY IN THE PASTA PLANT E.U. ADVANTAGES: The Totally Integrated Automation advantages are the followings: • Central control room to control upstream, mainstream and downstream areas data production • Repetitive quality and relevant improvement • Fast trouble shouting (more lines availability) • Less Spare parts (maintenance costs reduction) • Energy saving

  27. COSTS REDUCTION IN THE PASTA PLANT ENERGY SAVING Due to optimization of motors control according to production needs (less power consumption using drives technology) OUTPUT QUALITY Repetitive quality and relevant improvment ,due to integrated process control and less reject during shape change Fast trouble shouting ,less spare parts,resources optimization due to T.I.A. concept,central control room, diagnostic systems, intelligent allarms LESS HUMAN RESOURCES

  28. CONCLUSIONS T.I.A. concept will give an important contribution in terms of costs control and cost reduction. T.I.A. concept will increase the possibility to build up new plants in new geographical areas where there are new markets with less specific experience The experience tipically of the Mediterranean countries is now available using T.I.A. concept in the ROW. By using T.I.A. both the pasta lines manufacturer and pasta producer can achieve important market advantages.

  29. SIEMENS Thank for your attention Contact A&D Competence Center Food & Beverage - Mill &Pasta Antonio Rossetti :phone +39 02 66762933 Massimiliano Andreoli :phone +39 02 66762889 fax +39 02 66762916 E-mail to antonio.rossetti@siemens.it massimiliano.andreoli@siemens.it

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