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ECS Helps Private Labeler Spring Into Action
When opportunity knocked for a midwestern US private label condiment and sauce manufacturer, their relationship with ECS Solutions, Inc. (ECS) helped them to excel. Success in private-label food manufacturing is often a matter of being able to accept new projects when a chance arrives to expand or acquire new business. Raw capability is a driving factor, but modern manufacturing is not necessarily built on having volumes of idle capacity sitting and waiting for the next project to arrive. These endeavors frequently spawn from a quick flex in schedules, skillful leverage of less-than-optimized equipment, and/or an effective change in technology. Sometimes entirely new operations must rise from nowhere in a seemingly unachievable timeframe, as was the case with ECS’ client.
When this midwestern manufacturer was presented with a chance to land a series of large contracts with a well-known label they quickly pressed all their assets into action to create an entirely new red sauce kitchen. Long lead time items were ordered with less-than-optimal information available. Equipment that could be reused from their local storage cache was inspected, tuned up, and prepared for deployment. Their existing relationships with local contractors allowed them to begin infrastructure preparation immediately and quickly move into detailed piping and wiring. Perhaps most importantly, their relationship with ECS allowed them to quickly assess the project and create a framework so that budgets could be established and bids obtained. It was quickly evident that a fully integrated solution from ECS was not only possible but that it would be integral to long-term success because it would allow for as much effective automation as reasonable, thus minimizing the number of new operating staff members to run the system once complete.
With little more than a few preliminary conversations, ECS received an order in early January 2022. Working from preliminary P&IDs, the ECS team went to work using their methodical approach and vast experience in this arena to craft the solution.
The process itself consisted of multiple bulk ingredient tanks, batch process tanks, and additional tanks for intermediate and finished holding, homogenization, sterilization, and cooling. All the pumps, ancillary machines, and interconnection piping routes with associated valves had to be quickly installed and later controlled by ECS. The solution also called for hand-add capabilities, which the batch operating system easily provided for. Hold and recirculation loops, sanitation system interconnection, and manual operations all needed to be incorporated. Finished product was delivered to the packaging OEM for placement in individual-serving packets.
ECS’ investment in their S88 Builder product showed heavily in their solution. This application was invented and refined over many years to meet the needs of batch-processing companies. The latest version of the solution incorporates Rockwell Automation Process Objects into the backend PLC code to allow for seamless integration between the physical automation, the FactoryTalk Batch processing engine, and the Ignition-based supervisory and human interface project. The tight connection between the batch engine and the HMI allows operators to simply visualize what might be complex operations. Authorized users can watch a recipe’s progress while retaining control over start, stop, hold, resume, and required manual operations or input.
The robust nature of the ECS system allows for rapid deployment regardless of ingredient count or complexity of operations. The rapid deployment capabilities were key in this project. It also provides a flexible and customizable platform. For example, this client wanted a detailed roles-based security scheme, which ECS skillfully wove into the final solution.
Parallel to the ECS team’s work, others were receiving and rigging equipment for installation. Pipefitters installed the system plumbing and electrical contractors connected equipment, often as or just after the equipment was set in place. Once the control panels were connected it was time for ECS to begin system debugging and manual operations. The modular and mature nature of the system programming ensured that system testing could occur simply and without the need to interpret highly variable code as may be found in less refined solutions.
The testing of automatic recipe execution for more than half of the initial system recipes happened a mere two months from the time ECS mobilized. The fast nature of the project nearly assured that some minor changes were required on the physical equipment but, overall, the system ran as expected nearly out of the box. More importantly, the expertise shown by all parties involved, and especially ECS for the batch operations, allowed this client to meet their required delivery date and fulfill their contract with the brand label.
Posted In: Case Studies, Food Industry