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Case Study: Repurposing a Tank Farm

A large US food manufacturing company planned to repurpose a tank farm, originally used in the manufacture of ice cream.  The repurposing of the tank farm could be considered a greenfield installation, providing various oils to a new fryer system. The new designs would allow the storage and transfer of (1) newly delivered oil, (2) flavored oil to be reused and (3) waste oil to be discarded.

ECS Solutions was hired to help evaluate the existing system which was controlled by five Allen-Bradley SLC 5/03 PLCs.  The ECS engineers determined the IO was sufficient for the planned changes as well as many of the existing valves. ECS redesigned the controls incorporating one new Allen Bradley CompactLogix controller to control the system and an Ethernet network to connect each of the existing SLC racks, which would be repurposed as remote IO racks. In addition, we provided new PowerFlex variable frequency drives to control the pumps that would move the oil from place to place.  An existing Inductive Automation Ignition operator interface application was expanded to incorporate the oil storage system.  In effect, the scope of the project was to evaluate the control systems available and to incorporate new controls where required.

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Read More | Posted In: Case Studies, Food Industry, PLCs

Product Life Expiration Automation

All the production processes carried out in a particular process cell within a large, national food manufacturing company, must adhere to certain time guidelines, a consequence of the relatively short shelf lives of some of the ingredients.

A batch process is monitored manually with operators following the batch through the stages and vessels involved.  The production times are recorded on paper by an operator and tracked to ensure the time guidelines are maintained. The batching process at the various stages should not exceed the specified maximum time. Failure to meet these criteria will result in the product being scrapped. It is both difficult and cumbersome to reliably record and track the batch process creating the possibility for errors to occur. The food company sought a more reliable way to track the product life of the batches as well as providing information for quality control and regulatory purposes.  The company requested ECS Solutions evaluate the possible automation of the time guidelines. ECS proposed a solution for the automation but limited it to the guidelines on the “in process batching” vessels. Automation of other vessels and guidelines could be carried out, but due to information available and a desire to minimize the scope, the project was limited to the in-process batching vessels. (more…)

Read More | Posted In: Case Studies, Food Industry, News

ECS Solutions & Swedish Match on Ignition Community Live

ECS President, Tim Matheny and Brad Logsdon, Business Analyst at Swedish Match joined Travis Cox, co-director of sales engineering for Inductive Automation for a recent interview about the journey to Ignition through business analysis.

Learn how Swedish Match North America arrived at using the Ignition platform to solve a real business need, and how their IT Department drove this initial investment at their Owensboro Factory, in this exciting video!

Read More | Posted In: Case Studies, News

JTM Foods Case Study

JTM Foods challenged ECS Solutions and Blentech to create a SCADA system that included the full spectrum of process automation for their new state-of-the-art production facility. JTM wanted to expand their production capability with a new state-of-the-art facility featuring a Process Automated Kitchen. They wanted to track their process from the ERP Order through the procedural execution of the receipt and material tracking to a finished product. There were multiple solutions evaluated for each of the key aspects, via different islands of software. JTM operates efficiently with a very lean, experienced workforce, however, they prefer to minimize the requirements to support and sustain multiple technology platforms.

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Read More | Posted In: Case Studies, Food Industry, SCADA

Boosting Batch Performance at a Salad Dressing Plant

A well-known line of salad dressings was recently acquired by a major food manufacturer with the plan to establish a fully automated, paperless manufacturing process for the production. To do this efficiently and cost-effectively
represented a significant challenge.

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Read More | Posted In: Case Studies, FactoryTalk Batch, Food Industry

Large Consumer Goods Case Study

THE CHALLENGE

ECS was hired to upgrade and replace a CIP control system in one of the manufacturing areas for a large consumer goods company. The scope of work included a new control enclosure containing an upgrade from a SLC5 controller to a ControlLogix controller. The upgrade also consisted of all IO and connections within the enclosure. Additionally, the company wanted to solve the problem of inefficiencies in its CIP process by implementing FactoryTalk Batch and Batch control within this updated CIP system.

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Read More | Posted In: Case Studies, Clean in Place, Consumer Goods

Bardstown Bourbon Company Case Study

The Challenge

Bardstown Bourbon Company (BBC) is a Bourbon Distillery located in Bardstown Kentucky. Utilizing two mash cookers, 32 fermenters, two distillation stills, and nine cistern holding tanks, BBC produces a wide variety of high-quality whiskeys and bourbons. (more…)

Read More | Posted In: Case Studies, Distilleries, Inductive Automation