Batch & Formula Management on an Existing Architecture

A manufacturer of refrigerated pudding was experiencing phenomenal growth – sales had quadrupled over the past 14 years.  As such, there was a great desire to improve throughput and reduce product loses.
Product and time were lost to a combination of human error (incorrect ingredient additions, incorrect processing times) and an occasionally inconsistent process.  In addition, since processing parameters were captured manually, it was difficult (or impossible) to track errors.
The Challenge

The manufacturing plant had an existing, albeit older, Rockwell control system (PLC-5) and HMI (RSView32).  Replacing this system in its entirety was not an option and there was limited downtime available to address the issues.  It was clear that a phased approach would be needed – one that had minimal impact on the existing infrastructure.
The Solution

ACC designed an architecture that could be implemented in a phased manner with minimal disruption to operations or to the existing infrastructure. 

Phase 1: (42) New Powerflex VFDs on Ethernet
Phase 2: New ControlLogix CPU – PLC-5 I/O remains intact.  PLC Software updated to utilize phase manager
Phase 3: FactoryTalk Batch application implemented including E-Procedure and Formulation manager
Phase 4: Batch Reports Developed

• Simplified batching by automating 90% of the processing steps
• Decreased batch-to-batch variability
• Improved record keeping
• Reduced training time for new operators
• Faster new product introductions
• 92% reduction in lost batches!