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National Frozen Foods wanted to upgrade a vegetable blending system that used a dial system to manage the ratio of vegetables. It consistently receives top-level food safety scores and meets strict US Department of Agriculture guidelines. It wanted to do even better, as it achieved its goal of processing vegetables within four to six hours after harvest.

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A CASE STUDY: Achieve high production rates and efficiency

National Frozen Foods wanted to upgrade a vegetable blending system that used a dial system to manage the ratio of vegetables. It consistently receives top-level food safety scores and meets strict US Department of Agriculture guidelines. It wanted to do even better, as it achieved its goal of processing vegetables within four to six hours after harvest.

the-pointPROJECT DETAILS

ROI: Less than 12 months

Team
Client: 1
Concept Systems: 2 engineers

Results:

  • Improved vegetable blending consistency
  • Increased flexibility of product output
  • Reduced maintenance troubleshooting through improved diagnostics

Technology used:

  • Allen-Bradley PowerFlex 40 Ethernet drives
  • CompactLogix PLC
  • FTView ME HMI
  • PanelViewPlus (10-inch)

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The problem

The dial system was imprecise and the client also wanted more enhanced diagnostics. It was using a six-hopper/bin/feeder system with each feeder supplying a different vegetable.

The solution

The upgraded system allowed operators to enter the required vegetable ratios, adjust the master speed and select the appropriate conveyor belt through a user-friend Human-Machine Interface (HMI) that Concept Systems’ developed. Because diverter gates could direct product to different processing lines, the system was highly customizable. New status maintenance and diagnostics screens make troubleshooting easy.

The results

The C Line Controls upgrade provided increased consistency and flexibility while easing maintenance concerns. National Frozen Foods continues to be one of the world’s top quality frozen vegetable producers.