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A CASE STUDY: PLANTPAX PROCESS AUTOMATION SYSTEM

As part of building a new greenfield plant, a global frozen potato supplier wanted to standardize its French fry process and packaging control through all of its facilities. It required a platform built on a core set of tools and objects and a system that would be easy to operate and maintain. The system Concept developed is the new standard. As a Solution Partner within the Rockwell Automation PartnerNework™, Concept leveraged the power of PlantPAx to meet this project’s needs..

the-pointPROJECT DETAILS

Project duration: 12 months

Team
Client: 20 engineers
Concept Systems: 18 engineers

Concept Systems’ time on site: 90 days

SOLVE YOUR PRODUCTION PROBLEMS


The problem

In the past, this frozen potato supplier relied on in-house control engineers. While each plant used the Rockwell Automation control platform, every control system was designed and programmed differently. The local control engineer, or the integrator, designed and developed the systems individually. As the plants expanded and upgraded, and as their own control engineers retired or moved on, it became clear that this model was not sustainable. Additionally, it did not provide a consistent process in all facilities. For this greenfield plant, the company wanted a control platform built on a core set of tools and objects and one that could be supported by a third-party.

The solution

The new system was designed with the operator in mind; it’s easy to learn and operate. Concept leveraged the Rockwell Automation library of process objects to speed up programming and integration time saving development costs. The standard PlantPAx code allows for rapid configuration. Following a Main Automation Contractor (MAC) model, Concept designed and implemented a continuous-process automation system as an extension of the customer’s process engineering team. Concept’s MAC model includes thorough simulation and testing up front, working directly with plant engineers, managers, and operators to assure the control system is designed right the first time.

The results

From day one of production, the operators were running the facility. There simply were no issues. Using Rockwell’s library of process objects saved hundreds of engineering hours during development. The intuitive system and simulation tools reduced time for engineering troubleshooting and operator training after production started. Integrated production intelligence provides insight through real-time data.

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