Leveraging our experience as a Rockwell Automation Gold Level System Integrator to standardize process control with PlantPAx for a greenfield frozen potato processing facility.
A global frozen potato supplier was building a greenfield processing facility while looking for a better way to standardize process and packaging controls across its operations. Historically, individual plants had developed their own systems, creating inconsistencies that became increasingly difficult to support as facilities expanded and experienced personnel retired.
As a Rockwell Automation Gold Level System Integrator with extensive process control experience, Concept Systems was selected to help establish a repeatable automation standard and implement it at the new facility using PlantPAx.
The Problem: Inconsistent Automation Across Facilities
The manufacturer operated more than a dozen facilities using a variety of hardware, software, and programming approaches. Although many plants used Rockwell Automation controls, individual systems had historically been developed by local engineers or integrators, resulting in different standards from facility to facility.
As plants expanded and experienced control engineers retired or moved on, maintaining these independently developed systems became increasingly difficult. The company needed a standardized process control architecture that could be replicated, maintained, and supported across the enterprise.
The greenfield facility provided an opportunity to establish that new standard. The system needed a common set of tools, objects, and programming practices while remaining flexible enough to integrate process equipment, OEM systems, packaging equipment, and plant utilities.
The Solution: Standardizing Process Control with PlantPAx
Concept Systems served as the lead automation integrator, following a Main Automation Contractor (MAC) approach to develop and implement the greenfield facility’s continuous-process automation system.
Drawing on Concept’s experience as a Rockwell Automation Gold Level System Integrator, the team established a standardized controls architecture using PlantPAx. The platform provided a common library of controller code, display elements, faceplates, and process objects that could be configured and reused throughout the facility.
Building a Repeatable PlantPAx Standard
Rather than developing each process area independently, Concept used PlantPAx to create a consistent set of tools and objects for controlling and visualizing the production process.
The standardized architecture reduced custom programming requirements and made the system easier for operators, engineers, and third-party support resources to understand and maintain. PlantPAx also provided a scalable foundation that could support future facilities and automation projects.
Coordinating Process and OEM Systems
As the lead integrator, Concept coordinated controls across the plant and integrated equipment from multiple suppliers into the overall automation architecture.
PlantPAx was integrated with OEM packaging equipment, skids, clean-in-place systems, filtration equipment, and other process systems throughout the greenfield facility. This allowed individual pieces of equipment to operate as part of one coordinated production process rather than as isolated systems.
Simulation, Testing, and Operator Training
Concept used simulation and extensive testing before commissioning to validate system functionality and reduce startup risk.
Working directly with plant engineers, managers, and operators, the team tested the system during factory acceptance testing and used simulation tools to prepare operators before production began. This allowed both the engineering team and plant personnel to become familiar with the new automation environment before startup.
The Results
The standardized PlantPAx process control system helped the greenfield facility move from development to full production with a consistent automation architecture designed for long-term operation and support.
- Saved hundreds of engineering hours through reusable PlantPAx process objects and configuration tools
- Enabled operators to run the facility from the start of production
- Reduced startup troubleshooting and operator-training time through simulation and factory acceptance testing
- Established a standardized controls architecture designed for easier maintenance and third-party support
- Integrated process, packaging, OEM, clean-in-place, and filtration systems into a coordinated plant-wide automation platform
- Provided real-time production and equipment data for reporting, troubleshooting, and operational decision-making
- Created a repeatable automation foundation for future facilities and system upgrades
Project Details
Project Duration
About 12 Months
Team
Client: 20 engineers
Concept Systems: 18 engineers
Technology Used
Rockwell Automation PlantPAx® Distributed Control System
Rockwell Automation Library of Process Objects
FactoryTalk Historian/production intelligence
Process and OEM equipment integration
Build scalable, standardized process control systems designed for reliable operation, easier support, and future growth.