Replacing outdated manual controls with a user-friendly HMI to improve blending consistency, flexibility, and diagnostics.
National Frozen Foods needed to modernize a vegetable blending system that relied on manual dials to control the ratio of vegetables entering production. Concept Systems completed an HMI upgrade that gave operators more precise control of the blending process while improving system flexibility, diagnostics, and maintainability.
The Problem: Outdated Dial System
The existing vegetable blending system relied on manual dials to control six hoppers, bins, and feeders, with each feeder supplying a different vegetable. The dial-based controls lacked the precision and visibility operators needed to consistently manage product ratios.
The customer also needed better system diagnostics. When issues occurred, limited status and maintenance information made troubleshooting more difficult and increased the burden on plant personnel.
The Solution: A User-Friendly HMI Upgrade
Concept Systems upgraded the blending controls with a CompactLogix PLC and FactoryTalk View ME HMI, giving operators a more intuitive way to manage the production process.
Through the new HMI, operators can enter required vegetable ratios, adjust master speed, and select the appropriate conveyor belt for production. Diverter gates route product to different processing lines, providing flexibility across changing production requirements.
Concept also developed new status, maintenance, and diagnostic screens that give operators greater visibility into system performance and make troubleshooting easier.
The Results
The HMI and controls upgrade gave operators greater control and visibility over the vegetable blending process while creating a more flexible and maintainable production system.
- Improved consistency when managing vegetable blend ratios
- Increased flexibility across multiple processing lines
- Improved system visibility with dedicated status and diagnostic screens
- Simplified troubleshooting and maintenance
- Return on investment in less than 12 months
Project Details
ROI
Less Than 12 Months
Team
Client: 1
Concept Systems: 2 engineers
Technology Used
Allen-Bradley PowerFlex 40 Ethernet drives
Allen-Bradley CompactLogix PLC
FactoryTalk View ME HMI
PanelView Plus (10-inch)
Modernize aging controls without replacing the entire production system.