Project duration: About 12 months
Client: 20 engineers
Concept Systems: 18 engineers
Concept Systems’ time on site: 90 days
- Different process control systems at all global facilities prevented collaboration and economy of scale on maintenance or expansion efforts.
- Using custom process control software libraries limits ongoing support options.
- Using different hardware platforms for Process Control and Packaging creates the need for extra training, extra inventory, extra software licensing, and extra annual maintenance contracts.
- Typical system requires training new operators after system has been commissioned, stretching out the startup time and eating into production costs.
- Cut startup and commissioning time in half due to simulation capabilities.
- Accelerated time to full production.
- Implement standard, replicable process at other facilities, allowing for greater plant support from central engineering team.
- Capture production intelligence, so operators can manage plant operation efficiently using real-time data.
- PlantPAx® from Rockwell Automation, a scalable, flexible and intuitive modern DCS solution for plant-wide control.
That was the goal of one of the world’s leading frozen potato suppliers. With more than a dozen locations using a variety of hardware and software platforms, it wanted a new process control standard for its continuous-process French fry production facilities. Following up on a successful commissioning of a new facility in Louisiana, Concept Systems was selected to develop standards for the company’s process and packaging control systems, and implement them during the construction of a new facility. By using the MAC partnership model, the company now had a roadmap for its process control that would create consistent systems throughout the enterprise.
Leverage Rockwell’s PlantPAx system
Rockwell Automation PlantPAx offers a scalable, flexible and intuitive modern DCS solution for plant-wide control. Its pre-defined library of controller code, display elements and faceplates reduced programming and time to integration. The platform easily integrated with other equipment at the frozen potato facility, such as OEM packaging equipment, skids, CIP and filtration systems. Using the library, literally saved hundreds of engineering hours. And, the company received a core set of tools and objects that was easily supported by a third-party, which was exactly what it wanted.
Simulation tools ease operator onboarding and training
Simulation tools meant engineers could program and test the system before full implementation. The system was tested during factory acceptance and testing (FAT). Operator onboard and training was done in advance. At start up, the operators were running the facility; there were no issues.
Gaining real-time information
System operators use real-time data to monitor the system and ensure it functions efficiently. Integrated Historian software gathers data related to system cleaning, production and downtown and archives the data for electronic reporting and troubleshooting. System operators receive data in real time through comprehensive reports generated by production intelligence software.
This data also allows operators to predict issues that might occur. They can perform predictive maintenance procedures rather than be reactive to problems on the line. With a direct view into system granularities, operators can better manage bottlenecks and make decisions.
By using the new modern PlantPAx system, the plant was up and running in full production faster. That’s partly because the configuration tools made it easier to design, implement and roll out a new system. The tools saved design, implementation and training time. Once the project design and development started, the facility was in full-production within a year.