Higher Efficiency, Faster Processing. Achieved.
Under the hammer with increasing workloads and plant auditing requirements, a recent client was screaming out for a more accurate, faster and more comprehensive batching process for its food processing plant.
The client needed weighing accuracy to the nearest single gram to increase processing times and improve batch reporting systems throughout the business. This will make their processes easier and swifter—from the factory floor to office admin.
We chose the Rockwell 5380 processor due in large part to its high speeds and large memory, making it ideal for small to mid-size applications requiring high speed I/O (input-output).
The Rockwell 5380 provides enhanced diagnostics and controller functions including motion control, Device Level Ring/Linear Topologies and optimised troubleshooting and system performance. Its dual configurable ports support dual IP addresses handling full batching system processes and the option of reporting features if required.
The processing unit was then combined with the 12 x Rockwell 525 cat 3 Safestop Drive with inbuilt Ethernet communications. This provided faster integration and reduced wiring time. Key to its super efficiency and accuracy is the load cells for weighing systems. Teaming up with Sensortronics, we were able to provide the perfect solution around weight accuracy for bins from 2 tonnes to 100 kg.
Operating this batching process is now a cinch with order requests from office or from local HMI touch screens loaded, scanned and confirmed for operation in lightning fast times. The product is distributed to one of nine bins and the operator begins the batching process.
The entire process is monitored every step of the way and at the first sign of any problem, the system defaults to hold mode, allowing the operator to check information alarms and quickly resolve issues.
The commonest problem is product bridging, where the product fails to be delivered at all throughout the batching process. Being carefully monitored, pneumatic air is then blasted on dosing bins in anticipation of delivery, resulting in fewer stops/starts. Once the batching process is complete, a printout and email are automatically sent out for reporting purposes.
The introduction of the new batching processor has resulted in a much more efficient system, which also allows customers to see their blend if requested, to confirm exact product supplied.