One of our specialities is upgrading old machines with new technology and providing the client with more information via HMI (Human Machine Interface) control.We were approached to see if we could upgrade a counter pressure carbonation filling machine from an old DOS based program structure. The shutdown period was only one week, so there was little time and a lot of pressure to have this key machine running for the start of production.The project was broken down into key areas. We chose the Simatic s7-200 processor and expansion cards with a Siemens touch screen. Translation, programming and documentation was carried out, prior to shutdown. During the shutdown period, removal of the old controls, installation of PLC hardware and touch screen were completed. Programming and commissioning was completed with the filler back in production on time and on budget. We offered the client additional options including recipes for individual bottle sizes. With recipe selection, all variations for bottle sizing are taken care of in the program resulting in faster changeover times and only a single touch button operation.This addition to the job has resulted in greater efficiency at the plant with increased throughput, downtime has been reduced dramatically.

With an increased plant size and additional workload, our client needed to revamp his wastewater treatment to meet Christchurch City Council requirements.It is very important to remember that dumping costs after 4pm (non-peak) are substantially cheaper per cubic meter than during peak periods. With this in mind, a new dosing and holding tanks were installed. Control of the system was a Allen Bradley 1400 processor with inbuilt real time clock and online programming with a Jumo Aquis 500 PH controller and sensor providing accurate readings of the waste water PH.A flow meter was installed and readings sent to the BMS. With greater control and more detailed information, our client has made substantial savings. Ongoing regulation in this area has resulted in a range of companies seeking help with their wastewater treatment. If you are upgrading or putting in a new installations, we are more than happy to quote and give you the benefit of our expertise in this area.