Global Beverage Giant Selects PlantPAx Modern DCS to Improve Throughput

PB 25 Rockwell newlogo 400

April 20, 2020

By Kevin McEnery, CEO, McEnery Automation

When you commit to improving processes, some of the benefits are obvious – and some are not. It’s those “hidden” benefits that can’t be overlooked when assessing the total value of a new system. In a recent project with a global beverage producer, it’s those benefits that are producing some added bonuses.

The project originated because sales have increased for this global beverage company’s fizzy drinks, challenging one syrup manufacturing facility’s ability to keep up with demand. The plant needed to expand throughput, and to gain more flexibility.

To meet these challenges, they partnered with Rockwell Automation and McEnery Automation to incorporate a PlantPAx modern DCS.

The system delivered as promised: it has improved repeatability and recipe consistency, and it has dramatically increased throughput and eliminated bottlenecks. The solution is making it easier for employees to move product and do things right the first time.

Bottlenecks: Thing Of The Past

Every production area that I’ve ever encountered has some inherent potential for limitations and bottlenecks. There is nothing more frustrating for an operator or manager than having to live day-in and day-out with those bottlenecks and limitations.

In this particular case, production bottlenecks were caused by several factors which our new system was able to eliminate. For example, because recipe management has been automated and process intervention has been dramatically reduced, operators no longer have to manually enter recipes – removing the potential for error. Additionally, the layout of the new system brought the ingredients closer to the mixer, making transport safer and more convenient.

Those changes resulted in:

  •  –   Higher throughput
  •  –   Higher quality batches
  •  –   Greater consistency among batches
  •  –   Reduced potential to damage ingredients in transport
  •  –   Reduced potential for employee injury while transporting ingredients

While we fully anticipated the throughput, quality, and consistency to improve, it’s those last two benefits that stand out to me as the added hidden value of the project. The less an ingredient is handled, the better it is for the end product and the employee.

More of What We Want, Less of What We Don’t

Over time, it’s very common for employees to adapt their processes to parameters of their systems – meaning they’ll get things done even if it means walking 20 steps farther than necessary because that’s how the machine layout worked in the plant.

Those steps, those heavy lifts, they add up. Better layout, better process design, better technology, all contribute to reducing all of the things we don’t want to happen: product variability, process misalignment, even the potential for employee injury.

With less time spent on recipe management, process intervention, and ingredient transport, those operators are free to concentrate on other, value-add work. Essentially: More quality product is made with less equipment and operator involvement. And that means the plant is better able to keep up with global demand.

Source

Related Articles


Changing Scene


Sponsored Content
The Easy Way to the Industrial IoT

The way to the Industrial IoT does not have to be complicated. Whether access to valuable data is required or new, data-driven services are to be generated, Weidmuller enables its customers to go from data to value the easy way. Weidmuller’s comprehensive and cutting-edge IIoT portfolio applies to greenfield and brownfield applications. Weidmuller offers components and solutions from data acquisition, data pre-processing, data communication and data analysis.

Visit Weidmuller’s Industrial IoT Portfolio.


ADVANCED Motion Controls Takes Servo Drives to New Heights (and Depths) with FlexPro Extended Environment Product Line

Advanced Motion Controls is proud to announce the addition of six new CANopen servo drives with Extended Environment capabilities to their FlexPro line. These new drives join AMC’s existing EtherCAT Extended Environment FlexPro drives, making the FlexPro line the go-to solution for motion control applications in harsh environments.

Many motion control applications take place in conditions that are less than ideal, such as extreme temperatures, high and low pressures, shocks and vibrations, and contamination. Electronics, including servo drives, can malfunction or sustain permanent damage in these conditions.

Read More


Service Wire Co. Announces New Titles for Key Executives

Bruce Kesler and Mark Gatewood have been given new titles and responsibilities for Service Wire Co.

Bruce Kesler has assumed the role of Senior Director – Business Development. Bruce will be responsible for Service Wire’s largest strategic accounts and our growing Strategic Accounts Team.

Mark Gatewood has been promoted to the role of Vice President – Sales & Marketing. In this role, Gatewood will lead the efforts of Service Wire Company’s entire sales and marketing organization in all market verticals.

Read More


Tri-Mach Announces the Purchase of an Additional 45,000 sq ft. Facility

Tri-Mach Elmira Facility

Recently, Tri-Mach Inc. was thrilled to announce the addition of a new 45,000 sq ft. facility. Located at 285 Union St., Elmira, ON, this facility expands Tri-Mach’s capabilities, allowing them to better serve the growing needs of their customers.

Positioning for growth, this additional facility will allow Tri-Mach to continue taking on large-scale projects, enhance product performance testing, and provide equipment storage for their customers. The building will also be the new home to their Skilled Trades Centre of Excellence.

Read More


JMP Parent Company, CONVERGIX Acquires AGR Automation, Expanding Global Reach

Convergix Automation Solutions has completed the acquisition of AGR Automation (“AGR”), a UK-based provider of custom, high-performance automation design and systems integration primarily to the life sciences industry.

Following Convergix’s acquisitions of JMP Solutions in August 2021 and Classic Design in February 2022, AGR marks the third investment in Crestview’s strategy to build Convergix into a diversified automation solutions provider targeting the global $500+ billion market, with a particular focus on the $70 billion global systems integration and connectivity segments. Financial terms of the transaction were not disclosed.

Read More


Latest Articles

  • Implementing Functional Safety Requirements

    Implementing Functional Safety Requirements

    The Safety Functional Requirements Specification (SFRS; sometimes referred to as SRS or Safety Requirements Specification) is the plan for the safety controls on a machine and is the second step of the safety lifecycle. The SFRS document serves as a framework for the safety control system design, is informed by prior work done in the… Read More…

  • From Endress+Hauser, 24/7 Digital, Plant-Wide Health Monitoring for Rockwell Systems Optimizes Workflows and Processes

    From Endress+Hauser, 24/7 Digital, Plant-Wide Health Monitoring for Rockwell Systems Optimizes Workflows and Processes

    Endress+Hauser’s Asset Health Monitoring Solution–Rockwell Edition, now available for installation, provides operators with a centralized, digital overview of plant-wide device health to avoid unscheduled shutdowns and accelerate troubleshooting. It not only presents early visibility of problematic devices but distinguishes itself by adding likely causes and remedies to such a report so problems can be fixed… Read More…