Control System Upgrade Streamlines Pet Food Production

The facility was operating with outdated electrical equipment that had become increasingly difficult to maintain. The existing automation was minimal, with operators manually adjusting critical parameters like water and steam rates based on moisture content readings. What automation did exist was fragmented across multiple PLCs scattered throughout the plant, creating 'islands of automation' that required operators to physically walk the production line to monitor and adjust different systems.
 

The original Motor Control Centers (MCCs) were particularly problematic. During NorthWind's initial design assessment, the team discovered that the MCC layout was confusing and poorly documented, with unclear connections between buckets and the systems they controlled. This disorganization made troubleshooting time-consuming and complicated routine maintenance tasks.

Our Approach

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NorthWind developed a comprehensive control system modernization strategy that addressed both the electrical infrastructure and control system architecture. Rather than working with the existing MCCs as initially planned, NorthWind proposed designing and building new Motor Control Panels (MCPs) that would house all motor control equipment for each system in one organized location.
 

A key advantage in NorthWind's approach was the coupling of automation and electrical installation services. Instead of the manufacturer having to coordinate between separate vendors, NorthWind's integrated teams worked directly together to identify and resolve equipment changes, determine I/O panel locations and quantities, and design the network architecture. This collaborative approach minimized the burden on the manufacturer's team and allowed for rapid problem-solving without overwhelming the end user.

Phased Implementation

The implementation was carefully phased to minimize production disruption.
 

1. Phase 1, completed in August, involved removing the existing MCC and Dryer I/O panel and installing new MCPs and I/O panels to control the existing dryer and newly installed coater. Despite an ambitious two-week timeline for equipment removal, installation, electrical work, I/O checkout, and commissioning, NorthWind's automation and installation teams coordinated efforts enabled I/O checkout to begin two days ahead of schedule and equipment commissioning to start three days early.
    
2. Phase 2, which began 2 months after Phase 1 implementation, focused on the complete replacement of the second extrusion line. The NorthWind team maintained the project schedule and even performed some initial I/O checkout ahead of schedule. Their on-site presence throughout the installation process allowed them to identify and address system changes proactively, preventing potential delays during commissioning.
    
   

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On the automation front, NorthWind transformed the manual processes into an integrated control system. The new system automatically adjusts water and steam rates based on recipe setpoints, eliminating the need for manual valve adjustments. Instead of scattered PLCs and HMIs for each subsystem, the facility now has one unified control system per line with HMIs that monitor all systems, allowing operators to control and monitor the entire process from centralized locations.

The Impact

The modernization project delivered significant benefits to the pet food facility:
 

• Streamlined Operations: The unified control system eliminated the need for operators to physically walk the line to monitor different systems, improving efficiency and reducing labor requirements.
   
• Enhanced Maintenance Support: Updated electrical and controls hardware, along with accurate documentation, significantly reduced troubleshooting time and simplified maintenance procedures.
   
• Improved Process Control: Automated adjustment of critical parameters based on recipe setpoints ensures consistent product quality and reduces operator intervention.
   
• Operational Consistency: Similar controls for both production lines facilitate operator training and flexibility, allowing staff to seamlessly transition between lines.
   
• Reduced Downtime: The organized electrical system design minimizes the time required to locate and replace components, improving overall equipment effectiveness.
   
• Future-Ready Infrastructure: The control system upgrade provides a foundation for further automation and data collection initiatives.
   

The customer has expressed extreme satisfaction with both NorthWind teams, particularly noting the quality of the electrical installation work and the process knowledge demonstrated by the programmers and controls technicians.
 

Learn more about NorthWind's Solutions the Pet Food Industry or reach out to schedule a walk through of a system.
 

By Bryan Reinecke, Senior Project Manager
Source: NorthWind