Upgrading SCADA Software Functionality to its Fullest Potential

  • Upgrading SCADA Software Functionality to its Fullest Potential

The Challenge

Akzo Nobel wanted to improve their operational efficiency. To accomplish that, they needed to upgrade the Klieverik Automatic Dosing Unit (ADU). Before the upgrade, the Klieverik was limited on the amount of storage and could only hold about half of the ingredients needed for the formulas that are made on it. This resulted in most batches being made on and off of the machine, leading to inefficiency and waste. Akzo Nobel’s Research, Development & Innovation (RD&I) department revised over 1,000 formulas to reduce the overall ingredients in the formulas so they could all be placed on the ADU once it was updated. The programmable logic controller (PLC) on the Klieverik did not allow a “fine tuning” dispense feature, so overdosing ingredients in formulas was becoming common and costly. Also, their System Application Products (SAP) system could not be tied into their plant network causing delays in receiving new paint batch recipes from their lab to their plant floor. This was creating additional time and errors because plant operators had to manually transfer information from one system to another.

An upgrade to the Supervisory Control and Data Acquisition (SCADA) software created easy integration to improve efficiency

The Solution

It was important to update the software to reflect the changes that Akzo Nobel wanted with their new Klieverik upgrade. MartinCSI did a complete overhaul on the SCADA software and updated it from a G.E. iFix to an Inductive Automation Ignition software. Changing it to the Ignition software allowed MartinCSI to develop code that would grab files from Akzo Nobel’s SAP software in their lab, and put it into a local SQL database in the plant. By doing this, it eliminated manual data entry in the plant and decreased human error with the updated and improved formulas. With additional tanks and drum stations being incorporated into this upgrade, MartinCSI also created new SCADA screens and PLC functions. The new PLC code and programming gave Akzo Nobel the capability to automatically dispense all ingredients directly from storage tanks to the Klieverik- something they were never able to do before. This also gave Akzo Nobel the fine tuning feature they needed to dispense the right ingredients and help eliminate overdosing. Additionally, once MartinCSI completed all the upgrades for the Klieverik ADU, they provided training to plant operators on the SCADA system and a training manual was developed as a future resource

The Results

  • Akzo Nobel increased the amount of batches made on the Klieverik by 114%. 
  • The Klieverik ADU is fully automatic with no manual tasks required. 
  • With fine tuning of dosing, overdosing has been eliminated. 
  • Batch scheduling, inventory management and recipe management are now integrated with the new SCADA system. 
  • The ROI was less than one year.

Packaging Supplier Solves Ice Cream Headaches

ice cream cone

As one of the world’s leading suppliers of ice cream novelty packaging and filling machinery, Norse Dairy Systems, was watching its profit melt away through mechanical downtime and wasted materials on its production lines. It turned to Martin Control Systems for a solution that boosted production by more than 27%.

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Increased Operational Efficiency with Automation Technology

  • Increased Operational Efficiency with Automation Technology

The Challenge

An OEM machine builder had mechanical machines that were used to load, fill, and seal ice cream cups for a client. The mechanical cams that ran the machine, consisted of too many components, making it hard to service. The cams also limited the ability to change the line with ease. The machine did not run with a PLC or HMI, so it lacked in automation technology. The OEM knew that for their clients to keep up with their competitors, the machine would have to be fully automated, making it faster, more efficient, and producing more ice cream cups per minute.

An original equipment manufacturer(OEM) machine builder and MartinCSI create more flexibility with less components for the ice cream industry

The Solution

The OEM developed a completely automated system to replace the old mechanical machine. The cams on the old machine were converted into electric servos. With servo technology, a program controls all the motions of the machine instead of the mechanical cam, making the machine faster, and more adjustable. The program also provides the ability to troubleshoot remotely, so changes can be made within a matter of minutes. MartinCSI assisted with choosing the right servo equipment to fit the OEM’s needs. The OEM’s service staff were knowledgeable with Rockwell equipment, so MartinCSI integrated Rockwell Kinetix® servo drives, a ControlLogix PLC, and a PanelView Plus HMI to complete its automation overhaul.

The Results

  • One automated machine replaced (2) mechanical machines for their client.
  • Client was able to reduce their operator costs by half. 
  • The automated machine produced almost 40,000 more ice cream cups per day. 
  • Machine maintenance was significantly decreased. 
  • Ability to remote access to assist with troubleshooting.

Sensors Help Provide a Higher Quality Product

  • Sensors Help Provide a Higher Quality Product

The Challenge

An Ohio-based animal feed company noticed some of their feed bags were not completely filled to capacity before being put on a pallet for the delivery trucks. After careful examination of their production line, they noticed some feed would spill out of the bag when it was laid down horizontally after the sewing portion of the production process. At times, the sewing machine wasn’t completely sealing the bag shut, and there was no way of determining this had happened, until it was too late. The feed company wanted to ensure their customers were getting the full amount of quality feed in each bag. 

Now, operators don’t have to emergency stop the line if they notice the spill. The sensors easily detect a spill and will stop the line automatically.

The Solution

Initially, the feed company wanted to put in a laser profile sensor that would detect the thread of the bags to make sure they were being sewn accurately. Their current line equipment made it difficult for a system like this to be installed within their budget and timelines. MartinCSI recommended Omron E32 and beam fiber optic sensors be installed at the transition point where the bags were laid down horizontally on a conveyor after being sewn. The sensors would detect if any feed had fallen from the bag in between the transition point, if it had, the line would stop so production workers were able to remove the bag.

The Result

  • Sensors were able to be applied to the existing equipment infrastructure.
  • There was no downtime to the line because the installation of the sensors were done during production time.
  • Now, operators don’t have to emergency stop the line if they notice the spill. The sensors easily detect a spill and will stop the line automatically.
  • Decreased amount of open bags placed on pallets.

Upgrading PLCs

PLC
  • Upgrading PLCs

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PLC

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