Food Manufacturing (Biscuit & Crackers)
Replace an old relay-controlled ingredient delivery system and track and trace all ingredient delivery to a database.
Two control panels were upgraded to new Allen-Bradley ControlLogix controller systems with integrated networks. A customised Microsoft SQL Server database was built to track all operator actions from the plant, equipment accuracy, and ingredient delivery, with the option to later connect to a Warehouse Management Stock Control System (WMS).
An intranet web based reporting system was developed using Microsoft Reporting Services. All data from ControlLogix PLC was committed to the database using Rockwell Software Factory Talk Transaction Manager. The operator interfaces distributed on each machine were Allen-Bradley Panelviews.
A full Supervisory Control and Data Acquisition (SCADA) system was developed with Rockwell Software Factory Talk View SE Distributed Server. This SCADA system was expanded to cover other parts of the plant. Working closely with the onsite IT personnel, two Microsoft Server 2003 Servers where also installed and configured as part of the project.
An RFID tag system was also installed as part of this system to track ingredient movement from one part of the plant to another.
the Mixing room was extended and an additional project carried out to track and trace all mixing events and operator actions to the same database and reporting system.
At this stage a link was also created from the Main Recipe Specification database to the Production database to ensure the integrity of production recipes.
Objectives: Implement a batch track and trace system with an operator interface.
Overview: A customised database was built to achieve this based around a batch S88 Standard. Microsoft SQL Server and Crystal Reports software were utilised for all reporting.
The operator interface used was Rockwell Software RSView32 SCADA with an active display server for multiple screens. Data is passed from this interface to a transaction manager and committed to a customised SQL Server database for processing.