A large processing facility had nine individual, continuous process production lines each producing different products. These nine production lines required products to be distributed to 31 different packaging lines and nine(9) temporary storage areas. Products were distributed via a complex conveyor matrix. This matrix presented several unique challenges. EAD engineers had to figure out how to prevent different prodcuts from being mixed together prior to packaging, minimize waste product caused by the breakdown of packaging lines, and integrate over 40 different PLC controllers.
EAD performed several projects on this matrix system including adding new conveyors to allow products to be distributed to more packaging lines, installing gates to protect products from cross contamination, and installing new photo-eyes on storage bins that were susceptible to dust accumulation. Other improvements made by EAD engineers included upgrading the obsolete Allen-Bradley PLC-5 Controls systems to the new ControlLogix platform, utilizing SQL and OSI/Pi based database systems to monitor conditions and troubleshoot using historical data, and barcode systems. EAD engineers also implemented lot tracking to ensure the right products were packaged in the right container.
Client: Food Processing Industry
Location: North America
Market(s) Served: Food and Packaging
- Project Management