DMC worked with the client to implement a new process with a new ingredient to an existing line that improved the end product quality. The addition was an extensive change to the line, requiring additional PLC hardware, networked IO, control panel, mixing stations, and holding tanks.
PLC to PLC and PLC to IO communication is over ControlNet protocol. The factory contains over 50 PLCs of different families that share data and network and factory resources. Network load analysis was performed to ensure system performance was not impacted by new systems. The system runs two complex pressure control loops to attain optimal pipe pressure and flow rate. End system tuning is tolerant for a large range of set points.
Additional services included generating HMI screens, improving recipe management system, creating ingredient diverting system, configuring historian trending, and I/O checkout. The end system was robust; no additional issues or support were needed after implementation and initial training.