Food and beverage industry

Solution implemented and results achieved:

• Implementation of the MES system with extended modules for the analysis of production efficiency,
• IFIX visualization for comprehensive supervision – hard cheese production lines
• Supervision over HACCP procedures with automatic reporting,
  Excessive weight monitoring system

Benefits for the Customer:

• 10% increase in the overall capacity of the packaging department,
  Elimination of losses related to excessive weight resulted in increased production efficiency and savings of 30 000 kg of cheese per year.
• Precise reporting: ” List of the share of offcuts”, “List of average surplus”, “List of causes of downtime” for any period.
• Large format screens present the current progress of production – easy comparisons and the possibility of continuous improvement of production based on facts.

Solution implemented and results achieved:

• Implementation of the SCADA system together with the production database,
• Integration with weighing scales within the production line, presentation of clear diagrams to operators,
• Analysis of average excessive weight and monitoring of underweight packaging (production discard).

Benefits for the Customer:

• Increased production efficiency and reduced downtime associated with products with incorrect weight interrupting the line operations.
• Improved performance of operators – preview of graphs with real time scale reading,
• Quick reaction of personnel when the average weight drops steadily – adequate alert.
• History of scale readings for better production planning and optimization.

Solution implemented and results achieved:

• Implementation of MES system and algorithms estimating beer quality parameters during filling BBT,
• Integration with the current control system in the control room of the filtration department,
• A detailed insight into the history of each parameter thanks to the Historian industrial database.

Benefits for the Customer:

• Prediction of final quality parameter values,
  Automatic validation of compliance with the specification,
• Information for bottling plant operators about the release of individual beer tanks to further production,
• Reduced number of laboratory tests required.

Solution implemented and results achieved:

• Integration of the solution with the existing SCADA iFIX system
• Touchscreen interfaces for operators and streamlined reporting for the manager,
• Printing and affixing labels to containers.

Benefits for the Customer:

• Quality assurance by observing the salting time of cheese blocks,
• Optimized use of space in containers and on shelves,
• Easier production planning and genealogy for each batch (weight, number of units, containers used, place in the ripening facility),
• Significantly reduced time spent to date on filling out paper logs.

Solution implemented and results achieved:

• The previous SCADA system provided by a third party was replaced by Proficy iFIX, which is widely used in the Brewery,
• Launching of archiving and reporting system for additional production variables,
• Implementing application protection and management based on user groups.

Benefits for the Customer:

• Convenient selection of washing program from SCADA application, with indication of its type: Rinsing, Alkaline cleaning, Disinfection, Sterilization, Acid preparation, Candle filter sterilization and many others.
• Fast and clear setting of the washing equipment: monoblock or pasteurizer,
• Reporting available (including temperature status, information on possible errors),
• New data archiving mechanism provides complete process information for the technology or bottling manager.

Solution implemented and results achieved:

• Supporting the operation of laboratories of one of the largest sugar producers in Poland (4 sugar refineries / 20 stands),
• Advanced features of iFIX environment were applied – reflection of paper logs in the visualization window,
• Any kind of calculations on the data collected, including the Rens method for evaluation of sugar particle size.

Benefits for the Customer:

• Full records of the entire campaign, available to everyone ONLINE,
• Automatic specification control – coloring of data entered,
• Campaign reports available “on demand” – daily report, technical decade report, averages of any parameters in the selected period,
• Flexible process of goods release together with laboratory certification.

Solution implemented and results achieved:

• Update of iFIX licenses and modification of operating systems according to corporate requirements,
• Using virtualization in order to improve installation security,
• System migration for handling theformulations used by the customer together with the necessary tests

Benefits for the Customer:

• Faster response to problems with equipment
• Adjustable process parameters, process control, alerting and rapid response in the event of exceeding the given parameters in the brew house,
• More efficient application operation,
• Security achieved through virtualization,
• Redundancy of SCADA systems – ensuring system operation continuity