The Magical World of Chocolate Manufacture

Material tracking and mass balancing in Chocolate Manufacturing

Stefan la Grange (AMR Automations)Fiona Byrns (for Orley Foods)

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Mixing

•Cocoa Butter or Equivalent•Sugar or SweetenersGrin

ding

•Cocoa Mass or Powder•Emulsifiers•Powdered Milk

Liquefaction

Chocolate manufacture

Pressure and Temperature measurement

Project Scope

Orley Foods Manufacturing

Raw Material Receiving

Chocolate Manufacture

Fat Supply

Fat Melters

Storage

Tanks

Heat Exchangers

Mixing

Conches/

Grinding

Storage &

forming

Sugar Manufacture Finished Goods

Background to the Project

► Seamless and transparent integration throughout the Company manufacturing systems and business system

► Manufacturing system designed for expandability, ease of integration and contextuality.

► Information that is important, relevant and contextual to be published to a portal for easy access

► Ability to trend and trace process issues and speed up trouble shooting.

Project Goals

► Traceability of fat usage and additions against works orders

► Monitoring / logging of process parameters► ERP integration to Syspro► Overall system upgraded to latest technologies

▪ Network▪ Windows / SQL Server environment▪ SCADA system▪ PLC system

► Ingredient management of recipes► Introduction of expandable reporting

infrastructure

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Tender process

► Requirements of integrator and solution▪ Cape Town presence▪ Instrumentation, PLC, SCADA and database

development experience▪ Previous experience in food and beverage

industry► Several solutions investigated

▪ Siemens▪ Rockwell▪ Citect

Why Wonderware

► Proven functionality in the Food and Beverage industries

► Proven integration into business systems (SQL database)

► Well supported, widely used nationally and internationally

► Several solution providers / system integrators▪ Development into the future▪ Increased availability of resources (call-outs)

Project Design

► Functional specification prepared

► Detailed design process▪ Network topology

▪ PC/Server infrastructure

▪ PLC infrastructure

▪ Data flow

Project Description

► Develop ArchestrA model▪ S95 standard▪ Model includes future upgrades

► Use model to define data capturing points for EOM

Topology

EOM

Project Design

► Design Intouch SCADA▪ Dual display

► AMR’s first project with ArchestrA 3.0 and Intouch 10.0

► Converted AMR’s standard valve/motor SmartSymbols to ArchestrA graphics

Project Design

Project Description

Project Description

ERP Integration / WO Management

► ERP integration to Syspro via holding database▪ WO’s pushed down from Syspro indicating

• Raw material, tank and equipment allocation/scheduling

► Operators start and complete WO’s SCADA

Syspro serverWonderware

Historian

Intouch SCADA

ERP Integration / WO Management

► Example of WO Management at SCADA level

ERP Integration / WO Management

Project Description

Project Description

WO – Modify execution time

WO – Re-allocate

WO – Remove from plan

PLC

► Allen-Bradley Compact Logix

► Beckhoff Ethernet/IP remote I/O units

► Program designed with complete process control management in mind (for future phases)▪ Manufacturing instructions

▪ Process parameters (Mixing times, pressure and temperature checks and operator prompts)

▪ Fat transfer route allocation

► Current program only handles fat transfer route allocation

Reporting

► Wonderware Information Server

► MS-SQL Reporting services

Reporting

Reporting

Reporting

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Benefits / Goals Achieved

► Batch size consistency▪ No need for extensive additions to correct

recipe failures► Raw material allocations tracked

▪ What fat goes where► Better process control tracking

▪ Alarming at SCADA level▪ Trouble-shooting (temperatures, pressure,

grinding times)▪ Operators

Benefits / Goals Achieved

► Significant savings in fat usage► Batch processing times where standardized

▪ Less usage of resources i.e. power► Minimised batch/formulation corrections

▪ Savings in additional raw materials to batches.

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Lessons Learned (PLC)

► User defined data structure always good (duplication of devices similar control)

► I/O server integration with tagnames instead of address reference

► Ethernet/IP needs managed switches to handle IGMP Snooping (Internet Group Management Protocol)

Lessons Learned (Wonderware)

► Domain Security▪ Tighter control with existing business system and

network policies▪ Client responsible for user manager/rights (IT

department)

Lessons Learned

► Understanding scope and planning vital▪ Previous projects failures overcome▪ Plant downtime was managed

► Plant process visibility greatly improved▪ Updated P&ID▪ Operations / process flow

► Increased speed of data availability

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Project summary / conclusions

► Phase I successfully completed by AMR using Wonderware technology▪ Increased process control and shop floor visibility

► Phase II will further utilize the solution into other areas of the plant

► Future phases will allow for data to be written back to Syspro▪ Automatically closing works orders

Thank you