Client Challenge
Fuji Foods approached DSI Innovations to upgrade its controls system for its food seasoning process. The existing setup relied on three racks of Allen-Bradley PLC-5 hardware with one central processor which was the source of several critical issues:
- Foreign Integration: The original operator interface was developed by an out-of-country integrator using custom process control graphics, making it difficult for Fuji Foods to resolve any system issues.
- Obsolete System: The existing recipe control system had become unusable due to outdated technology.
- Manual Operation: Operators had to manually control the system by opening and closing valves. As well as adjusting pump speeds and temperature settings based on observed flow rates and temperatures.
Recognizing the need for a more consistent, efficient, and reliable automated process to improve product quality, Fuji Foods sought our expertise.
Our Solution
Our automation team worked closely with Fuji Foods to modernize and automate the food seasoning process. We developed a control architecture and approach tailored to their immediate and future needs:
- Controller Upgrade: As a Rockwell partner, we upgraded the system to a modern CompactLogix controller, which communicates with remote input/output devices over Ethernet. Additionally, we swapped the obsolete hardware with new, readily available products from Rockwell.
- New Control Program: We rewrote the control program using Rockwell’s PlantPAx Process Control Library v3.5 AOIs, ensuring support from a wide range of Rockwell integrators. This new program provided more control and configuration options directly from the operator interface, with PlantPAx diagnostic features aiding operators and maintenance staff in quickly identifying and resolving issues.
- Automated Process: We developed an easy-to-use recipe control system to automatically add and mix ingredients, and manage temperatures and flow rates. Enhanced graphics simplified the production process, ensuring consistency from batch to batch.
- Data Analysis Tool: We implemented FactoryTalk SE to track batch data such as temperatures and flow rates, allowing operators to easily spot trends and improve process visibility. Improved tuning of control loops for temperature, pressure, and flow reduced the need for manual adjustments.
The Results
The project delivered significant improvements and benefits:
- Efficient Installation and Testing: We completed the installation and testing in two weeks, with full production starting on schedule in the third week. The transition occurred with no downtime.
- Improved Recipe Controls: The new automated recipe system enabled operators to run multiple batches reliably without manual intervention, speeding up production times and ensuring consistent product quality.
- Enhanced Operator Interface: The updated control interface offered better visibility of the process, allowing operators to respond quickly to any issues. Startup, shutdown, and cleaning processes became more efficient with the new interface.
- Optimized Temperature Control: Improved tuning of the temperature control system reduced temperature overshoot from nearly 10°C to just 2°C and halved stabilization time, minimizing the need for manual adjustments.
- Increased Efficiency and Reliability: The fully automated system boosted consistency, efficiency, reliability, and product quality, meeting the client’s expectations and enhancing their operational capabilities.
This project demonstrates DSI Innovation’s ability to transform manual processes into efficient, reliable, and high-quality automated systems, making a significant improvement on the client’s operations.
