Client Challenge
A leading consumer product and packaging brand needed to upgrade the control system for their Coater 19 production line. The existing system, based on a legacy PLC-5 platform, faced operational inefficiencies and compatibility issues with modern equipment.
The upgrade required transitioning to a ControlLogix PLC platform, verifying all analog and digital I/O points, and ensuring correct operation of Variable Frequency Drives (VFDs), PID loops, and AC motors. The challenge was to complete the upgrade efficiently while ensuring seamless system functionality and minimal disruption to production.
Our Solution
DSI played a key role in the startup crew for the Coater 19 upgrade, ensuring a successful system transition. The team delivered a comprehensive solution that included:
- VFD and Motor Setup:
- Configured Variable Frequency Drives (VFDs) and AC motors for optimal performance, aligning with the new control system requirements.
- Tuned PID control instructions to achieve precise and efficient operation.
- I/O Point Verification:
- Verified all analog and digital I/O points against the electrical drawings to ensure accurate mapping within the upgraded ControlLogix PLC program.
- Logic Testing and Validation:
- Conducted thorough testing of the ControlLogix PLC program to confirm correct logic functionality after the controller upgrade from PLC-5.
- Addressed any discrepancies in logic or I/O mapping, ensuring smooth integration with the production line.
The Results
DSI’s efforts ensured the successful upgrade of the Coater 19 control system, delivering:
- Improved Operational Efficiency: The transition to the ControlLogix platform provided enhanced processing capabilities, enabling faster and more reliable system performance.
- Seamless System Integration: Accurate I/O verification and logic testing ensured smooth functionality, minimizing downtime and operational disruptions.
- Enhanced Control: Precise VFD configuration and PID tuning resulted in improved motor control and overall line efficiency.
- Future-Ready Infrastructure: By replacing the legacy PLC-5 platform, the Coater 19 production line is now equipped to integrate with modern automation technologies and expand as needed.
DSI’s technical expertise and hands-on approach were instrumental in the successful upgrade of the Coater 19 control system. This project exemplifies DSI’s ability to modernize legacy systems, improve operational efficiency, and deliver reliable, future-ready solutions for the consumer product and packaging industry.
