From manual control to automation, this success story highlights how Rockwell Automation solutions supported increased throughput and cost reductions.
Challenge:
Our client, a prominent supplier and producer of culinary spices, faced a critical need to transition their facility’s receiving and washing areas from a manual control setup to an automated control system. The challenge was to improve throughput, reduce cleaning and processing times, and establish visibility within these areas for ongoing enhancement. With the existing manual approach, the company encountered bottlenecks affecting operational efficiency, preventing them from reaching their production potential. This shift to automation was crucial not only for optimizing their processes but also for streamlining the overall workflow and paving the way for future advancements in their operations.
Solution:
The spice supplier aimed to enhance efficiency and cut costs by automating their manual receiving and washing areas, essential for maintaining spice quality and streamlining initial production stages. Automation Group, an E Tech Group company, conducted a comprehensive analysis of the customer’s manual system and developed a precise automation strategy. The customer wanted to integrate Rockwell Automation products due to their reputation for reliability and customer support. Therefore, we utilized a range of Rockwell Automation hardware and technologies to align with their objectives.
We incorporated various components including Flex IO, PanelView Plus 7 HMI, PowerFlex VFDs, Allen Bradley safety and non-safety contactors, Stratix managed switches, and Allen Bradley pushbuttons for the receiving hardware. This integration resulted in a more streamlined and responsive control system, bringing about significant improvements. Additionally, for upgrading the hot wash hardware, we seamlessly integrated a suite of Rockwell Automation components, including ControlLogix L82E, ControlLogix I/O modules, PanelView Plus 7 HMI, PowerFlex VFDs, Allen Bradley safety and non-safety contactors, and Stratix managed switches. These enhancements improved efficiency, reliability, and safety. We also leveraged Rockwell Automation’s Studio 5000 v33 and Factory Talk View Studio Machine Edition, which provided a seamless and user-friendly interface for the spice supplier.
Results:
With the dedicated support of our engineering firm, the project made significant strides toward achieving the customer’s goals of increasing throughput and reducing production costs. The anticipated return on investment is expected to materialize within a span of three years, demonstrating the projected cost-effectiveness of the solution. This transformation not only optimized operations but also paved the path for future improvements, highlighting the effectiveness of our collaboration and the strength of automation solutions like Rockwell Automation’s offerings.
