Technologies used for Malt-O-Meal integrated safety project

Safety PLC, adjustable speed ac drives, motor starters, and energy management software from Rockwell Automation, along with EtherNet/IP communications from ODVA helped reduce downtime and cut costs.

07/18/2012


The new risk-assessment process offers improved collaboration between operations, maintenance, engineering, and Malt-O-Meal’s OEM partners for better consistency and increased safety overall.To update its safety system and risk-assessment process, the Malt-O-Meal team turned to long-time automation partner, Rockwell Automation. "We've worked with Rockwell Automation for over 30 years, and really appreciated the in-depth safety knowledge and resources they were able to provide," said Scott Kluegel, manager, corporate electrical engineering, Malt-O-Meal Co. "When we decided to undertake this upgrade project, they were the only company we considered."

For the control system design and implementation, the Malt-O-Meal team partnered with Rockwell Automation and Rockwell Automation PartnerNetwork members Werner Electric, a distributor, and Wunderlich-Malec Engineering, a system integrator. Together, they selected an Allen-Bradley GuardLogix integrated safety system, from Rockwell Automation, which allows for both safety and standard control on one platform, and provides an easy path for standardization.

"We're installing the GuardLogix solution on each line as the opportunity presents itself, as our standard maintenance practices and upgrade schedules allow," explained Kluegel.

Malt-O-Meal also is updating its motor control solution to an intelligent motor control solution with integrated safety from Rockwell Automation. The company uses Allen-Bradley PowerFlex 40P adjustable frequency ac drives and PowerFlex 700S ac drives with a safe-off function and standardized motor starters, which communicate to the GuardLogix platform via an EtherNet/IP network from ODVA.

To standardize the risk-assessment process, the Malt-O-Meal team worked directly with the machine safety consulting team at Rockwell Automation.

"The machine safety consulting team met with our team several times to share their experience and best practices," said Kluegel. "We worked with them to customize their standard assessment process to address our specific production environment and safety requirements while driving proactive safety solutions."

The Malt-O-Meal team is already looking ahead to other areas of sustainability they can support in their manufacturing environment. They have started using Rockwell Software RSEnergyMetrix technology to get a baseline on current energy consumption, to help identify areas for possible improvements.

"Rockwell Automation and its partners have always been great technical resources for us as we look to continuously improve our manufacturing processes and deliver the best value possible for our customers. We definitely plan to continue those relationships in the future."

- Edited by Mark T. Hoske, content manager CFE Media, Control Engineering and Plant Engineering, mhoske@cfemedia.com.

www.rockwellautomation.com 

www.odva.org 

www.wmeng.com 

Read more about the application and see two more photos: Malt-O-Meal integrates safety, assessment process



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
World-class manufacturing: A recipe for success: Finding the right mix for a salad dressing line; 2015 Salary Survey: Manufacturing slump dims enthusiasm
2015 Top Plant: Phoenix Contact, Middletown, Pa.; 2015 Best Practices: Automation, Electrical Safety, Electrical Systems, Pneumatics, Material Handling, Mechanical Systems
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Getting ready for industrial IoT; Visualizing the (applied) automation continuum; Preventing VFD faults and failures; Using wireless for closed-loop applications
Migrating industrial networks; Tracking HMI advances; Making the right automation changes
Understanding transfer switch operation; Coordinating protective devices; Analyzing NEC 2014 changes; Cooling data centers

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.