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...
2016 Engineering Leaders Under 40; Future vision: Where is manufacturing headed?; Electrical distribution, redefined
Strategic outsourcing delivers efficiency; Sleeve bearing clearance; Causes of water hammer; Improve air quality; Maintenance safety; GAMS preview
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Driving motor efficiency; Preventing arc flash in mission critical facilities; Integrating alternative power and existing electrical systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

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.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me