Reliable Operations for Perishable Products

With its equipment installed in ice cream manufacturing plants all around the world, it’s handy to have a way to troubleshoot and edit operating and safety programs from centralized locations. As it designs and deploys its industrial ice cream plants, Gram Equipment uses Rockwell Automation’s scalable and flexible platforms to help provide the monitoring and control it needs to ensu...

08/01/2009


With its equipment installed in ice cream manufacturing plants all around the world, it’s handy to have a way to troubleshoot and edit operating and safety programs from centralized locations. As it designs and deploys its industrial ice cream plants, Gram Equipment uses Rockwell Automation’s scalable and flexible platforms to help provide the monitoring and control it needs to ensure process optimization and product quality. Located in Vojens, in southern Denmark, Gram Equipment delivers tailor-made, complete production lines to ice cream producers and other food processing firms looking for integrated solutions. These solutions include everything from individual assembly lines to complete production plants with mixing equipment and packaging lines. With more customers looking for increasingly advanced solutions, new installations now typically require increasing production speed, new levels of complexity, and many specialized functions. As an example, Gram Equipment is currently constructing a very large production line that will be able to produce 36,000 units per hour. Of course, every element in the system must work reliably and with a minimum of down time.

From many solutions to one

Before implementing Rockwell Automation’s Safety solution two years ago, Gram often experienced problems with traditional safety systems, typically comprising a PLC, a separate safety PLC, and a servo system. Operators and maintenance staff had to learn how to use three different software programs, including how to connect the systems so they could communicate with each other. If the plant had to be modified, it involved time-consuming changes to electrical documentation as well as programming changes which could only be carried out by a few, specially trained staff. The customer often had to do more testing spread over lengthy time periods.

Now, Gram Equipment has been able to simplify the process by moving it to one platform. Any changes related to Safety Zone control are commonly carried out in agreement with the end-user during commissioning.

Communication via EtherNet/IP

To simplify system complexity and usability, a major consideration for Gram was to base its control topology on an Allen-Bradley GuardLogix platform. This system combines standard process control and safety control in one platform.

“This saves Gram Equipment cabling and components,” says Bjarke S. Petersen, commercial engineer safety, Rockwell Automation. “But it also saves them the time it used to take to make the systems communicate with each other. Additionally, staff training is simplified and more effective, as understanding only one platform is now required.”

Combining the three functions also allows a wider variety of engineers to modify the plant according to customer wishes. In addition, electrical documentation has been simplified significantly.

Using GuardLogix, Gram Equipment has produced automation systems for plants that can run up to 30 servo drives with integrated safety (Safe-off). The system is scalable and flexible to accommodate different plant sizes and functions, and individual parts communicate via Ethernet/IP, which has proven to be an advantage when working with international customers.

Since the standard I/O and safety I/O modules run via Ethernet/IP, troubleshooting and repairs on a plant’s I/O points anywhere in the world can be carried out from Denmark. This saves both Gram Equipment and its customers time and travel costs. An international service and support agreement between Rockwell Automation and Gram Equipment keeps these costs to a minimum, and exemplifies the close cooperation between the two companies.

Rockwell Automation Safety solutions are certified according to international standards, so Gram Equipment can use Rockwell Automation Safety for customers around the world.


Author Information

Dan Hornbeck is safety market development manager for Rockwell Automation. Reach him at dbhornbeck@ra.rockwell.com .

Author Information

Dan Hornbeck is safety market development manager for Rockwell Automation. Reach him at dbhornbeck@ra.rockwell.com .




No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Leaders Under 40 program features outstanding young people who are making a difference in manufacturing. View the 2013 Leaders here.
The new control room: It's got all the bells and whistles - and alarms, too; Remote maintenance; Specifying VFDs
2014 forecast issue: To serve and to manufacture - Veterans will bring skill and discipline to the plant floor if we can find a way to get them there.
2013 Top Plant: Lincoln Electric Company, Cleveland, Ohio
Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.

Bring focus to PLC programming: 5 things to avoid in putting your system together; Managing the DCS upgrade; PLM upgrade: a step-by-step approach
Balancing the bagging triangle; PID tuning improves process efficiency; Standardizing control room HMIs
Commissioning electrical systems in mission critical facilities; Anticipating the Smart Grid; Mitigating arc flash hazards in medium-voltage switchgear; Comparing generator sizing software

Annual Salary Survey

Participate in the 2013 Salary Survey

In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.

Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.

2012 Salary Survey Analysis

2012 Salary Survey Results

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.