Changing ancient automation at a feedmill that has been in operation since 1953 takes more than replacing the current MMI, in this case buttons and lights, with a fancy new computer system. With an output of twelve-hundred (1200) tons per day, each and every day of the year, continuous feed delivery was paramount in the selection of a control systems integrator.
Operations needed to continue despite electrical/mechanical alterations, complete motor control center installation, and major electrical renovations during peak processing hours. The new automation equipment allows a single operator to control and monitor over twenty-five (25) macro and seventy-five (75) micro batches per day. A single Allen-Bradley PLC coordinates all facility functions, recipe management, micro batch direction, data collection, trending, and control.
Report generation is automatic and provides both detailed and summarized information of batch sizes, time, operator, actual and set point quantities, and inventory information. Micro batch control is accomplished by six (6) loss-in-weigh controllers and a single mix tank controller. Seventeen (17) VFDs are controlled and monitored utilizing both hardwire and Remote I/O control schemes.
Electrical requirements included the ability to continue blending in the event of a complete PLC failure. Core provided technical design, development, representation and on-site start-up services throughout.