Controls System Upgrade

Background

A key Fortune 100 client required additional production capacity and compliance with latest Good Manufacturing Practices (GMP) and latest applicable industry regulations (21CFR part 11). In addition to achieving the increased performance and latest compliance, Foth worked with the client and identified an overall control system modernization to allow for hardware longevity and system reliability improvements on an existing linked meat product production line.

Approach

This key client engaged Foth to execute a major upgrade project that entailed the review of the existing system and latest corporate and industry requirements. Foth designed and developed a new power and controls system based on the latest Allen Bradley Control Logix and Factory Talk View platforms with customized software to allow compliance with the GMP and regulatory requirements. An efficient interface was also provided that eased implementation of batches, Clean in Place (CIP) and tracking of production based attributes/changes to comply with 21CFR part 11 requirements.

Results

The upgrade / capacity increase allowed the client to take advantage of significantly increased automation in order to reduce operating labor and decrease utility demand. Precisely controlled and timed sequencing of cooking, cleaning (CIP) and production batching/scheduling led to an increase in equipment scheduled availability. New electrical power and controls hardware allowed for improved systems maintenance and troubleshooting and enterprise data visibility. An overall reduction of capital installation costs was achieved by minimizing electrical wiring to I/O and VFD drives.