Advanced Batching Control System Modernizes Animal Feed Production

Project Overview

An Animal Feed Producer in Costa Rica faced a critical challenge with their outdated standalone batching system in the main production area of their plant. The issues they were experiencing with their existing equipment were compounded by a significant operational bottleneck: all recipe information was locked within their current formulation software. The software managed the important nutritional ratios for their various products but lacked integration with production systems. This disconnection created inefficiencies, increased the risk of human error, and limited production flexibility.

NorthWind was contracted to develop an advanced batching control system that would not only replace the outdated hardware but also create seamless integration between formulation management and production systems, establishing a foundation for future growth and efficiency improvements.

Our Approach

NorthWind approached the batching control system project using a structured methodology based on the automation pyramid, addressing each level of the manufacturing process while maximizing value for the customer:

Field and Control Level Optimization

To deliver a cost-effective solution, NorthWind strategically repurposed existing field motors and actuators while upgrading critical control components. The outdated relay board was replaced with a modern PLC system featuring pre-wired modules designed to connect directly to the existing panel terminals. This approach minimized installation time and reduced capital expenditure while significantly improving system reliability and control capabilities.

Supervisory Level

NorthWind deployed Ignition’s Vision Supervisory Controls and Data Acquisition (SCADA) platform with unlimited licensing, establishing a new standard that could be extended throughout the facility. Utilizing NorthWind’s standardized Human-Machine Interface (HMI) components, including intuitive Hand-Off-Auto controls and graphical elements, we created a user-friendly operator experience that reduced training requirements and improved operational efficiency.

Planning Level Integration (MES)

The core of the solution is centered on two key components:

1. NorthWind PlantLOGIX® Implementation: NorthWind deployed their NorthWind PlantLOGIX® software with the BatchLOGIX® module as a new batching and recipe management platform eliminating potential human errors during recipe creation and management. The system provided structured workflows and validation processes that ensured consistent product quality.
2. Ignition as Integration Hub: Ignition served as both the communication interface between different software solutions and the graphical platform for implementing required features. This created an all-in-one solution that bridged the gap between the client’s Formulation software and the production systems.

Communication Interface Development

A critical achievement was establishing direct communication between the Formulation Software and the new batching control system. Previously, there was no automated data exchange between the formulation software and the standalone batching system, requiring manual intervention that introduced delays and potential errors. Our solution enabled live synchronization between systems, ensuring that production always used the most current formulations while maintaining the integrity of nutritional data.

Advanced Manufacturing Execution System (MES) Capabilities

• Enhanced Purchase Order Management: In their previous environment, the client had to manually divide production orders into sub-orders, creating scheduling and reporting challenges. The new system allowed scheduling of top-level POs directly from the MES platform with automatic association of sub-orders and products, enabling detailed reporting for every production order.
• Comprehensive Reporting: The integrated communication framework enabled consolidated reports drawing data from multiple sources. Specialized reports included raw material requirements based on production schedules, raw material consumption per formula, detailed batch information by PO (including lot numbers and error percentages), and formula listings by raw material.

The Impact

NorthWind’s advanced batching control system has revolutionized our client’s manufacturing operations by seamlessly integrating formulation management with production systems. This integration eliminated manual processes, reduced errors, and provided comprehensive data visibility across the organization. By strategically modernizing control systems while preserving existing equipment, the solution delivered maximum value with minimal disruption.