A Pet Food Manufacturer, home to two extrusion lines producing cat and dog food, faced significant operational challenges due to aging infrastructure and fragmented control systems. NorthWind was contracted to modernize one existing extrusion line while completely replacing the second line with new equipment and controls. The control system upgrade project aimed to transform scattered, manual processes into a cohesive, automated system that would enhance operational efficiency and simplify maintenance procedures.
The facility was operating with outdated electrical equipment that had become increasingly difficult to maintain. The existing automation was minimal, with operators manually adjusting critical parameters like water and steam rates based on moisture content readings. What automation did exist was fragmented across multiple PLCs scattered throughout the plant, creating “islands of automation” that required operators to physically walk the production line to monitor and adjust different systems.
The original Motor Control Centers (MCCs) were particularly problematic. During NorthWind’s initial design assessment, the team discovered that the MCC layout was confusing and poorly documented, with unclear connections between buckets and the systems they controlled. This disorganization made troubleshooting time-consuming and complicated routine maintenance tasks.
- Pet Food Manufacturer
- Located Ohio
NorthWind developed a comprehensive control system modernization strategy that addressed both the electrical infrastructure and control system architecture. Rather than working with the existing MCCs as initially planned, NorthWind proposed designing and building new Motor Control Panels (MCPs) that would house all motor control equipment for each system in one organized location.
A key advantage in NorthWind’s approach was the coupling of automation and electrical installation services. Instead of the manufacturer having to coordinate between separate vendors, NorthWind’s integrated teams worked directly together to identify and resolve equipment changes, determine I/O panel locations and quantities, and design the network architecture. This collaborative approach minimized the burden on the manufacturer’s team and allowed for rapid problem-solving without overwhelming the end user.
The implementation was carefully phased to minimize production disruption.
Phase 1, completed in August, involved removing the existing MCC and Dryer I/O panel and installing new MCPs and I/O panels to control the existing dryer and newly installed coater. Despite an ambitious two-week timeline for equipment removal, installation, electrical work, I/O checkout, and commissioning, NorthWind’s automation and installation teams coordinated efforts enabled I/O checkout to begin two days ahead of schedule and equipment commissioning to start three days early.
Phase 2, which began 2 months after Phase 1 implementation, focused on the complete replacement of the second extrusion line. The NorthWind team maintained the project schedule and even performed some initial I/O checkout ahead of schedule. Their on-site presence throughout the installation process allowed them to identify and address system changes proactively, preventing potential delays during commissioning.
On the automation front, NorthWind transformed the manual processes into an integrated control system. The new system automatically adjusts water and steam rates based on recipe setpoints, eliminating the need for manual valve adjustments. Instead of scattered PLCs and HMIs for each subsystem, the facility now has one unified control system per line with HMIs that monitor all systems, allowing operators to control and monitor the entire process from centralized locations.
The Impact
The modernization project delivered significant benefits to the pet food facility:
- Streamlined Operations: The unified control system eliminated the need for operators to physically walk the line to monitor different systems, improving efficiency and reducing labor requirements.
- Enhanced Maintenance Support: Updated electrical and controls hardware, along with accurate documentation, significantly reduced troubleshooting time and simplified maintenance procedures.
- Improved Process Control: Automated adjustment of critical parameters based on recipe setpoints ensures consistent product quality and reduces operator intervention.
- Operational Consistency: Similar controls for both production lines facilitate operator training and flexibility, allowing staff to seamlessly transition between lines.
- Reduced Downtime: The organized electrical system design minimizes the time required to locate and replace components, improving overall equipment effectiveness.
- Future-Ready Infrastructure: The control system upgrade provides a foundation for further automation and data collection initiatives.
The customer has expressed extreme satisfaction with both NorthWind teams, particularly noting the quality of the electrical installation work and the process knowledge demonstrated by the programmers and controls technicians.
Learn more about NorthWind’s Solutions the Pet Food Industry or reach out to schedule a walk through of a system.
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What were the main indicators that the plant’s control system needed to be updated?
The key indicators included outdated electrical equipment that was difficult to maintain, manual adjustment of critical parameters, fragmented automation across multiple PLCs creating “islands of control,” and poorly documented MCC layouts that complicated troubleshooting and maintenance.
How was production downtime minimized during the modernization project?
NorthWind implemented a carefully phased and highly detailed approach, working on one production line at a time and identifying automation and electrical tasks/timelines prior to shutdown. Their integrated teams of automation and electrical installation specialists worked efficiently complete the detailed plan ahead of schedule, with Phase 1 completing I/O checkout two days early and commissioning three days early.
What specific operational improvements resulted from the control system modernization?
The modernization delivered streamlined operations through a unified control system, automated adjustment of critical parameters, consistent controls across production lines, enhanced maintenance capabilities through updated hardware and documentation, and an organized electrical system design that minimized troubleshooting time. In addition, a similar automation approach to both lines provided operator familiarity across both system which allows flexibility on resource scheduling and staffing.
How does the new control system improve product quality consistency?
The new system manages and loads recipe setpoints to each system which reduces entry error during change overs. In addition, extrusion rates are automatically adjusted, eliminating the variability of manual adjustments and ensuring consistent processing parameters that directly impact product quality.
What made NorthWind's approach different from other system integrators?
NorthWind’s integrated approach combining both automation and electrical installation services eliminated the need for the manufacturer to coordinate between multiple vendors. This allowed for direct collaboration between teams, rapid problem-solving, and proactive identification of system changes during installation.
What long-term benefits can the manufacturer expect from this modernization project?
Long-term benefits include reduced maintenance costs, improved operational efficiency, enhanced ability to train new operators, greater production consistency, and a modern foundation that can support future automation initiatives and data collection capabilities.
How scalable is the new control system for future expansion?
The unified control architecture provides a standardized platform that can easily accommodate future expansion, additional equipment integration, and enhanced data collection capabilities without requiring significant redesign.
What ROI metrics should companies expect from similar control system modernization projects?
While specific ROI figures vary by facility, companies typically see returns through reduced downtime, decreased maintenance costs, improved product consistency, lower labor requirements, and enhanced production efficiency.
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