NorthWind Technical Services

Advanced Batching Control System Modernizes Animal Feed Production

Tue, 16 Jun 2026 20:48:36 GMT

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An Animal Feed Producer in Costa Rica faced a critical challenge with their outdated standalone batching system in the main production area of their plant.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NorthWind was contracted to develop an advanced batching control system that would not only replace the outdated hardware but also create seamless integration between formulation management and production systems, establishing a foundation for future growth and efficiency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:

Planning Level Integration (MES)

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

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.
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.

Written by

Eduardo Martinez

Project Manager

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.

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.

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.

AI for Manufacturers Guide

Tue, 21 Apr 2026 21:04:08 GMT

The white paper explores five high-impact areas where AI is delivering real results today:

Smart Scheduling & Inventory Optimization – Reducing waste, preventing shortages, and re-optimizing production plans in minutes instead of hours

Workforce Transformation & Training – Accelerating onboarding, preserving institutional knowledge, and lifting the cognitive burden on operators

Automated Process Tuning – Flagging deviations and suggesting adjustments while keeping humans firmly in control

Predictive Maintenance & Downtime Prevention – Surfacing hidden patterns and micro-downtime events before they compound into costly failures

AI-Driven Quality Control & Anomaly Detection – Moving quality checks upstream to catch issues during production, not after

Perhaps most importantly, the authors make clear that the best AI implementations support people, not replace them . The goal isn’t autonomous decision-making; it’s better, faster decision-making support that helps every member of your team perform at a higher level.

Ready to explore what AI could mean for your facility? Read the full white paper to get the complete picture, including real-world examples, implementation guidance, and practical advice on where to begin.

Artificial intelligence is no longer a distant concept reserved for tech giants, it’s arriving on the plant floor, and manufacturers who understand how to deploy it strategically stand to gain a significant competitive edge.

A new white paper from AZO and NorthWind cuts through the hype and delivers a grounded, practical guide for manufacturing leaders asking the most important question: Where do we start?

The reality is that most plants today are navigating fragmented systems, retiring skilled workers, labor shortages, and relentless pressure to improve throughput, quality, and safety. All at the same time. AI won’t solve these challenges overnight, but when deployed deliberately and with the right partners, it can act as a powerful force multiplier for the people and processes you already trust.

The AI Guide for Manufacturers: Improve Uptime, Throughput, and Quality

Quality Assurance Station

Wed, 15 Apr 2026 20:29:49 GMT

A Smarter Way to Measure What Matters: Utilizing Vision Technology to Enhance Product Testing Process

Developed in collaboration with Wenger Manufacturing and Extru-Tech , recognized leaders in extrusion technology, our Quality Assurance Station (QAS) represents a significant leap forward in how manufacturers execute and document in-process quality checks.

The QAS is a semi-automated measurement and reporting system that pairs cutting edge vision technology with great design to guide operators through the process of measuring product density and piece dimensions. These are two of the most critical quality indicators for extruded food and pet food products. It takes a process that has historically relied on manual measurement, individual technique, and paper-based recording, and transforms into consistent, efficient, and immediately actionable.

Implementing Vision Technology

At the heart of the QAS’s dimensional measurement capability is an industrial-grade depth camera that brings precision imaging to the production floor. The development team conducted extensive accuracy testing before finding a solution that accurately measured from the required distance and incorporated an IR filter suited to the station’s operating environment.

The station software leverages Intel’s existing RealSense libraries, providing a stable and well-supported software foundation. The camera connects and communicates exclusively via Ethernet.

The vision technology delivers on two fronts simultaneously:

Color sensor imagery captures a visual image of the product sample
Dual infrared sensors provide in-depth data, enabling precise dimensional measurement of individual product pieces

The station’s software then processes this combined data to identify individual product pieces and calculate their dimensions and color values automatically, in seconds.

Beyond dimensions, the camera captures product color and includes an image of the kibble directly in the quality report giving operators and quality managers a visual record alongside the numerical data.

Density Measurement

Bulk density is a critical quality metric for extruded products, and it’s notoriously sensitive to measurement techniques. The QAS addresses this with a purpose-built approach: a consistent fall distance and a standardized method for scraping the cup are built into the station’s process, ensuring that density measurements are repeatable across operators, shifts, and facilities.

Seamless Integration Into Your Quality Process

The QAS is designed to fit into your existing operation.

The station can operate in standalone mode, where operators manually enter order and product information, or it can integrate directly with a production line via PLC connection to pull this data automatically. After samples are measured, results are pushed to the database and optionally back to the PLC. The extruder operator immediately sees whether the sample meets specifications, right at the machine.

Additional Features

Operator Guidance Built In: On-screen instructions walk the operator through each step of the measurement process, reducing training time and ensuring the procedure is followed correctly every time.

Scale Check Management: Scale verification checks are prompted on-screen at the appropriate intervals, and the results are recorded to the database and included in the web report.

Trend Visibility: Charts displayed within the application show operators whether measurements are trending up or down over time, enabling proactive adjustments.

Timed Check Reminders: An on-screen timer and banner alert the operator when it’s time to perform the next quality check. Keeping sampling intervals consistent without relying on the operator to track time manually.

Multi-Line Capability: A single QAS station can support up to 4 production lines, making it a scalable solution for facilities of varying sizes.

Accessible Reporting: Quality reports are available via web browser on the same network and can be exported to Excel. Making data accessible to quality managers, supervisors, and leadership without requiring specialized software or IT involvement.

The Bottom Line

Quality assurance has always been essential to food and pet food manufacturing. What’s changing is the standard for how it’s done. Manual, operator-dependent, paper-based processes are giving way to smarter, more consistent, and more connected systems.

The Quality Assurance Station, developed in partnership with Extru-Tech, is purpose-built for exactly this moment. It brings the precision, consistency, and real-time visibility that modern manufacturing demands.

Interested in learning more about the QAS or scheduling a demonstration? Contact us to start the conversation.

Ignition 8.3: What We’re Excited About the Most

Wed, 11 Feb 2026 20:38:00 GMT

Git Integration

Ignition 8.3’s Git compatibility feature is one I’m particularly excited about! This integration allows us to easily maintain a complete audit trail of modifications throughout the project development.

With Git integration, we can easily identify which changes were made in each revision, who made them, and why. This level of transparency not only helps us mitigate undesired changes but also streamlines our quality assurance processes significantly.

Development Modes: Streamlined Environment Management

The new development modes feature addresses a critical workflow challenge we’ve faced. Being able to pre-configure gateways for both production (on-site) and test (office) environments, then seamlessly switch between them, will revolutionize our testing and deployment processes.

This capability allows us to validate new features in a controlled environment before pushing changes to live systems. The risk mitigation alone makes this feature invaluable, but the time savings in environment setup and configuration switching will significantly improve our project timelines.

Enhanced System Functions

Ignition 8.3 introduces two new sets of system functions: system.vision and system.historian. These replace several deprecated functions, and we’re planning to implement them across our standards immediately. By eliminating deprecated functions proactively, we avoid future conflicts and ensure we’re using the most efficient methods in our scripts.

This modernization of the scripting framework will improve both performance and maintainability of our solutions.

Security Improvements: Secrets Management

Security has always been a priority, and the new Secrets Management feature provides a significant boost to SCADA password security. By storing sensitive information like passwords, certificates, and encryption keys outside of gateway configurations and backups, we can ensure only authorized administrator personnel have access to decrypt sensitive data.

Event Streams Module in Ignition 8.3

The Event Streams module represents a powerful new approach to building event-driven architectures. This feature allows us to connect and manage data from external sources in a centralized location, creating data endpoints for tags, SQL databases, and other sources with minimal coding requirements.

I believe this module will significantly simplify data collection in both MES and SCADA systems, reducing development complexity while improving system flexibility.

Looking Forward

What excites me most about Ignition 8.3 is how these features work together to elevate our entire solution delivery process. The combination of Git compatibility, Perspective enhancements, Core Historian, development modes, and the drawing tool creates a comprehensive platform that addresses our most significant development challenges.

For our customers, the benefits are equally compelling. The Core Historian reduces hardware costs, native drawing tools provide better visual representation of their equipment, Forms components improve data handling efficiency, and Secrets Management enhances security. The new Solution Suites licensing model also offers more budget-friendly options tailored to specific needs.

Upgrading to Ignition 8.3 isn’t just about accessing new features – it’s about fundamentally improving plant performance and operational efficiency. As we begin implementing these capabilities in our upcoming projects, I’m confident we’ll see measurable improvements in both developmental velocity and solution quality.

The future of industrial automation just got significantly brighter with Ignition 8.3.

Written by

Jose Pineda

Standards Engineer

With years of experience designing intuitive HMI interfaces that help operators run more efficiently, I’m genuinely excited about the release of Ignition 8.3 . Having worked extensively with Ignition and earning Ignition Gold Certification, I’ve had the opportunity to evaluate the platform’s evolution firsthand. After reviewing the new features and enhancements in 8.3, I can confidently say this version delivers meaningful improvements. Below, I share my perspective on the most impactful updates from a system integrator’s point of view and how they will continue to strengthen our project delivery.

Perspective Enhancements: Forms and Drawing Tools

For our MES solutions, the new Forms component is a significant advancement. We’ve previously developed manual form functionality, but this native feature will allow us to generate forms much more quickly with less setup overhead. The offline/online capabilities make data handling more robust and user-friendly.

The Perspective Drawing Tool is equally exciting for our control solutions. We can now design custom objects directly within the platform that accurately represent equipment on the plant floor, eliminating our reliance on third-party design tools. This native capability will improve both development efficiency and visual consistency across projects.

Fairview Mill’s Journey to Data-Driven Manufacturing

Fri, 09 Jan 2026 21:52:00 GMT

Digital Transformation: Fairview Mill’s Journey to Data-Driven Manufacturing

Customer Profile

J-Six Enterprises – Fairview Mills, Fairview, KS
High-quality grinding and milling solutions for agriculture, pet food, and industrial applications.

Project Overview

Fairview Mills partnered with NorthWind to implement a comprehensive Manufacturing Execution System (MES) to address operational challenges at their milling facility in Fairview, KS. In 2024 Fairview Mills had a strategic goal to begin their digital transformation journey to ease the use of their plant-level systems, digitize the paper-based processes, and connect data across multiple locations for faster decision making.

MES Project Goals

Provide Real-Time, user-friendly data for the whole team
Data Centralization
Paperless Plant Floor
Make data-based decisions on the floor

NorthWind designed and implemented an MES solution that digitized their production workflows, automated data collection, and provided real-time visibility into operations. The system was built on the Ignition platform using the Perspective module, creating a centralized source of truth for production data and eliminating paper-based processes.

Customized Dashboards for Different User Roles

Operator dashboards showing current production status, upcoming work orders, and required forms
Supervisor dashboards providing comprehensive visibility into all production areas
Management dashboards with efficiency metrics and production performance data

Digital Form Builder: NorthWind developed a flexible form builder that allowed Fairview to convert their 25-30 daily paper forms into digital formats. The system includes:

Automated form triggers based on time or production events
Digital signature capabilities for quality verification
Searchable form history for easy retrieval during audits
User-friendly interface allowing Fairview staff to create and modify forms without developer assistance

Real-Time Production Monitoring:

Custom efficiency tracking tailored to Fairview’s specific metrics
Production status visualization across all manufacturing operations
Automated downtime tracking and reporting
Integration with existing control systems

Enhanced Communication Tools:

Digital user notes replacing handwritten notes between shifts
Centralized communication for production issues and status updates
Visibility of customer specifications and order comments for operators

Process Setting Management:

Digital “cheat sheets” for machine settings by product
Recommended values for operators to reference
Consistent process parameters across shifts

The Impact

Eliminated 15+ daily paper forms , significantly reducing administrative burden and improving data accuracy
Reduced production reporting time by 45-60 minutes per shift for supervisors through automated data collection and reporting
Enhanced quality control with digital verification and improved process consistency
Improved shift-to-shift communication through digital user notes and centralized information
Streamlined audit processes by making documentation instantly searchable and accessible
Increased visibility into production metrics allowing for real-time decision making rather than relying on day-old data
Enabled real-time decision making rather than relying on day-old data, allowing management to respond immediately to production issues and opportunities
Created a foundation for future digital initiatives including ERP integration and advanced analytics

Future Outlook

With the successful implementation of their MES foundation at the Fairview Kansas facility, Fairview Mills is now positioned for the next phase of their digital transformation journey.

Integration with their ERP system for seamless data flow
Expansion of the MES to additional production facilities
Further automation and AI for scheduling processes

Fairview Mills has expressed extreme satisfaction with MES solution NorthWind delivered. “The MES implementation has fundamentally changed how we approach manufacturing at Fairview Mills,” stated Darrin Hermesch, Director of Operations. “We’re now making decisions based on real-time data rather than gut feel, and our operators have the information they need at their fingertips. This digital foundation positions us for continued growth and efficiency improvements in the future.”

Learn more about NorthWind’s MES Solutions or reach out to schedule a walk through of a system.

Our Approach

NorthWind began with a thorough assessment of Fairview Mills’ operations, working closely with operators, supervisors, and management to understand their specific challenges and requirements. The implementation team conducted extensive user interviews to identify pain points and opportunities for improvement.

The project followed a phased approach, with weekly feedback sessions to ensure the system met the user’s needs. NorthWind’s team worked one on one with Fairview’s operators and supervisors to ensure adoption and provide training on the new system.

The MES implementation included several key components

Control System Upgrade Streamlines Pet Food Production

Tue, 04 Nov 2025 20:36:00 GMT

Control System Upgrade Streamlines Pet Food Production

Customer Profile

Pet Food Manufacturer
Located Ohio

Project Overview

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.

Phased Implementation

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.

Written by

Bryan Reinecke

Senior Project Manager

Frequently Asked Questions

Trademarks such as Allen-Bradley, FactoryTalk, Rockwell Automation, and PowerFlex belong to Rockwell Automation, Inc.

The Challenge

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.

Technology Used

Our Approach

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.

Precision Panel Building in Our UL Certified Control Panel Shop

Thu, 30 Oct 2025 14:33:00 GMT

Precision Panel Building in Our UL Certified Control Panel Shop

Go behind the scenes of a real build in action

At NorthWind, our Control Panel Shop delivers custom UL-certified control panels. Every panel is built to meet UL and National Electric Code (NEC) standards. Our process guarantees that every control panel is engineered and built with accuracy.

In this video, we take you behind the senses of a real panel build, from initial setup to final testing, showcasing our team’s attention to detail and commitment to quality.

From Design to Build

NorthWind’s Design Team draws on extensive process experience and expertise to develop control system designs. Every system is designed with efficiency, maintainability, and safety in mind.

Once the design is approved, our manufacturing team brings it to life on the shop floor.

Building the Panel: Step-by-Step

Our 10,000 square foot manufacturing space is climate-controlled, with high bay doors and load docks for efficient material handling and transport. This ultramodern facility is designed for optimal panel fabrication with designated areas for each panel stage.

1. Panel Prep – Cutting & Pre-Drilling

We begin by preparing the back panel using the Perforex Panel Cutting & Pre-Drilling Machine. This automated system reads directly from the approved drawings to make precise cutouts, ensuring every component fits from the start.

2. Part Installation – Panel Assembly

Next, our technicians mount all electrical components according to the approved layout. Each device is installed with attention to spacing, organization, and accessibility, making it easier for the next step. Watch this short video on the Perforex

3. Wiring- Wire Preparation & Routing

Our Wire Terminal Machine automatically cuts, strips, and labels wires to exact lengths, enhancing the process and making it consistent. Every wire is routed neatly and labeled clearly to support easy maintenance and troubleshooting down the road. Watch this short video on the Wire Terminal Machine

4. Final Checks – Testing & Quality Assurance

Before any panel leaves our shop, it undergoes a complete functional test and quality review. Our team performs these tests to verify that the system operates safely, on time, and ready for installation.

Why It Matters

A well-built control panel keeps your system running smoothly. A poorly built one can lead to downtime, safety issues, and delays when something goes wrong.

In NorthWind’s Control Panel Shop, we focus on clean wiring, clear labeling, and organized layouts, so your panel is easy to install, easy to maintain, and built to last. Every panel is built with safety in mind.

Want to see more of what we build? Check out our Panel Build Services or Contact Us to start your next project.

AI & Digital Transformation Seminar 2025

Wed, 10 Sep 2025 18:22:00 GMT

AI & Digital Transformation Seminar 2025 Recap

This August, NorthWind hosted our 2 ^nd annual AI & Digital Transformation Seminar . Over the course of three days, attendees from across many industries gathered to explore transformative technologies, share use cases, and engage in hands-on experiences that showcased the power of AI and automation.

With a packed agenda that included live demonstrations, thought-provoking case studies, and networking with industry leaders , this year’s event reaffirmed our commitment to empowering manufacturers with the tools and knowledge they need to evolve in the digital age.

Technology in Action — Innovation Tours at NorthWind

The event kicked off at our headquarters in Sabetha, KS , where attendees toured six key innovation stations, each highlighting advancements in manufacturing technology:

Product Handling with AMRs – Autonomous Mobile Robots in live application
BatchLOGIX with AI analytics – A new web-based interface with integrated AI insights
Quality Assurance Station – Enhancements for real-time monitoring
EXPRO AI Demo – Digital twin and predictive production insights
AI-Driven Business Use Cases – NorthWind’s practical applications of AI across clients
Automated Panel Shop – Showcasing NorthWind’s automated control panel manufacturing

The tours offered a first-hand look at smart factory solutions , sparking meaningful discussions about integration, scalability, and operational ROI.

Real-World Case Studies & Expert Panels

The following day was filled with insightful presentations and collaborative knowledge sharing:

Case Studies in Focus

“A Digital Transformation Journey” with Schwan’s Food Company and NorthWind – This collaborative session provided perspectives from both the customer and the implementation team, offering practical insights into managing large-scale industrial modernization projects.
Fairview Mills and NorthWind shared “ The Right MES Tools for Your Operations ,” detailing how data visibility and automation are driving strategic decision-making on the plant floor.
Matthew Leonard (Northslope Technologies) and Rob Infinger (Barrett Petfood) closed the day with “The AI Journey – A Production Use Case” , highlighting practical AI deployment of a scheduling tool for smarter manufacturing.

Emerging Tech Highlights

Dan Racklyeft (Rockwell Automation) demonstrated how Digital Twin Simulation with Emulate3D is reshaping production modeling and scenario testing.
Jacob Dill (OTTO Motors) and Brandon Johnson (HaFSBX) examined the future of AMRs in material handling , with a look into strategy, deployment, and scaling.

Cybersecurity & AI Strategy

A panel on Cybersecurity in Industry 4.0 featured experts from NorthWind , KLN Family Brands , and Inductive Automation , underscoring the urgency of protecting data as AI systems grow more integrated.

Recognizing Our Sponsors

A sincere thank you to the sponsors who helped make this year’s seminar a success:

Platinum Sponsors: Haf Equipment , Northslope Technologies , Extru-Tech , D1 Resources
Gold Sponsors: Rittal, EPLAN, Vortex , Horizon Systems
Silver Sponsors: Scan American Corp , Rensenhouse Sabetha

Their support enables us to continue delivering value and fostering innovation in the manufacturing space.

Thank you to all who attended and contributed to the success of the 2025 AI & Digital Transformation Seminar!

PlantIQ® Alarms Module Troubleshooting Alarms

Fri, 13 Jun 2025 16:20:00 GMT

Control System Troubleshooting on the Plant Floor Faster with PlantIQ® Alarms Module

Control System Troubleshooting on the Plant Floor Faster with NorthWind’s PlantIQ® Alarms Module

Experience the power of AI-driven troubleshooting in action

NorthWind’s PlantIQ® Alarms module utilizes our advanced AI Platform to transform control system troubleshooting on the plant floor. In this demonstration, we follow an operator’s journey through resolving an Over Tolerance Alarm with efficiency.

Inside the Troubleshooting Process

When experiencing the “Old Micro 5-Feed Point Over Tolerance Alarm,” the operator simply selects “Diagnose Using AIP” within the Alarms Module. Immediately, the AI platform delivers:

Detailed Alarm Information
Potential causes
Additional Insights

Guided Problem Resolution

Continuing to dive into the alarm, the operator navigates to the “Troubleshoot Alarm” tab and selects “Troubleshoot Using AIP.” The system then provides:

Clear problem description
Root cause analysis
Step-by-step troubleshooting instructions
Preventative measures to avoid future occurrences

Knowledge Capture for Continuous Improvement

After successfully resolving the issue with PlantIQ’s guidance, the operator documents the resolution process in the dedicated “Resolution” tab. This valuable information becomes part of PlantIQ’s knowledge base, automatically appearing when similar alarms occur in the future.

PlantIQ® — Solving problems faster

Learn more about PlantIQ or reach out to schedule a walk through of a system.

Eliminating Cross-Contamination at a Leading Pet Food Manufacturer

Tue, 10 Jun 2025 18:24:00 GMT

Material Validation: Eliminating Cross-Contamination at a Leading Pet Food Manufacturer

Customer Profile

Pet Food Manufacturer
Minnesota, USA

Project Overview

A leading pet food manufacturer partnered with NorthWind to address an operational challenge: preventing cross-contamination during raw material unloading. The facility was experiencing recurring issues with unloading trucks into incorrect silos, resulting in quality control problems and potential product contamination. NorthWind implemented an advanced material validation system that not only eliminated these errors but also digitized the company’s reporting processes, bringing greater efficiency and accountability to their operations.

The Challenge

Without a robust validation system in place, operators would occasionally unload raw materials into incorrect silos, leading to:

Cross-contamination between different product ingredients
Quality control failures requiring costly rework or disposal
Production delays and inefficiencies
Compliance risks with food safety regulations
Paper-based documentation that was time-consuming and prone to human error

These challenges were not only impacting operational efficiency but also potentially compromising product quality and safety—critical concerns in the pet food industry where ingredient integrity is paramount.

Our Approach

NorthWind met with the customer to understand the current process and began development on a material validation system that would put safeguards and constraints on the unloading process while still providing operational flexibility. The solution centered around integrating barcode scanning technology with their control systems, creating a foolproof method for ensuring materials were directed to the correct silos.

The Impact

The implementation of NorthWind’s material validation system delivered immediate and significant benefits to the pet food manufacturer:

Enhanced Quality Control

Complete elimination of cross-contamination incidents from incorrect silo loading
Improved product consistency and quality
Reduced risk of costly product recalls or rework

Operational Efficiency

Streamlined unloading process with clear validation steps
Elimination of time-consuming paper-based documentation
Reduced production downtime from contamination incidents

Data-Driven Decision Making

Comprehensive digital records of all material transfers
Enhanced traceability from receipt to production
Ability to analyze material handling patterns and identify optimization opportunities

Regulatory Compliance

Improved documentation for food safety compliance
Enhanced traceability for audit requirements
Digital records accessible for inspection and verification

The manufacturer reported high satisfaction with the solution, noting that the system has not only resolved their cross-contamination issues but also improved overall operational efficiency. The digital transformation of their reporting process has provided management with greater visibility into their material handling operations, supporting better decision-making and continuous improvement initiatives.

Learn more about NorthWind’s Solutions the Pet Food Industry or reach out to schedule a walk through of a system.

Written by

Kyle Bell

Project Manager

Flexible Management Controls

The system was designed with operational flexibility in mind. Operators can clean out silos when material levels fall below configurable setpoints, allowing for smooth transitions between materials. For situations where level scanners might not be functioning correctly, supervisors have override capabilities to clean out destinations when they know a silo is empty despite sensor readings.

Additionally, supervisors can manage the material database directly through the system, adding new materials as they enter the supply chain. This ensures the validation system remains current with all ingredients used in the production process.

Digital Reporting Transformation

NorthWind also digitized the manufacturer’s paper-based reporting system by implementing digital reports within Ignition. The new system automatically tracks and records:

Silo destination for each material transfer
Product name and specifications
Lot number for traceability
Trailer number for logistics tracking
LPN (License Plate Number) for inventory management

This digital transformation eliminated the need for manual witness signoffs, as all information is now scanned into the system at the time of unloading. The data is logged to a database and can be queried, with records maintained for up to a year, significantly enhancing traceability and compliance capabilities.

Material Validation System

We integrated barcode scanning technology with the facility’s existing control system using Ignition Vision HMI Platform to create a robust validation process. When operators prepare to unload a truck, they are required to scan a barcode from the milling company that contains a unique identification number. The software searches through a material database to identify the specific material associated with that ID. The system then automatically verifies whether the selected silo destination matches the scanned ingredient information.

If the destination does not match the scanned material, the system prevents the unloading process from being enabled, effectively eliminating the possibility of cross-contamination. This hard stop in the process ensures that materials can only be unloaded into appropriate silos containing matching products.

Technology Used

Ignition Vision HMI platform
Tag historian for data logging and analysis
OPC UA communication protocol
Barcode scanners for material validation

Developing an Actionable Digital Transformation Journey

Tue, 25 Mar 2025 15:04:00 GMT

Digital Transformation Journey: Guiding a Pet Food Manufacturer to Industry 4.0

Customer Profile

Petfood Manufacturer
Located in Lima, Peru

Our Approach

To start the audit, NorthWind’s Team met with plant production leads and process experts from each area of the plant, including forecasting, planning, production, maintenance, information and technology, research and development, purchasing, distribution, and accounting, with the primary goal of gathering information about current operations and flow of data throughout the organization. These meetings helped the NorthWind team understand the existing infrastructure and identify focus points.

Information Gathering Focus Points

Evaluation of current technological infrastructure
Diagnosis of the level of automation and current digital methodologies
Identification in areas of opportunities for improvement
Manufacture’s capabilities to integrate industry 4.0 technologies
Review of current metrics on operational efficiencies and quality
Evaluation of current metrics on safety and sustainability
Review of current key performance indicators (KPIs)

After gathering the information NorthWind developed, in collaboration with plant personnel, an on-site agenda planned around production schedule and personnel availability. While on-site NorthWind identified and analyzed the existing gaps, deficits, and areas of opportunities with respect to the adoption of Industry 4.0 standards.

At the conclusion of the site visit, NorthWind developed a comprehensive report outlining the plant’s digital transformation journey. The report included the current status of the manufacturing practices, diagnosis of areas of opportunity, and proposed an actionable plan with progressive milestones to fully achieve Industry 4.0 manufacturing standards.

Digital transformation recommendations

Below is a sample of the recommendations the NorthWind Team provided or discussed with the manufacturer based in the findings in the audit.

Discussed the importance of a Raw Material Silo Inventory System.
Reviewed Manual Documents that would benefit from a digital format.
Recommended a replacement and modernization of the existing control system.
Reviewed alternatives to implement seamless upstream and downstream equipment.
Reviewed data collection and material tracking benefits for ingredients throughout the plant.
Reviewed automation alternatives for Setpoint management for dosing raw material.
Established Rework Integration Protocol on Production Line.
Reviewed the benefits of automation for the Extrusion Process.
Reviewed the benefits of automation for unloading finished product silos and provide material tracking.
Proposed a data collection system in the packaging area by communicating with robotic arms, bagging machines, and using a barcode tracking system.
Reviewed implementation of a Warehouse Management System (WMS).
Increase cybersecurity of the plant control system.

The recommendations can be completed in phases, and the desired Industry 4.0 goals can be achieved with modernization of the process control system, MES Dashboards (Manufacturing Execution System), Digital Solutions (network architecture and topology), Integration with their ERP System, Cloud connectivity, and redundancy.

Written by

Aldo Martinez

Account Manager

The pet food manufacturer gained a clear, actionable roadmap for their digital transformation journey toward Industry 4.0. The comprehensive site audit provided valuable insights into their existing infrastructure, allowing them to identify key areas for improvement. With NorthWind’s guidance, they now have a strategic plan to enhance efficiency, performance, and future scalability. As they implement these recommendations, they are well-positioned to optimize operations and stay ahead in an increasingly digital and automated industry.

Learn more about NorthWind’s Solutions the Pet Food Industry or reach out to schedule a walk through of a system.

The Impact

Based on the report’s findings, the customer can expect the following Customer Benefits after implementing Industry 4.0 practices:

Increased Efficiency : Automation and connectivity lead to streamlined processes, reducing downtime and enhancing productivity.
Improved Quality : Advanced technologies such as machine learning and AI can monitor production quality in real-time, allowing for quicker adjustments and reducing defects.
Greater Flexibility : Smart manufacturing systems can quickly adapt to changing market demands, enabling mass customization and shorter lead times.
Enhanced Data Analytics : Industry 4.0 collects vast amounts of data, allowing manufacturers to gain insights into operations, customer preferences, and market trends for better decision-making.
Cost Reduction : Optimized processes and predictive maintenance can lower operational costs through efficient resource utilization and reduced waste.
Supply Chain Optimization : Real-time data sharing enhances collaboration across the supply chain, improving inventory management and reducing bottlenecks.
Sustainability : More efficient energy use and reduced waste contribute to more sustainable manufacturing practices, aligning with environmental goals.
Workforce Empowerment : Digital tools can enhance worker capabilities and safety by providing real-time information and training resources, fostering a more skilled workforce.
Remote Monitoring and Management : IoT technologies facilitate remote oversight of manufacturing processes, enabling quicker responses to issues and greater operational control.
Innovation benefits : The integration of advanced technologies encourages continuous innovation, allowing manufacturers to develop new products and services quickly.

Project Overview

The Pet Food Manufacturer contracted NorthWind to help them identify areas in the plant for improvement and set an actionable plan for bringing the plant up to Industry 4.0 standards. NorthWind’s Team performed a site audit to highlight the quality and status of the current control infrastructure. At the end of the audit, the NorthWind Team delivered an actionable report that served to evaluate, advise, and create the digital transformation journey to Industry 4.0 standards focusing on improving performance and efficiency.

Case Study: Grain Handling Control System

Thu, 23 Jan 2025 17:02:00 GMT

Grain Handling Control System Helps Frontier Cooperative Battle Labor Shortage

Customer Profile

Frontier Cooperative

Full-service Coop that provides services in the areas of grain, agronomy, energy, and feed.
Location of Project Plattsmouth, Nebraska
Learn More about Frontier Cooperative

Project Overview

After combating labor shortages during peak season, Frontier Cooperative recognized a need for change. In collaboration with NorthWind, a plan was developed to upgrade the current manual panels with a fully automated system. The goal of this modernization was to eliminate outdated hardware and software while providing a grain handling control system that runs with minimal operator assistance.

The control solution developed to reach this goal involved replacing outdated and obsolete hardware with new componentry, adding hazardous monitoring equipment to increase safety at the facility, and new user-friendly PLC and HMI programs to reduce the crew size needed to run the storage equipment and assist with troubleshooting.

The NorthWind deliverables included programming for control and monitoring of 6 storage bins, 1 load out bin, 2 legs, 2 distributers, and 11 conveyors. Hardware deliverables include PLC, Remote IO, and 2 HMI Panels along with a computer for remote access and hazard monitoring equipment for the legs and conveyors.

The Impact

The Grain Handling Control System allows the system to be operated with a smaller workforce. Allowing personnel to focus on other tasks and alleviates labor shortage issues during harvest.
New operators quickly learn how to independently operate the system due to eliminating the reliance on tribal knowledge to successfully operate the system.
The new automation system shows in real-time what equipment is running and it shows the destination of the material.
The continuous hazard monitoring sensors on all the conveyors, drags and legs automatically shut down the equipment if running temperatures are unsafe.
Other impacts of automation are still in progress. Frontier Cooperative can run the entire facility with one person if needed, and additional redundancy has been added. Frontier has had a successful 2024 harvest season using the new equipment and will continue to benefit from the efficiency and effectiveness of the automation system.

Learn more about NorthWind’s Solutions or reach out to schedule a walk through of a system.

Written by

Hannah Wenger

Project Manager

NorthWind’s software automation team wrote the PLC & HMI programs to be intuitive and easy to use. A server was installed to host the HMI graphics that were built using Inductive Automation’s Ignition SCADA Software. This allows remote monitoring and control of the system from the site office enabling the crew to run and monitor the entire system from a conditioned space and with a reduced workforce.

Key Technologies

Ignition SCADA Graphics
CompactLogix PLC and components
AGI HazMon (hazard monitoring) equipment

Our Approach

To kick off the project, NorthWind’s team traveled to the Plattsmouth Nebraska location to conduct a design review. The team took account of all current hardware, software, and equipment being used to accurately provide electrical drawings.

The design team provided a new electrical drawing set that outlined the hardware, panel construction, IO distribution, and network connections. The existing push button panels that monitor bins and transfer equipment were replaced with a NorthWind PLC panel which houses the PLC and IO as well as power to feed two HMI panels. A new motor control center (MCC) was provided by the electrical installation contractor.

The modernized system allows the Frontier operator to select which leg to use during material transfer and to select a source and destination. The operator presses enable on the HMIs to begin the transfer. The PLC communicates via ethernet with the legs’ distributors to position the distributors to the correct destination for material transfer. The equipment will use amp loads to know when the elevators and conveyors are loaded with material. This allows for automatic shut off if the equipment is empty for a configurable time.

A sixth bin was constructed and NorthWind provided a manually controlled panel for the discharge and loading of trucks from this bin, which is identical to the existing bins in this system.

Ping Pong Tournament

Tue, 14 Jan 2025 18:10:00 GMT

Battle of the Paddle

When winner Mitch was asked what his secret was to Ping Pong victory, Mitch stated that he simply enjoys the game. He has been playing since he was little and attributes repetition and lots of practice for improving his performance and to his tournament win. The crowd, as well as the participants found the game play exciting and enjoyed the opportunity to interact with people from other departments. Newcomers to the company felt the tournament helped to form new bonds within the company. The tournament provided NorthWind employees with another opportunity to experience one of NorthWind’s Core Values – Relationships. We focus on building relationships with customers and each other by demonstrating fairness, trustworthiness, reliability, and humility.

When employees feel connected to each other, they are more likely to collaborate and work together more creatively. And although the Ping Pong Tournament was a competition, the end result was that bonds were formed, a sense of community and camaraderie was felt, and relationships were strengthened. And that, is the NorthWind Way!

Learn More About NorthWind CORE VALUES

Written by

Martha Bray

TECHNICAL WRITER

NorthWind held its first ever Ping Pong Tournament on Nov. 22 ^nd at our Sabetha, KS office. The tournament was the collaborative brain-child of Account Manager, Aldo Martinez and Sales Engineer, Mitch Heiman. Learning of each other’s love of the game, Aldo and Mitch purchased a ping pong table and brought it to NorthWind to play a few rounds. Other employees caught ping pong fever and soon, people would pair off to play a game during their breaks. More people wanted to join in the action and before long, they had a tournament on their hands. The tournament was designed with 4 pools, comprised of 7 members each. Pool play consisted of round-robin format, with each member playing one another twice. These matches took place over several weeks before the tournament date. The top two scoring players from each pool progressed to bracket play. All players were invited to the tournament to watch the top players battle it out. Other employees gathered to cheer on their favorite player. Mitch Heiman took the crown, Eric Meyer (MES Developer), took second place, and Ryan Strahm (Design), took third. After tournament play ended, lunch was served.

2024 Thanksgiving Celebration

Mon, 02 Dec 2024 20:24:00 GMT

Giving Thanks at NorthWind

NorthWind values this time of reflection and sharing, not only by celebrating a wonderful Thanksgiving meal with one another, but by extension, demonstrating some of our core values, such as Relationship – where we focus on building relationships not only with customers and vendors, but with each other, and People, where we believe every person has intrinsic value and we have a responsibility to care for the communities where we work and live. These core values are very much exhibited by NorthWind employees and are reflective of the spirit of Thanksgiving.

The meal was catered by Buzz Cafe, Sabetha. KS. Buzz prepared the delicious turkey, mashed potatoes, gravy, and green beans. The rest of the food was brought in by the NorthWind employees who attended the event. There were all kinds of homemade breads and rolls, side dishes, dips, charcuterie items, homemade pies, and desserts, and one of my personal favorites – a delicious chocolate caramel poke cake that was so decadent, it should be illegal. No one should have left work that day hungry.

Mike led the group in a prayer of Thanksgiving, and the meal was enjoyed by 45-50 NorthWind employees. Komari Aberle, HR led us in a game of “Would You Rather?” which included questions such as “Would you rather eat a pound of creamy yellow butter or drink a gallon of thick brown gravy?” “Would you rather make all your food into a giant Thanksgiving sandwich or find out that there are no leftovers whatsoever?” and “Would you rather get pie crumbs all over your computer keyboard or mashed potatoes and gravy smeared all over your computer screen?”. Laughter ensued.

After the meal, our monthly Lunch and Learn was conducted and then the happy, well fed employees returned to their workstations to finish out the day. Now, I cannot confirm or deny if much work was accomplished after that hearty meal, but I can confirm that we all are thankful not only for the turkey and trimmings, but for the friendship, the fellowship, the strong relationships we have built and for being part of the NorthWind family!

Learn More About NorthWind CORE VALUES

Written by

Martha Bray

TECHNICAL WRITER

Each year, NorthWind hosts a Thanksgiving Dinner for the employees. This year, the Thanksgiving Dinner was held on site, in conjunction with our monthly Lunch and Learn meeting.

Thanksgiving is a celebration of sharing and abundance. It is an appreciation for all that life brings us, whether it is good or bad, because even our worst moments can serve as a learning experience and shape us in positive ways. Thanksgiving is a time to reflect on the things we are most grateful for and to share that gratitude with the people who matter most.

AI & Digital Transformation Seminar Recap

Wed, 11 Sep 2024 19:25:00 GMT

NorthWind recently hosted its first seminar focused on Digital Transformation and AI in process automation. The event provided a space for attendees to learn about enhancing their process and new technologies as well as network with industry experts. With presentations and case studies from our industry partners on guiding manufacturers along their digital transformation journey, each manufacturer went away ideas and plans for enhancing their process.

Educational Sessions

Our distinguished presenters, including industry leaders and experts, shared valuable insights, practical strategies, and success stories on digital transformation:

Reese Tyson from Inductive Automation opened the seminar with “Laying the Right Foundation for Digital Transformation.”
Mark Sailer and Lance Schutlz with KLN Family Brands and Nathan Karmer with NorthWind Technical Services co-presented a case study on MES (Manufacturing Execution System) implementation.
Udaya Kumar from Rockwell Automation discussed “Embracing Smart Manufacturing: Trends, Challenges, and Technological Solutions.”
Jay Pokorny from Extru-Tech covered Digital Twin Analytics.
Zoe Nengite from Palantir spoke on “Connecting AI to Operational Decision Making.”
Bill Ward from Northslope Technologies , along with Michael Bosworth from NorthWind, co-presented a case study on AI and Large Language Models for process automation.

AI & Digital Transformation Seminar Recap

NorthWind Innovation Tour

The following day, attendees joined NorthWind for a hands-on tour at our Sabetha, KS headquarters to explore the latest innovations.

NorthWind Presents at Palantir’s AIPCon

Tue, 11 Jun 2024 19:19:00 GMT

NorthWind Keynotes at Palantir AIPCon 4: Factory Automation Meets AI

NorthWind CEO, Mike Bosworth, presented at Palantir Technology ’s AIPCon 4 on June 6th. NorthWind has been collaborating with Palantir to deliver AI solutions for our customers in the manufacturing industry. We foresee numerous areas where AI will benefit manufacturers, enhancing efficiency at every turn. Mike’s presentation at AIPCon focused on two modules developed to address the shortage of skilled labor in the workforce.

Our AI solution uses technology to provide access to process and project knowledge and to an expert’s problem-solving skills. The presentation focused on two of our modules PlantIQ™ Assistant and AlarmIQ™. PlantIQ™ Assistant is a comprehensive and interactive chat tool with the ability to search across internal information, manuals, and training information to answer production and process related questions. AlarmIQ™ provides an in-depth analysis of devices, alarms, and events.

You Might Also Be Interested in This AIPCon Content

AIPCon 4 June Full Presentation

Palantir’s Backstage Pass to AIPCon

Palantir’s Research: Huge Results at AIPCon 4

We’re embedding this technology into our control systems and production software allowing our customers to access sophisticated AI tools. This will empower their employees to make better, more timely decisions and effectively reduce downtime, resulting in increased efficiency and considerable cost savings.

To say we’re excited about these developments is an understatement, we cannot wait to see how these tools enhance the manufacturing process!

Watch NorthWind’s Full Presentation

True North Core Value Award

Thu, 29 Feb 2024 20:20:00 GMT

The True North Core Value Award is a prestigious acknowledgment within the NorthWind Team, reserved for individuals who embody the company’s core values, providing direction, stability, and purpose to those around them. This year, we proudly present the True North Core Value Award to Tyler Fredrick! Tyler serves as the Wiring Team Lead in our Manufacturing Department, consistently demonstrating the NorthWind Core Values in his daily interactions, both within his department and across the entire company. Tyler was nominated for the award by his peers. Comments of his hard work, dedication, and willingness to lend a hand to anyone highlighted his nomination.

Tyler’s dedication and commitment to our core values exemplify the spirit of NorthWind. Please join us in extending a big congratulations to Tyler for his well-deserved recognition!

NorthWind Core Values

Core values are the standards, ideals and principles that direct the way we conduct ourselves as a business and as individuals. They are expressed in two ways: in writing and through actions. Core values are not aspirations or statements of what we would like to be or how we would like to behave, but are instead a description of who we are, what we do and how we do it.

Relationship – We focus on building relationships with customers, vendors, and each other. We demonstrate:
Fairness, Trustworthiness, Reliability, Humility, Moral Principles, and Transparency

Work Ethic – We work diligently to achieve professional success. We are:
Ambassadors of NorthWind, Self-Driven, Committed, and Accountable

Customer Service – We serve customers with respect and understanding, going the extra mile. We practice:
Doing the Right Thing the First Time, Effective Communication, Collaboration, Teamwork, and Empathy

People – We believe every person has intrinsic value and care for the communities where we live and work. We value:
Growth, Supporting Each Other, Family, Local Involvement, and Forgiveness

Innovation – We innovate our products and processes to benefit our customers and the company. We embrace:
Curiosity, New Technology, Continuous Improvement, Industry Expertise

Case Study: Schwan’s Historian Project

Wed, 28 Feb 2024 21:45:00 GMT

Using Data to Implement Process Changes Results in Substantial Savings

NorthWind develops custom historian utilizing Ignition’s Perspective Software saving Schwan’s thousands annually.

In 2020, Schwan’s replaced one of the fryers at an appetizer production facility. The new fryer came with updated technology including controls features and capabilities. Although there are many new features available, accessing and deciphering them proved difficult and thus, inaccessible to Schwan’s. As Schwan’s implemented the new fryer into production, they began to suspect they were wasting resources. At the time, the fryer temperature could not be tracked. Because of this, the fryers constantly ran at high temperatures. Steven Lim, Schwan’s Principal Project Engineer stated, “they were replacing oil daily which was not only a waste in itself, but they were spending 4hrs in sanitation to switchover.” At this point they reached out to NorthWind to investigate what data was available to be tracked from the new fryer and to put it in a format that was usable.

The Schwan’s Company is a leading provider of quality foods in the United States. With over 10 production facilities throughout the US, you can find their brands in the frozen food aisle at your local grocery store. NorthWind has partnered with Schwan’s to provide automation solutions to four of their manufacturing facilities. These projects include ingredient delivery, mixing and batching dough, recipe management and alarming software, as well as data collection and reporting for their pizza production.

Developing the Solution

NorthWind began developing a solution that would give Schwan’s access to the information they needed in an easy-to-use format. The interface would give Schwan’s the functionality to access and analyze the fryer temperature data to make cost saving process changes. When the NorthWind Team began to develop the solution, they examined all aspects of the need.

Visibility Needs

Monitor the fryer temperature and additional data points
Remote access to fryer data

Project Complexities

Over 1000 PLC tags and the current software did not allow for PLC tag manipulation
Remote access was not available with the current software
Software available on the market did not easily achieve both needs

In developing a solution that would address all aspects of the issue, NorthWind presented Schwan’s with a plan to use Inductive Automation’s Perspective Software . This new tool would allow for visual customization with responsive design features meeting a need of Schwan’s to access the information from any device. Although this platform met the mobility needs, the software was still newly released. The historian provided with the software would not allow for the search and tracking of individual tags needed for this project. To provide the search, tracking, and trending features NorthWind’s Team would develop a custom interface. Schwan’s agreed to the plan presented and the team got started on development.

The first step on the development track was to sift through the thousands of tags available for tracking. This took collaboration between NorthWind, Schwan’s, and the fryer manufacturer.

Next, the NorthWind Team designed the interface that communicates between the Perspective software and the PLC to successfully track the fryer setpoints. Remote access to the interface was built in for easy data monitoring and management.

Historian Interface Features

Search, track, and trend tags
Save custom trends
Import individual tags
Set alarm parameters
Print reports
Remote monitor fryer tags

The custom historian interface gave Schwan’s the functionality to access and analyze the fryer data. With the newly accessible information, Schwan’s can fluctuate the fryer temperatures to only run at high temperatures when needed for production, and to cool them down when not.

Measurable Benefits

Estimated savings of $100,000 annually on the cost of oil
Reduced sanitation time by 3.5hrs per week

The cost savings realized by Schwan’s more than paid for the project in the first couple of months after the implementation. The historian not only provided the measurable benefits above, but according to Lim “an additional benefit is the ability to use the historian to troubleshoot the fryer itself.”

The Schwan’s Company continues to utilize the historian to analyze and optimize production. “NorthWind has been great to work with and we didn’t have to provide a lot of direction” says Lim on NorthWind and the project process.

NorthWind and Schwan’s continue to work together in partnership creating efficiency at every venture. At NorthWind, the goal with every project is to make your process as efficient as possible.

Implementation

Learn more about NorthWind's Solutions or reach out to schedule a walk through of a system.

Pinnacle Automation Community Partner Award

Wed, 10 Jan 2024 17:49:00 GMT

NorthWind Receives Pinnacle Automation Community Partner Award

The criteria for this distinguished award centers around partners who exhibit proactive engagement and strategic collaboration, particularly those who have successfully implemented connected technologies into their industrial ecosystem. NorthWind’s ecosystem seamlessly integrates Rittal Products, Eplan software, and Rittal Automation Systems. “From our perspective, NorthWind is a valuable lighthouse customer and partner for EPLAN and Rittal. Due to their core business principles and thoughtful integration of our solutions, the NorthWind team provides a powerful demonstration of our value chain solutions for other companies considering significant improvements to their workflows”, Van Miller – Rittal/EPLAN Value Chain Consultant.

In December 2023, NorthWind proudly accepted the Pinnacle Automation Community Partner Award, a distinguished accolade presented by Rittal Automation Systems and Eplan Software at their Community Event. This is the first time the two companies have recognized partners in this way.

Learn More

Automated Project Development Process

NorthWind has been working to automate and streamline the entire process of designing, building, and programming control systems since 2005. The result of this effort is our automated process that increases quality while reducing production time.

Learn more about NorthWind’s Panel Manufacturing .

NorthWind had a vision to automate the panel design and production process. By partnering with Eplan and Rittal systems we made the vision a reality. We are honored to be one of the inaugural recipients of the Pinnacle Automation Community Partner Award and look forward to continuing to innovate our panel design and build process with Rittal and Eplan solutions.

Kansas Department of Commerce Merit Award

Mon, 18 Dec 2023 20:53:00 GMT

NorthWind Receives Award of Merit from the Kansas Department of Commerce

We are delighted to announce that NorthWind Technical Services has been named a Northeast Region Award of Merit winner in the Manufacturing/Distribution category for the 2023 To the Stars: Kansas Business Awards. The recognition was presented by Ernie Beaudet, Northeast Business Development Project Manager.

The To the Stars Competition , an annual event hosted by the Kansas Department of Commerce, recognizes businesses for their exceptional contributions to the Kansas economy and local communities. Ernie Beaudet highlighted NorthWind’s outstanding achievement, noting, “In the Manufacturing/Distribution category, NorthWind Technical Services stands out as one of the 37 Merit winners statewide. Out of 4,470 businesses, this places NorthWind in the top 1% of Manufacturing/Distribution enterprises in the State of Kansas.”

Mike Bosworth, CEO of NorthWind, expressed appreciation for the recognition, stating, “Being acknowledged by the Kansas Department of Commerce is a testament to our hard work and commitment. These awards reinforce that we are consistently moving in the right direction, always striving to deliver excellence.”

Learn more about NorthWind’s Controls and Automation Solutions .

Premier Ignition Integrator

Thu, 07 Dec 2023 21:39:00 GMT

NorthWind is proud to announce our new status as an Premier Ignition Integrator! Achieving Premier level is a significant milestone, allowing us to elevate our customer service and provide innovative, dependable automation solutions.

Inductive Automation’ s integrator program is comprised of five levels: Registered, Credentialed, Certified, Gold, and Premier, with Premier being the highest tier. Premier level is reserved for system integrators with proven competence, Ignition Gold Certification, and a track record of consistently delivering high-quality work. Reaching this level reinforces our commitment to excellence.

Our collaboration with Inductive Automation allows us to better serve our customers as our engineers and technicians gain access to additional technical resources. NorthWind is excited about continuing to utilize Inductive Automation’s cutting-edge products to deliver high quality controls, SCADA, and MES solutions to manufacturers worldwide.

Learn more about our MES Solutions and Contact Us today about your project.

Manufacturing Execution System Capabilities

Tue, 24 Oct 2023 14:29:00 GMT

Manufacturing Execution Systems can tie into existing batch management systems, such as BatchLOGIX®, and use the existing inventory and production information to give further insight into yield and production metrics. MES connects existing ERP systems, PLCs, and databases. The combined data from those sources can create unique metrics, reports and dashboards that streamline operations, improve productivity, and ensure quality. Using a versatile platform like Ignition Perspective , the capability exists to connect all those data sources, create flexible dashboards, custom reports, custom modules, and Ignition’s platform is designed for mobile access.

Real-time Data

MES platforms provide real-time production information. This valuable information opens the door for quick production snapshots. Dashboards combine real time operating rates and statuses with features like historical run information and production goals. Doing this provides an efficient way for a user to quickly see production status and identify areas that need attention.

Historical Data

With comprehensive access to plant-wide data, MES offers extensive reporting capabilities. This is another area where the Ignition platform is helpful. Leveraging Ignition’s Reporting module, information can be gathered from all the different data sources (ERP, Control System, and SCADA) allowing for the creation of tailored reports that effectively convey data for analysis. Through Ignition’s broad array of device drivers, information from data from all parts of the plant can be logged and displayed in a central location. Additionally, the Ad Hoc trending tool proves to be a valuable asset, facilitating easy trend analysis of data points from all sources and saving those trends for later analysis.

Common MES Features

With all this data, both real-time and historical, there are many different modules that can be implemented. The goals and priorities of each plant and workstation guide which modules should be implemented or if a custom module needs to be developed. Below is a list of common modules.

Scheduling

Provides a global view of the planned production orders. This module can include changeover information, anticipated production time, equipment and materials needed with specific job details to complete the order.

Work In Progress (WIP) Inventory Management

Track and manage inventory through the different stages of production. MES accomplishes this by helping management fine-tune forecasting by providing real-time inventory audits. With the connection to the ERP system and the control system, validating the inventory levels between the two systems is now automatic. This eliminates the need to manually verify inventory levels on the production floor with what is on the books. The system can also verify materials will arrive in time to complete orders by looking at the delivery data on purchase orders and running it against the upcoming production schedule.

Recipe Management

A recipe consists of a list of ingredients, ingredient amounts and sequence for combining those ingredients, and the amount to be made (batch size). Create consistency from product to product and run to run as well as make the best use of resources to minimize waste and streamline the manufacturing process. >>Read more about recipe management

Production Tracking and Dispatch

Manage the bidirectional flow of production data in real time between the ERP and the plant floor.

Lot Tracking and Tracing
From raw material receiving through final product, lot numbers are traced throughout the entire production facility. MES allows for quick recording of batches of raw material, semi-finished products, and finished products, utilizing product genealogy which tracks raw materials, equipment used, dates, quantities, lot, and serial numbers.

Quality management and Control

Manage the quality of manufacturing processes and units including quality deviations and exceptions. Integrate quality check reminders and recordings for QA. These can be as automatic as implementing density and moisture sensors or more manual with an alarm signaling the operator to complete quality assurance (QA) checks and record them in the system. Each records the information to the MES system for the QA team.

Preventive Maintenance

Optimize the planning of preventive maintenance operations to reduce the impact on manufacturing.

Overcoming Common Challenges to Implementing MES

Implementing a Manufacturing Execution System is a large undertaking and to provide the best solution, collaboration between the integrator and the manufacturer must be frequent.

A common challenge is providing the right information and tools to the right audience. When developing dashboards and reports, it is very important to remember who is using the feature and what the goals and priorities are. An operator will want to see different metrics and widgets than someone in a management role. When developing dashboards and reports it is very important to remember who will be using the feature. Separate dashboards for different groups can be created, or widgets can be dynamically hidden/shown depending on the log in permissions and who is viewing the application.

Often facilities have used multiple integrators and software systems throughout the plant. This poses a challenge to gathering data in an accurate and efficient way, as there are a variety of sources. NorthWind maintains consistency wherever possible and keeps documentation on where metrics are pulled in from. Documentation is available straight from the MES project. The user can see a description of how a widget works and where the information is being pulled from, whether it is from BatchLOGIX database, a customer’s existing ERP system, or a PLC Program.

A key to overcoming these challenges is to have open and effective communication with plant personnel to ensure there is clarity on what information is needed. This starts with setting a detailed scope for each area of the system to avoid unnecessary and potentially costly distractions. NorthWind provides a detailed design/development/deployment process and holds meetings with the customer throughout each stage to discuss the project progress and steps to be taken to reach the next stage.

Manufacturing execution systems identify inefficiencies and optimize production. This powerful system can be everything from Overall Equipment Efficiency (OEE) for one area of a plant to a fully integrated solution with a paperless plant floor and everything in between. Implementing these features takes deep process and control system knowledge and because every plant has different processes, machinery, KPIs, and process targets the best solution is going to be a tailored fit. At NorthWind we utilize production and process data for plant optimization with a manufacturing execution system developed for you, with you.

Learn more about NorthWind’s MES Solution or reach out to schedule a walk through of a system.

Written by

Sydney Bosworth

MES Programmer

A Manufacturing Execution System (MES) is a robust software solution that manufacturers are increasingly implementing to increase plant efficiency. MES solutions replace traditional paper-based manufacturing procedures and implements a proactive approach to manufacturing execution. Sometimes manufacturers implement reporting functionalities that fall within the scope of MES and sometimes a full-scale MES solution is integrated across the entire plant. Regardless of the size of the solution, the results of implementing MES include decreased costs and increased support for continuous improvement and lean initiatives. MES is used in conjunction with ERP and SCADA systems, bridging the daily plant operations to the rest of the business.

Performance Analysis

Centerlining includes adjustable thresholds for each device set the acceptability and alert levels for each indicator. Selected KPIs (key performance indicators) such as Right first time (RFT), Rework, Scrap, Process capability (Cpk), and Overall equipment effectiveness (OEE). With one click, the dashboard can provide a detailed analysis of causes of shutdowns and rejects, batch quality rates, and other production indicators.

Enhancing Quality and Efficiency with Recipe Management Software

Fri, 06 Oct 2023 15:14:00 GMT

Automation streamlines the manufacturing process and allows manufacturers to easily monitor and make modifications to the production process from anywhere. Implementing a good recipe management software gives manufactures product consistency, lot tracking, production reports, and it can be easily integrated with ERP (Enterprise Resource Planning) software for a seamless solution.

Importance of Recipe Management

Implementing the right recipe management software is key to maximizing plant performance. This software manages and stores all the recipe information for the plant, as well as important process information for lot tracing and production analysis. This includes raw material delivery and storage, final product storage, mapping materials throughout the entire process, and important batch, campaign, and ingredient usage details. It is worth spending the time researching recipe management software to ensure the package implemented aligns with your business needs.

Common Features

Create and store recipes
Recipe modification
Ingredient location mapping
Ingredient parameters
Lot tracking
Production records
Campaign Management

Manufactures often use several software packages to have these features and encompass all processes within the plant. When looking at a system that can fully handle all production needs, features, additional advanced features are needed.

Advanced Features

Recipe modifications from the HMI
Ingredient location mapping
Process variables
Micro-ingredients and micro-batching management
Integration with ERP and MES (Manufacturing Execution System) software
Capability of handling both batching and continuous processes

Recipe management software such as NorthWind’s BatchLOGIX® , provides all the common and advanced features in one robust platform. With features such as material mapping, recipe creation, process variables, micro-ingredient tracking, and production reports, it’s able to fulfill production demands. NorthWind offers additional integration that connects the plant floor to the rest of the business. By integrating with the plant’s ERP system, data continually transfers back and forth from both systems for seamless and high-level business management.

Recipes

Recipes or formulas are often complex and need a robust piece of software to handle all variables and both batching and continuous processes within the plant. Often recipes only refer to the amount of each material needed, but there is a lot more that goes into establishing product consistency than simply ingredient amounts or weights. To produce consistent product, recipes should include both ingredient and process variables and the entire production process from micro ingredients through continuous extrusion.

Ingredient Parameters

Ingredient parameters include setpoints, rate tolerances, and upper and lower setpoint trim allowance. Setpoint is the target ingredient rate, tolerance is a percent of error acceptable, and trim allowance is the amount that the setpoint can be adjusted by the operator during production. For example, an ingredient has a setpoint of 100kg/hr, tolerance at 10%, and trim allowance of 10kg/hr. The operator could adjust the ingredient rate and call for 110kg/hr. The actual rate could potentially be 121kg/hr and still be within the acceptable tolerance.

Process Variables

Process variables are all the mechanical setpoints on the production floor. For example, a few of the extruder’s common process variables include Head Temperatures, Die Temperature, and Die Pressure. These variables are critical for complying with quality standards, making it a vital piece of the recipe.

Micro-Ingredients Batching

Hand batched micro ingredients are important and often high dollar ingredients that play a significant role in the final product. This part of the process is often handled separately from the recipe management software. Because this step is not included in the recipe management and plant automation system, errors often occur during the weighment and lot tracking of these ingredients. BatchMATE® by NorthWind , connects the hand batching step to the rest of the plant by automating the hand batching process and including the steps in the recipes. Once connected, BatchLOGIX can track the lots and produce production reports.

Lot Tracking

Lot Tracking is one of the most critical aspects of any Recipe Management Software. The lot tracking process starts from the receipt of raw materials through final product. By tracking lot numbers in this way, the system can pull specific lot information for each campaign and batch. This is invaluable when a noncompliant lot or a major fault is detected by the quality department. Using the information provided by the lot tracking feature, production data can be analyzed, and contaminated ingredients and products can be identified, isolated, and pulled from the batch or campaign.

Production Reports

Production Reports are key for any Recipe Management Software. The information provided in these reports helps in scheduling production and can be helpful in identifying the cause for missed targets and other inefficiencies. Production reports can also identify when to schedule maintenance and other necessary stops for production. Ingredient usage and run reports are also available to ensure quality and production targets are being hit.

Some of the key benefits of good production reporting are business insights, higher customer satisfaction, higher efficiency, and better data-driven decisions.

ERP Integration

Integrating the plant floor with the rest of the business allows for production data to be seamlessly used throughout the business. It is common for APIs (Application Programming Interface) to be written for connecting the plant floor to the ERP system.

Having the ability to share data between the different systems is a huge advantage to companies, with this they can schedule production and analyze production in real time. When all the data is readily available, business decisions are now easily backed by data.

Whether scaling recipes into a batch or metering ingredients into a continuous system, a quality recipe management software is key to maximizing plant performance and increasing product consistency. BatchLOGIX® has the scalability to accommodate systems of any size with the flexibility to incorporate all processes.

Written by

Eduardo Martinez

Project Manager

NorthWind Named 2023 System Integrator of the Year

Tue, 06 Dec 2022 21:04:00 GMT

NorthWind Technical Services in Sabetha KS has been named 2023 System Integrator of the Year by Control Engineering and Plant Engineering Magazines. The annual award is presented to top-notch system integration companies like NorthWind based on criteria in three main areas: use of industry best practices, technical competence, and customer satisfaction.

Each year, a panel of magazine editors and industry expert judges select winners in three categories based on the size of the company. For 2023, NorthWind was selected as the winner in the “medium-sized business” category. NorthWind was also named System Integrator of the Year in 2019 in the “small business” category.

Mike Bosworth, NorthWind CEO attributes company success and receipt of the award to the hard work, dedication, innovation, and commitment of the NorthWind team. When asked about what the award means to NorthWind, he commented, “One of our company goals is to be the recognized automation leader in the market segments we serve. Being recognized as System Integrator of the Year is a tremendous honor and validation that we are doing many things right. It is humbling to be recognized as part of a such an elite group of the best system integrators in the country.”

Control and Plant Engineering Magazines have recognized top system integrators with the System Integrator of the Year program for the past 19 years. Click here to read Control Engineering’s Announcement Article .

Manufacturing Day 2022

Tue, 18 Oct 2022 16:56:00 GMT

The Sabetha Chamber of Commerce hosted a community Manufacturing Day on October 5 ^th . Manufacturing Day is an initiative of The Manufacturing Institute that encourages manufacturers across North America to open their doors to high school students, exposing them to the many opportunities and career paths in manufacturing and energizing a future generation of skilled workers.

Students from Sabetha High School, Wetmore High School, Prairie Meadows Private School, Nemaha Central High School, Falls City High School, Horton High School, and Jackson Heights High School attended the event.

All schools met at the Sabetha Main Event Center first thing in the morning where students were welcomed by the Sabetha Chamber, local companies, and Congressman Jake LaTurner. The students then traveled to four of the local companies (Schenck Process, Wenger Manufacturing, Triple C, and NorthWind) for facility tours. During lunch students had the opportunity to visit informational booths setup by many of the local manufacturing companies as well as Colleges and Technical Schools.

Schools Participating

Highland Community College
Kansas State University
Pittsburg State University
Washburn University
Washburn Tech

We were excited to provide facility tours to over 250 students! During their time here at NorthWind they learned about control systems and factory automation, listened to several of our employees’ background and career paths to their current positions, became aware of the different technical positions NorthWind offers, and toured our panel shop where they observed both the panel cutting and wire terminal machines running.

We enjoyed having the students here and giving them insight into manufacturing career opportunities as they begin to plan their futures.

Successful Control System Modernization

Fri, 12 Aug 2022 15:20:00 GMT

Safety Considerations

There are misconceptions involving safety considerations: Many people think that safety guidelines are grandfathered in by the date of the original mechanical equipment installation. However, on any substantial electrical modernization project, safety circuits and functionality need to be reevaluated.

Electrical Installation

One of the biggest concerns with control system modernization is the amount of time it will take for installation and requalification. Working with an industrial electrician with the expertise to understand how to work within schedule constraints and provide creative, custom solutions to meet outage windows is critical. Installation can be done in phases, during production downtimes, or any other number of solutions to keep downtime at a minimum.

Best Practices

As a Senior Project Manager at NorthWind, I have implemented many modernization projects throughout my career. In this time, I have found a few tried and true practices that lead to a successful control system upgrade.

Customer/Project Management Planning

When mo dernizing any system, a collaboration between customer and Project Management is a must. Through this collaborative approach, a forward-looking plan is made to include functionality, risk avoidance, down time reduction, migration solutions, project phasing, etc. to ensure the project scope is clearly outlined and understood.

Design Trip

There is a misconception that modernization will “break” the current system and lead to significant downtime. Conducting an initial design trip is instrumental for designing a project that takes into consideration the existing system and its functionality and designing a system that will meet the customers scope and needs.

Before any modernization takes place a review of pre-existing equipment, electrical, design and functionality is conducted. Any existing drawings and documentation are also thoroughly reviewed. In the event there are no drawings of the existing system, a new set will be created.

Written by

Blake Bennett, P.E.

Senior Project Manager

4 Best Practices for Successful Control System Modernization

Manufacturers produce the products that our communities need. In today’s market of doing more with less, manufactures are often required to extend process system lifecycles longer and longer to avoid the time and expense of a greenfield project to replace the systems. What remains is an aging infrastructure that was built at a time when industrial automation was in its infancy. Weighed against new systems, these existing processes often have the same underlying mechanical technology but are generations behind in terms of controls and automation technology.

The most obvious illustration of this is systems that have obsolete electrical components and legacy software that is no longer actively supported by original manufactures. As we move into Industry 4.0, the old standard of each individual machine having an isolated “island” of automation is being replaced by more integrated automation systems that communicate to each machine, sharing and creating significantly more data than even 15 years ago. With this added data is the desire to connect the plant floor data to business systems. More and more facilities want production orders to come down from ERP systems to process controls, producing real-time consumption data that is utilized to reduce inventory. To stay competitive, many facilities have made the business decision to modernize their legacy machine and controls systems. Typically, this can be done at a fraction of the cost and time of a greenfield project.

Modernizing a Control System

A control system upgrade can bridge all these gaps by integrating mechanically sound process systems with a modern automation system. At a minimum these projects consist of substantial replacement of obsolete components, sometimes even retaining the original PLC logic. These projects can also be expanded to include high level integration of different machines, adding new machines to an existing system, ERP integration, and ground-up re-writes of logic and operator screens.

Modernization projects are known to be complex, especially because engineers are required to work inside an existing framework as opposed to building a system from the ground up. There may be missing documentation or drawings. Additionally, some field modifications may not be included in the drawings. Minimizing production downtime is a significant concern, so the implementation window to get the system back in production is often small.

A successful modernization project considers these factors and others during the initial phases of the control system upgrade. Key to any project is developing a deep understanding of the existing system. This is paramount to implementing the upgrade without breaking what is currently in place.

Benefits of Modernization

Updating hardware and software with better automation control systems can improve plant performance, increase productivity, improve communication between the process information and business systems, provide useful production data, provide alerts to improve response times, increase plant system security and perform system diagnostics.

With NorthWind you can achieve an effective modernization project that manages safety, health and environmental risks, get documentation for field devices in the system, and be assured of a more efficient, consistent and optimized operation, with the support of the system for years to come. Contact us today to talk about your system.

CSIA Certification 2022

Wed, 03 Aug 2022 14:57:00 GMT

NorthWind achieved CSIA Certification for the fifth time!

To become certified, a system integration company must show that they conform to the Benchmarks and Best Practices laid out by the Control System Integrators Association . The Best Practices and Benchmarks cover all areas of the business including:

General Management
Human Resources
Sales and Marketing
Financial Management
Project Management
Supporting Activities
Quality Management
Service and Support
Info Systems Management and Cyber Security

NorthWind personnel from every department worked with Martha Bray, NorthWind’s Technical Writer, to ensure the proper documentation and supporting evidence was written, assembled and met best practices for the audit. The audit took place in Sabetha, at NorthWind’s office. The audit was conducted June 23 and 24 ^th by Exotech auditor, Jack Barber.

“Congratulations to the Northwind team for meeting the CSIA Best Practices requirements for the fifth time,” commented Jack Barber. “Mike and Marlene have done an excellent job building a relatively young and energetic leadership team, who actively participated in the audit process, showing their accountability by actively participating in the improvements to the practices in their respective areas. It’s a great way to create stability and opportunity for growth.”

We are proud to announce our successful CSIA certification for the fifth time! The process for certification was truly a team effort. Almost everyone at NorthWind had a hand in the audit preparation, from either writing documentation, giving valuable input on procedures and policies, or making suggestions for improvement. This great accomplishment could not have happened without the dedication and hard work of all NorthWind employees.

NorthWind Celebrates 25 years!

Tue, 26 Jul 2022 20:18:00 GMT

On July 8 ^th NorthWind celebrated their 25 ^th Anniversary! Mike and Marlene Bosworth reflected on the past years in an address to the company each echoing words of gratitude, value, community, accomplishment, and admiration for the NorthWind employees. The celebration kicked off at 5pm with NorthWind employees, their families and guests enjoying outdoor games and activities for all ages. Before dinner Mike and Marlene said a few words and the Sabetha Chamber of Commerce had a ceremonial ribbon cutting to commemorate the 25 year milestone. The evening celebration was full of fun, friends, and family!

COMPANY HISTORY

1997 NorthWind Technical Services, LLC was established by Mike and Marlene Bosworth in their home outside of Sabetha, Kansas. At that time, the company primarily offered engineering consulting services.

1999 NorthWind began offering automation system solutions and moved into a small office space in downtown Sabetha. Control panels for automation systems were constructed in the Bosworth’s garage at their home.

2001 The company’s first full time employee was hired.

2003 A new 5,000 sq. ft. office and panel shop were constructed in the Sabetha industrial Park for the growing business.

2010 NorthWind becomes CSIA certified.

2012 A major expansion added 2,600 sq. ft. of space that included a test lab, lunchroom, and additional office space for a growing number of employees.

2014 NorthWind expanded for a second time, adding another 3,250 sq. ft. to the facility’s panel shop and warehouse area.

2017 A third expansion of approximately 10,000 sq. Ft. provides additional space for control panel fabrication and personnel.

2019 NorthWind opens the Latin America Office located in San Jose Costa Rica. NorthWind is also recognized as System Integrator of the Year by Control Engineering Magazine.

2021 NorthWind opens an office in Kansas City.

NORTHWIND TODAY

Our headquarters is located in Sabetha, KS. The majority of employees and all panel fabrication activities are located at this facility. A second location was established in San Jose, Costa Rica in June of 2019 to better serve customers in Latin America. The Costa Rica office houses twelve employees that work in Service, Sales, and R&D. A third office in Kansas City opened in 2021 housing a small group of employees who live in the KC area.

NorthWind strives to achieve high standards that meet customer needs, promote employee wellbeing and development and to ensure company stability. The company has been Control Systems Integrators Association (CSIA) certified since 2010 and consistently employs CSIA Best Practices and Benchmarks to provide the best value to its customers, combining technical proficiency with sound business practices. NorthWind is also an accomplished Rockwell Automation Gold Partner, providing proven services and solutions that meet our customers’ automation needs.

2022 Intro to Automation

Thu, 30 Jun 2022 18:16:00 GMT

2022 Intro to Automation Course

NorthWind sponsored and hosted an Intro to Automation Course for high school students May 31 – June 3. Professor Clark Shaver from the Electronics Engineering Technology Department at Pittsburg State University presented the course to twelve students. While one-half of the students were from Sabetha, students from surrounding communities including Fairview, Seneca, Wetmore, Horton, Centralia and Humbolt, NE made up the other half.

The students learned basic programmable logic controller (PLC) programming and controls wiring to complete approximately 25 projects that included buzzers, strobe lights, and conveyor systems. Automation industry experts from NorthWind and other companies shared information on career paths in the rapidly expanding field of automation throughout the world as well as in our local area. Students were presented with a Certificate of Completion and have the opportunity for scholarships and course credit if they pursue an engineering degree with an automation minor at Pittsburg State University.

The owners of NorthWind, Mike and Marlene Bosworth commented, “We enjoyed hosting the course and giving these young individuals a small taste of the automation industry. We are hopeful that we can host this course again next year.”

Kicking off 2022

Fri, 28 Jan 2022 21:02:00 GMT

In January of each year NorthWind holds an annual Christmas Party in celebration of the previous year and to kickoff the new year. This year the company traveled to Kansas City for a fun night of bowling and bocce at Pinstripes. Kicking off the day the company held a soccer game between NorthWind US office vs NorthWind Latin America office! Each team had prepped from weeks prior to the event. After a quick 2-0 lead by the US team the LA team turned on the burners and came out victorious! With 4 goals, Jonnathan Rojas was named MVP! Enjoy a few pictures from the events.

Remote Access for Industrial Control Systems

Thu, 16 Dec 2021 20:46:00 GMT

Remote Access for Industrial Control Systems

Remote access is the ability to access a computer or network from any location through a network connection. This tool is particularly helpful in servicing control systems through a network connection. By connecting to the system’s programmable logic controllers (PLC), Human Machine Interface (HMI), and other Ethernet compatible devices, integrators are able to efficiently monitor, troubleshoot, and fix an issue without having to physically travel to the site.

Manufacturers can receive many quality services via remote access such as troubleshooting, remote startup, remote monitoring, software upgrades or additions, proportional-integral-derivative (PID) tuning (adjust the PID controller), User Interface (UI) additions, and other improvements to the customer’s automated system. Service technicians have access to tools and software solutions that many manufacturing plants may not have and these can be utilized remotely to enhance the service experience.

This article discusses best practices for establishing remote access, services provided using a remote connection, and help determining if remote access is right for your plant.

Best Practices for Establishing Remote Access

When establishing remote access to a plant’s control system for the first time, there are several guidelines to follow from both the integrator and the plant’s side.

The first step to connecting remotely is to obtain permission from the plant’s IT department to access the virtual private network (VPN). The integrator provides the plant’s IT department with a list of authorized technicians who will provide service and support for the plant. The plant’s IT department will set up user accounts for those authorized technicians. If applicable, non-disclosure agreements will be signed.

Safeguards for a Secure Connection

Integrators use a VPN for connecting to the plant’s control system
Plant IT has an isolated network for the VPN
Routine system backups
Utilize virtual machines (VM)

Remote Access – Technical Service and Support

A major benefit for establishing remote access to a plant’s control system is the ability to quickly be connected for service and support. In the event there is a problem with the control system, such as a production sequence is out of order, a burner is not reaching a high enough temperature, or a conveyor is not moving fast enough, plant maintenance personnel can contact an integrator for technical support. A service technician is speaking directly with the plant personnel. By working together, problems are solved faster, immediate feedback is provided, questions or concerns are addressed, and this is an opportune time to provide plant personnel some system training.

With remote access available, service technicians are able to support plants quickly and efficiently. With prior remote access established, a technician can be connected to a plant within 15 minutes of calling about an issue. This quick connection time allows for troubleshooting to begin immediately, while reducing plant down-time.

Remote access allows the service technician to monitor the system live to catch any intermittent problems. Control Systems can be remotely accessed and watched for a specific problem or issue over a number of hours or days. Then when the problem occurs, the service technician can isolate what caused the problem, what conditions were present when the issue occurred and provide a solution.

Another benefit to remote access is being flexible within the time frame of system maintenance. Service can be provided around rigid time and production schedules, as remote access can occur at any time during the day. This eliminates waiting until regular business hours to contact support and then having to make travel arrangement to get a technician on site. Remote access can also serve as an extension of the customer’s maintenance and continual improvement departments.

Remote Access – Control System Startup

Some Control System modification and addition projects can be started up remotely. The benefits to a remote startup are similar to remote access service.

Time (travel and onsite)
Money (costs of travel, rental, accommodations, etc.)
Resources

Help can be offered immediately, the customer only has to pay for labor time to fix an issue, fixes can be provided around rigid production schedules, and additional resources can be utilized.

Remote Access can also be used in conjunction with onsite startups to provide additional training and which helps build on more complex ideas and unique operating situations. And lastly, with the restrictions of travel and health concerns surrounding Covid 19, quarantine restrictions and safety protocols can be eliminated if remote access is used.

Is Remote Access Right for You?

Remote Access for industrial control systems can provide a quick, affordable solution for control system maintenance. Remote Access saves travel time, accommodation costs, and costs associated with down-time. Remote access provides the customer with immediate help and resources any time day or night and remote access can also be used to monitor intermittent problems. Remote Access can be utilized not only for start-ups, service, and maintenance, but operational training as well.

NorthWind’s Service Team provides remote service and support for all control system issues. Learn more about our technical support here or call 785-284-0080 for immediate assistance.

Written by

Jake Taylor

Service Manager

Identifying Critical System Data with High-Performance Graphics

Fri, 09 Jul 2021 19:22:00 GMT

Manufacturing plants consist of many different pieces of equipment working together to make a product – from building materials like PVC pipe to food items like tortillas . The control system’s human machine interface (HMI) is the connection between an operator and each machine. HMIs provide processing data for operator and maintenance personnel to interact with the equipment. Traditional HMI graphics that are full of color, moving components, and detail are visually impressive but inefficient as the colors and animations detract from the actual data needed. Plant operators and maintenance personnel must quickly identify critical process information and high-performance graphics (HP graphics) allow them to do just that. By understanding HP graphics and how they help operators identify critical information, companies can confidently make the shift to new technology.

High-Performance Graphics vs Traditional HMI Graphics: Visual Differences

HP graphics reduce troubleshooting time by highlighting pertinent information. While maintaining a visual representation of the equipment and system, HMIs provide a user with helpful alerts and status information. In traditional graphics, the proliferation of color is distracting. HP graphics reserve bold colors and movement only for instances when attention is needed.

For example, if a receiver refill is disabled and the receiver is below low level, the low-level indication is visible, but the banner will be gray instead of yellow. This color change allows the operator to better focus on critical information.

How to Transition an HMI to HP Graphics

It’s possible that some personnel will not be initially accepting of the new graphics. The biggest push back when upgrading to HP graphics generally comes from operators that have been working with traditional HMIs for a long time and are used to a lot of color and detail on the screen. The grayscale color scheme brings a misconception that the new HP graphics will make it harder to understand what is happening in the system. However, with more muted tones, alerts and warnings are very easy to spot, providing the user a very readable HMI.

HMI alerts and alarms that benefit from HP graphics include:

System Status
Device Faults
Low Feed Rate
Ingredient Setpoints
Trends
Process Variables
Batch Details

Implementing HP Graphics on the Plant Floor

NorthWind has moved to HP graphics as a standard for all projects. With this change, we have maintained the same overall feel, while providing a more readable HMI. Our HOA banners, menu bar, and feed point objects maintain similar aspects to our old graphics package but are now more visible when data is most critical.

A lot of the changes incorporate the intentional use of color and adding dynamic visibility – displaying exactly what information the user needs to see at the critical moment. To further ease troubleshooting, reference points are built into the HMI, PLC, and electrical drawings, allowing personnel to quickly find the information they need.

Written by

Sydney Bosworth

Standards Programmer, Level II

NorthWind trains and supports customers through the transition to HP graphics – from the startup process to complete integration. We also transition existing HMIs to HP graphics for a streamlined user experience across the entire manufacturing plant.

At NorthWind, we’re all about data. The efficiencies gained with the new graphics are everything we’re about – accurate process data in the most usable form.

Kickball Night

Tue, 30 Mar 2021 20:39:00 GMT

Spring is in the air & NorthWind Employees took full advantage of the nice weather with a kickball game! Utilizing the local Sabetha baseball fields, the employees took the field. This is one of the first employee group outings since the beginning of the pandemic. The game became competitive with some lighthearted taunting and even a few sliding wounds. Employees enjoyed the fun time “It was a chance for people to get to know each other better” says Controls Engineer, Robert Lee. When asked what his favorite part was, Lee responded with “The teamwork each team showed while playing.” At NorthWind, we like to play after a busy day at work!

Join the NorthWind Team – literally! We have several openings, click here for information.

UL Certifications

Wed, 24 Mar 2021 16:44:00 GMT

UL markers are most seen on industrial equipment and home appliances. These include furnaces, fuses, electrical panels, circuit breakers, and thousands of other products. Industrial Control Equipment is no exception. Virtually all cities and states require a third-party inspection of industrial control panels before those panels can be powered up. The requirements for testing by third-party inspection are based on section 1910.303 of OSHA. This assures that the panel will operate safely and will not cause shock or fire. To earn the right to put UL-certified stickers on industrial control panels; procurement, production processes, and finished panels, must undergo examination and inspection on a regular basis.

NorthWind Technical Services is a certified Industrial Control Panel manufacturer. NorthWind Technical Services is proud to be UL508A certified since 2005, and UL698A since December 2020. Customers have come to value the quality of panels that NorthWind provides, and the UL Certification guarantees not only quality, but a high level of workmanship, trained personnel, and a documented quality control process. (Anderson, T., NorthWind Technical Services Quality Control).

What does it mean to be UL Certified?

UL (Underwriter Laboratories) was founded in 1894 in Chicago. UL is a third-party certification company, a safety organization, that sets industry-wide standards, ensuring that products are constructed correctly for the highest level of safety. UL certifies products with the aim to make the world a safer place for both workers and consumers (ul.org).

A common misconception is that UL tests every product themselves. This is not always the case. Instead, UL authorizes a manufacturer to test the product themselves using the UL stamp. UL then follows up on a regular basis to make sure that the products are being tested, following proper safety guidelines (www.ul.com). This is one of many reasons that UL certification is attractive to businesses.

Although the UL stamp is very recognizable, there is not a general UL seal of approval (ul.org). Instead, to obtain UL certification, there are three distinct categories of approval.

UL recognition is for components and UL Listed is for stand-alone products. While both ensure a set of industry standards, they are used for different products and in different capacities. Therefore, UL Listed is more recognizable to consumers because it ensures the safety of consumer-ready products on the market.

UL Standards for Industrial Control Panels

 UL508 – The primary certification for industrial control equipment is UL 508. UL508 covers industrial control and related devices rated 1500 volts or less used for starting, stopping, regulating, controlling, or protecting electric motors. In accordance with the National Electrical Code, ANSI/NFPA 70, the equipment is intended for installation in ordinary locations where the ambient temperature does not exceed 40°C (104°F) maximum (hightechsafety.com).

UL508A – UL508A is the standard for the construction of industrial control panels, where panel builders have expertise in proper component selection, wiring methods, and circuity calculations. The UL 508A Listing Mark covers industrial control panels with a voltage of 1000 volts or less. The UL508A Listing Mark provides evidence of third-party certification to the municipal inspection authority and to the purchaser of the panel. A UL 508A Listing Mark shows that the panel complies with an acceptable safety standard (hightechsafety.com).

To allow the installer to properly install the panel in accordance with National Electrical Code (NEC) and other codes, electrical ratings and instructions are to be clearly explained on the panel.”

Installation of a control panel can be completed in two ways: in an enclosure as “enclosed type” equipment or arranged onto a mounting panel as “open type” equipment. For “open type” equipment, the assembly is installed in an enclosure provided by others, or at the installation site (hardcore-electric.com).

Enclosures can help mitigate fire hazards, reduce the risk of shock, and minimize other risks that could happen during accidental contact with electrical equipment. The rating of the enclosure will determine if the panel can be inside or outside. The UL Enclosure Rating determines if the panel can be inside or outside (irtrectifier.com). The UL Ratings are as follows:

Type 1- Indoor use to provide a degree of protection against contact with the enclosed equipment and to provide a degree of protection against falling dirt.

Type 2- Indoor use to provide a degree of protection against contact with the enclosed equipment, to provide a degree of protection against falling water dirt, and to provide a degree of protection against dripping and light splashing of non-corrosive liquids.

Type 3- Indoor or outdoor use to provide a degree of protection against contact with the enclosed equipment; to provide a degree of protection against falling dirt, windblown dust, rain, sleet, and snow; and that will be undamaged by the formation of ice on the enclosure.

Type 3R- Indoor or outdoor use to provide a degree of protection against contact with the enclosed equipment; to provide a degree of protection against falling dirt, rain, sleet, and snow; and that will be undamaged by the formation of ice on the enclosure.

Type 3S- Indoor or outdoor use to provide a degree of protection against contact with enclosed equipment, to provide a degree of protection against falling dirt, windblown dust, rain, sleet, and snow; and in which the external mechanisms remain operable while ice laden.

Type 4- Indoor or outdoor use to provide a degree of protection against contact with enclosed equipment, to provide a degree of protection against falling dirt, splashing water, windblown dust, rain, sleet and snow, and hose-directed water; and that will be undamaged by the formation of ice on the enclosure.

Type 4X- Indoor or outdoor use to provide a degree of protection against contact with enclosed equipment, to provide a degree of protection against falling dirt, splashing water, windblown dust, rain, sleet and snow, and hose-directed water, and corrosion; and that will be undamaged by the formation of ice on the enclosure.

Type 5- Indoor use to provide a degree of protection against contact with enclosed equipment, to provide a degree of protection against falling dirt, settling airborne dust, lint, fibers, and flyings; and to provide a degree of protection against dripping and light splashing of non-corrosive liquids.

Type 6- Indoor or outdoor use to provide a degree of protection against contact with enclosed equipment, to provide a degree of protection against falling dirt, rain, sleet, snow, hose-directed water, corrosion, and the entry of water during occasional temporary submersion at a limited depth; and that will be undamaged by the formation of ice on the enclosure.

Type 6P- Indoor or outdoor use to provide a degree of protection against contact with enclosed equipment, to provide a degree of protection against falling dirt, rain, sleet, snow, hose-directed water, corrosion, and the entry of water during prolonged submersion at a limited depth; and that will be undamaged by the formation of ice on the enclosure.

Type 12 – Indoor use (for enclosures without knockouts) to provide a degree of protection against circulating dust, falling dirt, lint, fibers, flyings; and to provide a degree of protection against dripping and light splashing of non-corrosive liquids, and against light splashing and consequent seepage of oil and non-corrosive coolants.

Within the UL 508A standard, there are two sections that are relevant to enclosures and cabinets.The GENERAL section addresses requirements for all panels, and these requirements include:

Protection Against Corrosion
Support and Securement of Live Parts
Spacings
Conduit Bushings
Insulating Barriers
Insulating Materials
Grounding – General
Grounding – Size of Terminal or Bonding Conductor
Identification of Grounding and Grounded Circuit Conductors and Terminals

The ENCLOSURE section contains requirements for enclosures, addressing items such as:

Enclosure Openings
Accessibility of Live Parts
Ventilation Openings
Bonding
Observation Windows
Enclosure Environmental Control Devices
Enclosure Maintenance Lighting

To summarize, 508A certification means that components used in the panel design must be from “listed” or “recognized” sources that are certified. UL508A certification ensures the buyer that all components used in the panel design are used in accordance with the requirements of that component (Drew, B., NorthWind Technical Services Project Manager).

UL698A – The UL698A certification governs panels “relating to hazardous locations.” This applies to industrial control panels that are intended to be placed in a safe environment but have circuits that feed out into hazardous environments. The panels do not require explosion proof, dust-proof, or pressurized enclosures, but do require intrinsically safe control circuits. Intrinsic safety is a key consideration of industrial control panel manufacturing for hazardous and unclassified locations, as it directly restricts the availability of energy to unprotected field devices to prevent ignition (www.ul.com).

Explosion-proof and hazardous location panels prevent explosions by containing the blast. These types of panels have robust enclosures to contain the flames and ignite elements inside, preventing damage to surrounding equipment. On the other hand, intrinsically safe control panels prevent ignition from sensors and other unprotected field devices. Intrinsically safe control panels utilize specifically designed wiring and equipment that limits the level of electrical and thermal energy transmitted to a level below what is required to ignite a specific hazardous atmospheric mixture. Limiting the energy levels that passes through wiring and equipment effectively prevents ignitions from occurring ( www.ul.com ). The UL698A certification allows NorthWind to assemble panels with intrinsic safety barriers for connection to circuits residing in hazardous locations.

Are all Industrial Control Panels UL Certified?

Although most Industrial Control panels go through rigorous quality and safety controls, they may not be UL certified. Non-certified panels make up about 80% of the market (www.ul.com). When it comes to control panel safety, the sum can be no better than the parts, and a UL listing for a panel depends, in part, on it being assembled from UL listed components. Many states and counties require UL certification. A few important considerations when choosing a control panel is:

Is the panel made from UL listed components recognized for its specific application?

Is the panel built according to UL standards?

Is the panel verified through onsite inspections that adhere to safety standards?

What constitutes a hazardous environment?

Hazardous locations are defined by the National Electric Code (NEC), NFPA 70. (www.nfpa.org).

Classes:

Class I: Denotes areas where flammable gas, vapor, or liquid is present.
Class II: Denotes areas where combustible dust is present.
Class III: Denotes areas where ignitable fibers are present. The difference between flammable, combustible, and ignitable all has to do with the different temperatures at which a substance will ignite.

Groups:

Group A (Class I): Acetylene
Group B (Class I): Hydrogen
Group C (Class I): Cyclopropane, ethel ether
Group D (Class I): Acetone, butane, propane, hexane, natural gas fuel oil.
Group E (Class II): Combustible metals (e.g., lithium, magnesium, titanium)
Group F (Class II): Carbonaceous materials (such as coal dust)
Group G CLASS II): Flour, starch, plastic

The NEC further categorizes areas into three different divisions (www.nfpa.org):

Division 1: Areas where flammable or combustible concentrations exist under normal circumstances OR are highly likely to exist under other circumstances.
Division 2: Areas where flammable or combustible concentrations exist under abnormal circumstances OR are not likely to exist under other circumstances.
Non-classified/Unclassified: Areas where the presence of hazardous material is so infrequent, Electrical Area Classification is deemed unnecessary.

Many of NorthWind’s panels go into Group G (Class II) locations (Anderson, T., NorthWind Technical Services Quality Control).

Summary

NorthWind Technical Services has worked to earn and maintain UL certification, and the UL mark on a NorthWind panel assures the customer that the panel was built in a precise and organized manner, that rigorous quality standards were followed, and critical safety details were not overlooked.

Sources

Anderson, T., NorthWind Technical Services Quality Control

Drew, B., NorthWind Technical Services Project Manager

hardcore-electric.com

hightechsafety.com

irtrectifier.com

nfpa.org

ul.com

ul.org

Far more testing is involved in UL Listed certification (ul.org). The UL Listed seal means that the product has been tested by UL to nationally recognized safety and sustainability standards and is free from a reasonably foreseeable risk of fire, electric shock in a Division 2 environment (an area where ignitable concentrations are used).

Advanced Manufacturing

Motor Control Panels

Motor Control Panels are a great alternative to motor control centers. Our innovative design is built with cost saving and safety minded features.

We strive to continuously improve our products & processes. In 2017 we added the panel cutting machine and in 2020 we added the wire processing machine to our Panel Shop. Both of these additions have increased our efficiencies allowing us to deliver quality panels with shorter lead times.

Learn More

Las siete cosas que debemos analizar antes de Automatizar

Wed, 19 Dec 2018 20:35:00 GMT

¡HAY QUE TOMÁRSELO EN SERIO!

La automatización de procesos industriales es cada vez más necesaria si queremos eficiencia, precisión, trazabilidad y como resultado mayores utilidades en nuestros procesos.

Hoy la rápida expansión del mercado mundial les exige a las empresas mejorar sus procesos, para poder ser más competitivos y obtener mayor presencia en el mercado globalizado. Para lograr esto, los grandes del mercado de la automatización han desarrollado diferentes herramientas, componentes, y dispositivos que nos permiten consolidar nuestros procesos en un sistema de control unificado el cual si es bien diseñado, nos dará precisión, mejorara nuestra calidad, y asegurara los diferentes procesos dando un ambiente en el que los humanos se dedican a velar por la calidad y las maquinas se encargan de las labores repetitivas e incluso peligrosas, brindando mayor seguridad para el empleado y bajando costos de producción.

¿INVERTIR O GASTAR?

Cuando decidimos entrar en el mundo de la automatización, debemos estar seguros de si queremos invertir para mejorar, o solamente gastar un poco de dinero para simular estar al lado de la tecnología.

Cuando decidimos invertir, generalmente buscamos la forma de gastar lo menos posible, pero hay una delgada línea que nos separa del concepto de inversión, y nos lleva al término gastar.

En el mercado podemos encontrar múltiples marcas de equipos para automatizar, desde una simple tarjeta la cual nos dará entradas y salidas tanto digitales como análogas, y que le permite a un estudiante de informática por un costo de $50.00 crear un pequeño sistema de control, hasta los sistemas robustos y diseñados para perdurar y justificar su valor a lo largo de un razonable periodo de tiempo.

La pregunta es, ¿Dejaría usted su empresa en manos de un juguete para estudiantes?, o ¿quiere en realidad invertir en un sistema de control robusto y confiable, que además de manejar su industria de manera eficiente, le de los datos resultantes de su proceso para prever cambios, y continuar mejorando cada vez más?

Los líderes del mercado de la automatización como Rockwell Automation, se dedican día a día, a crear herramientas y componentes para hacer más eficientes y seguros sus procesos de producción.

¿CONTRATAR O HACERLO EN CASA?

Muchas empresas y corporaciones ya están abandonando la idea de crear sus sistemas de control en casa. ¿Por qué? La respuesta es sencilla, cuando creas un sistema de control en casa, lo haces confiando en 1, 2 o 3 buenos ingenieros, quienes con la mejor de las intenciones tratan de crear un sistema eficiente, pero esto se ve afectado por tres puntos críticos:

Generalmente estos ingenieros no tienen todo el conocimiento requerido, tanto en el área de automatización, como en la funcionalidad de los equipos a automatizar.

Si resultan ser tan buenos como se requiere, pronto tendrán una mejor oferta, o decidirán crear su propia empresa.

En el momento en que se vayan, el que venga a cubrir el puesto requerirá de meses para lograr entender como pensó quien diseño el sistema, y así poder continuarlo o mejorarlo.

El mismo efecto se produce cuando se contrata para una automatización completa a una pequeña empresa basada en uno, dos o tres personas. Llegará el momento en que estén tan ocupados que no podrán darle soporte a su sistema.

Hoy en día, muchas de las empresas que tenían su propio departamento de automatización, han cambiado el rumbo y lo dedican a estandarizar los equipos a usar, velar por la infraestructura de red y por la seguridad informática de la misma, así como por implementar prácticas de seguridad en los sistemas, que les permita desde un punto central detener en caso de emergencia toda la planta si es necesario.

Ese departamento logra acuerdos con proveedores de equipos de cómputo como DELL o HP, para tener un tipo de servidores y estaciones de trabajo estándar donde la cantidad de repuestos sea mínima, y estos proveedores les garanticen una entrega a tiempo de lo que se requiera.

¡¡LA LETRA PEQUEÑA QUE NADIE LEE!!

Cuando cotizas un sistema de automatización, generalmente te fijas en el precio final de oferta, y decides por el mejor precio, ¡y como no hacerlo si en teoría todos ofrecen el sistema para controlar los mismos equipos! Pero la realidad dista mucho de eso.

Cuando se diseña un sistema de automatización, se debe hacer pensando en que la empresa crecerá, y por lo tanto requerirá de más señales, para controlar y mejorar cada vez más, de manera que, si diseñas utilizando equipos justos a los requerimientos iniciales, te encontrarás con un cambio de equipos a muy poco tiempo, por lo que volvemos a la conclusión de que lo barato sale caro. Es muy claro que los equipos de automatización pequeños, son creados para automatizaciones aisladas y pequeñas donde no se espera crecimiento alguno.

¿QUÉ VIENE DESPUÉS?

Una vez definido e implementado el sistema ideal, viene la mejor parte, el soporte.

En este tema es donde las grandes inversiones se convierten en chatarra si no se analizó esto al contratar.

Cuando hablamos de soporte, hablamos de horario, tiempo, costos, idioma, disponibilidad. Su sistema debe ser hecho por una empresa con soporte real 24/7, una empresa dispuesta a responder el teléfono de noche, madrugada o días feriados, sin que eso le cueste a usted miles de dólares más por el hecho de despertarlos.

Es de suma importancia que quien les da soporte, hable su idioma para que sus operarios puedan comunicarse eficientemente. El ingeniero de soporte debe tener a mano toda la información de su sistema, paneles, PLC, pantallas de control, etc, de esta manera un paro operativo se podrá resolver en el menor tiempo posible.

SEGURIDAD DEL SISTEMA

Cuando hablamos del soporte, una de las áreas críticas es el acceso remoto a su sistema por parte de la empresa encargada de ello, y para esto, su sistema debe de estar conectado a internet.

Según los especialistas de Kaspersky Lab, en el 2017, el 54.6% de los ataques a sistemas industriales, fueron en empresas de manufactura, e indican que el 38,9% de los equipos de automatización industrialque son protegidos por sus sistemas en Latinoamérica, fueron atacados, logrando neutralizar la amenaza.

Para poder tener acceso sin arriesgar su sistema, se debe contar con software y hardware específicos que les garantice un alto nivel de seguridad.

En la actualidad son muchas las empresas que utilizan software para acceso remoto de uso popular, los cuales no les garantizan una seguridad real, y peor aún muchos de ellos ya han sido hackeados por lo cual los piratas informáticos tienen acceso a sus sistemas.

Los hackers ya se dieron cuenta que el bloquear el acceso a archivos de texto y hojas de cálculo, no les ha dejado ninguna ganancia, por lo que, ahora, sus virus ya buscan archivos de tipo industrial.

Por este motivo, se debe tener claro que ningún equipo de uso industrial, debe ser usado para acceder a sistemas de email, navegación u otros usos que comúnmente le damos a los computadores de oficina. Y más aún, se debe asegurar que la red de equipos industriales no sea parte de su red administrativa. Una pregunta que ninguna empresa hace al contratar un sistema de automatización:

¿TIENE LA EMPRESA DE AUTOMATIZACIÓN, SUS PROCESOS AUTOMATIZADOS?

El que la empresa que diseñe su sistema tenga automatizados sus procesos de diseño, configuración, diagramación y fabricación de paneles, le da a usted como cliente la oportunidad de que su departamento de mantenimiento sea más eficiente al momento de detectar y reparar una falla, sin tener que invertir grandes cantidades de dinero en licencias de desarrollo de software para poder realizar modificaciones en la aplicación.

Asegúrese de la empresa que contrate, le brinde a su personal las herramientas necesarias para poder atender su sistema sin depender 100% de ellos. En otras palabras, usted puede casarse con una empresa de automatización, pero por ningún motivo se convierta en su esclavo.

En resumen, el diseño de un sistema automático, implica muchos más que solo saber programar o conectar unos cuantos cables. Implica el tener el conocimiento multidisciplinario, experiencia en el área a controlar y la cantidad y calidad de personal que permita ofrecer un servicio profesional, eficiente y justo a tiempo.

Kenneth Astorga

NORTHWIND TECHNICAL SERVICES

This article was originally published on PetFood LatinoAmerica Website on December 17, 2018.

PID Control Loops

Sun, 12 Feb 2017 07:43:00 GMT

PID control loops can be very useful in automation and in many different applications.

Fine-tuning PID loops

There are a couple ways to fine-tune PID loops. If you have a system model, you can calculate the necessary gain values which would make the tuning process easier. There is also the Zeigler Nichols method which uses an overall system gain and which then gives you equations to calculate the specific KP, KI, and KD gains. Without a system model or some of the info necessary to use the Zeigler Nichols method, your only option is to watch the process variable change and make small changes to the gains based on your observations. Some best practices when tuning a PID loop this way are to start with KP to get the response needed out of the system. Once you have the desired response move on to KI, and KD, correct any steady state error and setpoint overshooting.

PID control loops can be very useful in automation and in many different applications. They can be used to control a feeder used in a loss in weight or gain in weight system, or to control pumps that need to run to a setpoint. They can also be used in motion applications with different position targets while maintaining the position against external forces. To illustrate the functional flexibility of PID control loops, I will describe a parallel PID implementation. This example is illustrated below with a block diagram of this control algorithm.

Malware and Your Industrial Control System

Sat, 12 Nov 2016 17:11:00 GMT

Malware and Your Industrial Control System

Most of us have had the unfortunate experience of getting malware on our personal computers. Removing some of these nuisances can be as easy as running a simple virus scanner. Others can maliciously take over a computer and make it impossible to use. While this malware is troublesome on a home computer, it can be disastrous to an industrial control system (ICS). With access to an ICS, a threat actor could take down critical computers and cause costly downtimes, or they could go a step further and take control of equipment which could result in property damage or injury to personnel.

According to a recent Booz Allen Hamilton report, the top three industries targeted by malicious software attacks in 2015 were critical manufacturing (33 percent), energy (16 percent), and water and dams (11 percent). The majority of these attacks came from Nation-State groups, which are groups that operate under the direction of, or in coordination with national military and intelligence services. The top offending Nation-States are Russia, North Korea, Iran, and China. Of these countries, China is the most likely to attempt to gain access on U.S. networks primarily with the intent of intellectual property theft. North Korea is the most likely to attempt a destructive type of attack.

According to the report, ICS operators reported 50 more security incidents in 2015 than in 2014, an increase of 20 percent and more than any year prior. Taking a step back, this information isn’t all that surprising. Industrial control systems are becoming increasingly connected in order to allow data collection and system monitoring. This unfortunately also creates an increase in the number of targets of opportunity. In many cases the benefits of connecting these systems justify the risks, but it is necessary to be aware of the potential dangers when designing the operational technology (OT) network that the ICS resides on.

System security is not measured in black and white terms of secure/not secure, but is measured on a “more secure/less secure” continuum. The only way to know your systems are protected from outside intrusions is to create an “Air Gap”, i.e. disconnect the network completely. However, to be completely disconnected is not an ideal solution in most cases. An understanding of the risks that are involved and an attempt to mitigate those risks is necessary when connecting the IT and OT networks.

Mitigation of risk involves more than simple IT steps, like setting up a firewall and applying patches. It must also involve creating an incident response plan and training personnel. It can be thought of as being similar to protecting against fire damage. You build a building to prevent a fire from happening, but you still install exit signs, train people on fire prevention, install fire extinguishers and sprinkler systems, and inform staff of what to do and how to act quickly if a fire does start.

Examples of risk mitigation steps to take on the IT side include proper firewall configuration and keeping system patches updated. Also, a planned network architecture with segmentation is a good way to isolate intrusions to one area. Since the IT network is an easier point of attack than the OT network, it should be viewed as a potential threat entry point to the OT network. There should be a “demilitarized zone” (DMZ) between the OT network and the IT network to prevent any intrusions from spreading from one to the other. All traffic between the IT and OT should terminate in the DMZ. See the Purdue model below.

An example of an area where training can be helpful in risk mitigation is in teaching staff how to spot suspicious emails. Booz Allen Hamilton reports that spearphishing emails were the primary means of attack in 2015. Making sure people are aware that emails can be dangerous, helping them know what clues to look for, and that emails that seem odd should be reported, is the first line of defense against spearphishing. Activities such as email and internet browsing should be restricted to the IT network, but preventing them on the IT network altogether is a good step toward keeping threats from spreading to the OT network.

An incident response plan is an excellent tool for effective responses to malicious attacks. Things that might be included in such a plan include who to call in case of an intrusion, network and data flow diagrams, logging information, etc. Any affected devices should be immediately isolated from the network and the internet until they can be assessed. It is also important to know how to not tamper with potential evidence.

There are many benefits that can be derived from connecting the OT network to the IT network such as data collection and system monitoring. It can provide insight into how the ICS is operating and how it can be improved. When making this connection, however, a plan should be laid out and the risks identified. The network should be properly segmented to prevent an intrusion from easily spreading to other parts of the plant, an incident response plan should be defined, and personnel should be informed of the plan. Only then will your ICS be “more secure”.

Temperature Measurement in Industry

Fri, 12 Feb 2016 10:17:00 GMT

There are many different choices that can be made when selecting temperature measurement devices for industrial systems. When faced with these decisions, there are many factors to consider: accuracy, sensitivity, price, temperature range needed, etc.

This article will discuss three types of temperature measurement devices, a brief description of how each works, and some of the benefits and downfalls to each based on the way they are used to measure temperature.

Thermocouples

In industrial applications, thermocouples use two wires made from different materials that are joined on one end to create a voltage difference at the opposite end of the wires. The temperature difference along each wire creates a magnetic field which varies for each because of the different materials used in the two wires. The two magnetic fields cause a voltage potential to be generated at the unconnected end of the wires. For PLC applications, this potential is measured by the processor. Most I/O cards used to measure temperatures via thermocouples will have pre-programmed values for the rate of change of the measured voltage versus temperature. For Type J thermocouples, made using iron and constantan wires, this rate of change is approximately 50µV/ºC. This is then used against the known temperature at the I/O card to calculate the temperature at the mounting of the thermocouple.

This is where CJC’s (cold junction compensators) come into play. CJC’s are essentially additional thermocouples used to measure the temperature at the I/O card. If no CJC is used, there is no temperature to reference against, making the voltage signal received from the thermocouple essentially useless. This also shows why using the correct type of wire is so very important in industrial applications. If a Type K thermocouple is installed, but copper wire is used to connect to the measurement device, the magnetic field that is created across the two copper wires should be essentially the same so no voltage will be generated by these wires. The magnetic field created across the two thermocouple wires will be created by the temperature difference between the place where the wires join and the end of those wires. The temperature at the end of these wires will likely be much different than the temperature at the PLC cabinet causing errors.

Any corrosion or interference from other signals will have a large effect on the accuracy of the measurement with thermocouples. Corrosion can cause the magnetic field created by the temperature difference across the wires to be much lower than expected and the very low voltage signals are highly susceptible to interference. Like most temperature measurement devices, the relationship between the measured signal and the temperature is not actually linear, but it assumed to be so, which can also be a source of some error. However, since wire is essentially the only limiting factor, temperature ranges for thermocouples can be very wide making them useful for applications where very high or very low temperature measurements are necessary.

RTD’s (Resistive Temperature Devices)

RTD’s use the measured resistance of a coil of wire to calculate temperature. PT100 RTD’s are the most common type of RTD used in industrial applications. PT100 RTD’s are made with a platinum wire coil and 100 is the measurement of the resistance of the device in ohms at 0ºC. Nickel and copper are other materials that may be used for an RTD coil.

RTD’s come in two, three, or four wire configurations. Two wire RTD’s are the simplest, with the two wire being the opposite ends of a single resistive element used to measure the temperature. Three wire RTD’s add one more wire which is used to compensate for the resistance of the wire lead running from the instrumentation out to the RTD in the field. This is essentially achieved by measuring the resistance between the two wires that are on the same side of the RTD and subtracting it from the resistance measured across the device. Four wire RTD’s essentially take two different measurements of the resistance and use them to eliminate any thermocouple-like magnetic effects caused by differing wires or any voltage drop issues that may come from long lead lengths.

Temperature is calculated for RTD inputs using what is called the temperature coefficient of resistance of the material used for the RTD. Generally this must be specified in the measurement device at set up. One common value used is Platinum-385, which has a temperature coefficient of resistance value of 0.00385/ºC. This means that for the PT100 device mentioned above, the slope of the chart for resistance versus temperature will be approximately 0.00385% or R=0.385(T)+100. At 50ºC, the measured resistance would be approximately 119Ω.

RTD’s use the temperature coefficient of resistance calculated between 0ºC and 100ºC. This along with other factors limits the temperature range at which RTD’s may be used as compared to thermocouples, while still being wide enough for most applications (-300ºF to 1500ºF for PT100-385 for example). RTD’s have a fairly slow response time, so for rapidly changing temperatures, other measurement devices may be preferable. However, RTD’s are very accurate for most temperature ranges in industrial applications and can last much longer with fewer irregularities than many other temperature measurement devices.

Thermistors (Thermal Resistors)

Thermistors are identical to RTD’s in concept but differ in material used. Thermistors are typically made with ceramic elements rather than metal which changes resistance with respect to temperature. Thermistors usually have a very broad resistance range as compared to RTD’s (on the order of between 4kΩ and 100kΩ over the range of 0ºC to 100ºC for a 20kΩ thermistor.) The rating of thermistors also differs from RTD’s in that a 10kΩ thermistor has that resistance value at 25ºC rather than 0ºC like the rating of RTD’s. NTC (negative temperature coefficient) type thermistors are commonly used in industrial applications. This means that as temperature increases the resistance of the device will decrease.

Measurement of temperature using thermistors is more complex since the relationship between resistance and temperature is very non-linear as compared to the same relationship in RTD’s or thermocouples. This severely limits the temperature range at which thermistors can be used. However, thermistors typically can achieve good accuracy and have a much higher sensitivity than RTD’s within the limited temperature range at which they can be used (approximately -130ºF to 250ºF.) This makes thermistors good for applications where there are rapid changes within a narrow temperature range.

Conclusion

When choosing a temperature measurement device, it is important to consider all factors and specific conditions of the application. If high accuracy is desired and cost is less of a factor, using an RTD would probably be recommended. If accuracy is less important, then a thermocouple could be more beneficial. Whichever way that you go, it is useful to understand how your temperature measurement device is operating. Hopefully after reading this article, you will be a step closer to achieving your goal.

Considering the Options – Pushbutton vs. HMI Display Controls

Tue, 12 Jan 2016 10:13:00 GMT

Those of us that are familiar with controls systems have seen some of the benefits that can be gained when using a human machine interface (HMI) vs using a simple pushbutton control panel. Some of the main benefits an HMI provides include increased efficiency, safety, and overall functionality. While a pushbutton panel is easily understood and simple, it can be severely limited in the level of complexity of the systems it can handle. Another limitation is that the efficiency of a pushbutton panel depends solely on the experience of the operator.

Pushbutton Control Panels

Plants have been running for ages using pushbutton equipment control. This method is well understood by the people who operate these systems and their efficiency is directly tied to the experience, proficiency and focus of the operator. Because pushbuttons are simple, it is sometimes an inexpensive solution for use in small systems. Ideally, a pushbutton panel is used on a simple system with just a few pieces of equipment. For example, it may be easier to understand and functionally adequate to run a small vacuum and receiver system by simply using a “start/stop” button.

Pushbutton panels begin to exhibit shortcomings when the system grows to more than just a few pieces of equipment. With multiple machines in operation, it is not always clear which machine is running at any given time and this can make diagnosing issues a nightmare. Another shortcoming of pushbutton panels is that it is hard for new workers to learn how different operating systems interact with others on the plant floor. This can lead to increased training time and lower production as a trainee is learning to use the system. Further limitations of pushbutton panels come in the area of documentation. Because there is no display available on the panel, it is often necessary to go to each piece of equipment in the plant to document weights, flow rates, etc. Also, in order to troubleshoot a pushbutton panel, the panel door must be opened. This can lead to safety hazards with live voltage or difficulties troubleshooting if the panel is powered off.

Maximizing production and testing is also easier using HMI’s because many values can be altered through the display. It is possible to set the display to show all of the data a user may need to document including production levels and efficiencies. Lot tracking, weights, flow rates, and trending information are some of the more common types of information that are documented with an HMI. The HMI can also be designed to include faults and warnings in order to more easily troubleshoot problems. In fact, the capabilities of HMI panels can exceed the actual needs of a system.

The program file for an HMI display can be developed concurrently with the project electrical installation. This can lead to reduced lead times since the file can be installed during the system start-up phase. With large and complicated systems, wiring for an HMI panel can also be a much cleaner and safer affair. Since only an Ethernet cord needs to be run to the door of the HMI panel, the amount of wiring is greatly reduced compared to wiring a large number of pushbuttons that would otherwise be needed to obtain similar functionality.

Some of the shortcomings of an HMI are higher cost and potential deterioration in abusive environments. For systems where harsh chemicals are used or other inhospitable conditions exist, the more rugged pushbutton option may be recommended. A way to circumvent this is to use a pushbutton panel in the abusive area linked with an HMI panel located in a more accommodating environment. While most HMI’s are fairly sturdy, the display screens may not be able to stand up to prolonged abuse. And while HMI panels offer increased functionality, they simply may not be cost effective for very small systems.

Retrofitting Pushbutton Systems

It is almost always better to decide at the beginning of a project (during the design phase) to use an HMI rather than to add one in later. However, it is possible to retrofit an older pushbutton panel with a display in order to gain the advantages of an HMI. When changing from a pushbutton to an HMI panel, physical copies of drawing packages can be condensed into the program file on the display. This allows the user to easily find I/O and tag information that is otherwise difficult to find. In addition, while drawing sets can be lost or damaged during normal production, the program file in an HMI provides a more stable platform to store information.

Since an HMI display often reduces the required size of the panel, it is usually unnecessary to purchase a new panel. A retrofit may simply require that a new door be ordered to eliminate the holes left by buttons and accommodate the HMI display screen.

Summary

In summary, the main benefit to using a pushbutton panel comes in the form of simplicity and cost savings, especially for small, simple processes. However, this is generally only true on systems that can be run with fewer than 8-10 buttons. While an HMI can be more expensive to implement, it is possible to manage much larger systems through the use of a screen. In addition, documentation and information availability is much greater and easier with a system display. An HMI display can also provide greater safety than pushbutton panels. The decision about which type of control panel will be right for a project should therefore be based on the size of the system to be controlled, how much functionality the system will require and the project budget.

HMI Control Panels

As factory processes and control systems grow more complex, it is apparent that having a graphical display on control panels becomes the best solution in almost all cases. Also, systems that need to communicate with each other, such as an extruder/dryer system, require a display in order to run efficiently. In most cases, an entire system with multiple pieces of equipment can be run from one well integrated HMI display.

Job Site Safety: Working With Control Panels

Sat, 12 Dec 2015 10:42:00 GMT

We are all aware of the dangers of electric shock, but few realize how little current and how small voltages can cause a fatal shock. Current as low as 30mA can be fatal. Since a standard toaster uses about 12500mA, you can see that the threat of electric shock is ever present. However, using the right tools and safety procedures can greatly reduce this risk.

When working with electrical panels, a “lock out-tag out” procedure is an easy way to quickly reduce hazards and should always be enforced. If possible, de-energize circuits prior to working on or near them. Unfortunately, when working with control panels in a manufacturing facility that is in production, this is not always an option. In this case, wearing the correct protective gear appropriate for the panel rating is very important.

The Importance of Protective Gear

Wearing flame resistant clothing, removing watches and other jewelry, wearing insulated gloves, safety glasses or a face shield, and using insulated tools are all great protective ware. So, how much and what kinds of protective gear should be worn for each panel rating? The best way to answer this question is to research safety standards and stay up-to-date with the most recent standard releases found in NFPA 70E Article 130.

There are 5 hazard risk categories that require different protective gear (category 0 through category 4). According to NFPA 70E Article 130, a category 0 task will require you to wear long sleeves and long pants of a non-melting material along with safety glasses and hearing protection. Operating a circuit breaker with covers on it would fall into category 0.

Category 1 will require Arc-rated clothing of at least level 4 along with hard hat, safety glasses, hearing protection, insulated leather gloves, leather work shoes and an arc rated face shield. Voltage testing of live circuits under 240 V will fall under a category 1 task. It would also require the use of insulated hand tools. For information about protective gear for other categories, use Article 130 referred to above.

Working with Live Circuits

Always make sure to visually inspect all tools before using them on a live circuit. Also make sure the meter is correctly rated for the circuit you are testing. Connect the ground lead first then the hot lead. When finished, remove the hot lead first then remove the ground lead. It is also a good idea to hang or rest the meter in a secure location and avoid holding it in your hand in case of a meter fault.

Communication and Coordination

Communicating and coordinating with the people in your work environment to make the area as safe as possible is essential. Making people aware of the work you are doing in that area. Putting together a plan and discussing it with others on-site is a good way to ensure that everyone is cognizant of what is happening. You have to think about everyone that could come in contact with the work being performed. Use orange cones and caution tape to guide people away from hazardous work zones.

Safety is one of the most important issues of working with electricity on any site. A little planning and attention to safety during implementation is all it takes to make a safe work environment.

24VDC vs 120VAC

Mon, 12 Oct 2015 10:38:00 GMT

In the process of designing and purchasing new equipment, the decision about what digital control voltage to choose for a facility to standardize on is often not clear cut. Manufacturers, control engineers, plant personnel and other decision makers can lean different directions with reasons ranging from specific design requirements to personal preference. There are a multitude of different options, but by and large the two most popular options are 24VDC (volts, direct current) and 120VAC (volts, alternating current). Both 24VDC and 120VAC powered devices are readily available and each have their advantages and drawbacks.

Starting with the more familiar of the two, 120VAC is the legacy control voltage. It is robust, reliable, and has a very broad existing installation base. With a higher potential voltage, voltage drop over long distances is seldom an issue and current requirements are smaller than lower voltage systems. 120VAC is often produced by a step-down transformer from 240V or 480V, and being a passive device, these transformers are very reliable.

However, 120VAC does have one large disadvantage — this level of voltage can be dangerous and potentially lethal. This risk is compounded by the fact that wide accessibility of 120VAC has desensitized us to the danger, leading many electricians and maintenance staff to underestimate the power of 120VAC. Although 120VAC poses little arc flash hazard when compared to common main power voltages such as 240V and 480V, there is still a very significant shock hazard. Because of high levels of access and disregard for safety measures, more people die in the United States from 120VAC shocks than any other voltage. Personnel don’t have to wear arc flash suits will working with this voltage in live panels, but they do need the proper shock resistant PPE (Personal Protective Equipment).

Unfortunately, the risk does not exist only at the control panels. It exists out on the plant floor at every piece of equipment wired to the control system. The risk is especially high on 120V control sensors. If the control system is on, voltage is always present in these locations even if the equipment is not running. The temptation is very great for personnel to adjust or reposition a sensor without turning off the control panel or putting on proper PPE. Often there is no immediate consequence to this action until an internal short or an exposed wire presents an increased shock risk.

Conversely, 24VDC’s main advantage over other voltage levels is safety. No arc flash hazards are present and the voltage is low enough that the shock hazard is almost negligible. But make no mistake, electricity is not a toy. If a perfect storm of bad conditions presents itself, it is still possible for 24VDC to be lethal. However this perfect storm will not be present in a properly designed control panel, so it is safe for personnel to work in such a panel without any additional electrical PPE equipment.

24VDC’s low voltage does come with some draw backs as well. Unlike 120V, 24V will suffer from voltage drop issues much sooner over shorter distances. The problem can be remedied with larger wire, but if we get a little more creative, there are other solutions available. If voltage drop problems show up after wires have been pulled, a technician can increase the voltage generated by the power supply. It is important to check your system’s specifications, but many DC control systems are rated from 10-30V. This allows you to squeeze a few more volts out of the DC power supply and still leave room for over-voltage conditions. If you have the opportunity to influence the system design, voltage drop issues can also be solved in the engineering phase. New PLC schemes are available with remote or distributed I/O architectures. In this setup, I/O racks are located nearby equipment then communicated back to the PLC via a protocol such as Ethernet/IP. This reduces the length of wire runs required, solving voltage drop issues and providing savings on installation costs in the process.

Another potential downside of 24V control voltage is that lower voltage leads to more current. Solenoids with high power requirements such as large motor starters will draw substantially more amps at 24VDC than 120VAC. In addition to higher amperage requirements, these solenoids are often sold at a premium over 120V solenoids.

With the pros and cons to each voltage laid out, it is worth mentioning that there is risk involved in mixing voltages. Effort should be made in all installations to standardize on one control voltage and use it for all sensors and devices. Though some engineers attempt to obtain the best of both worlds by placing 24VDC on inputs (sensors) for safety and 120VAC on outputs (solenoids and devices) to avoid voltage drop and high current difficulties, this design style should be avoided. In addition to creating more points of failure, mixing and matching control voltages creates a headache for future personnel trying to sort through which devices are on which voltages.

At the end of the day, decision makers need to review comments and concerns from all involved parties when faced with the choice of control voltage. Often if new equipment is being placed into an existing plant standardized 120VAC, it makes the most sense to remain consistent throughout, continue to use 120VAC in equipment upgrades and provide additional electrical safety training to personnel. Most greenfield plants elect to utilize the emerging 24VDC as a plant wide standard. In between the two ends of the spectrum, this decision requires a lot of thought and careful planning. Jim Schmelzle, Service Technician

The Importance of Protective Gear

Working with Live Circuits

Communication and Coordination

Safety is one of the most important issues of working with electricity on any site. A little planning and attention to safety during implementation is all it takes to make a safe work environment.

Aging Control System Equipment

Fri, 12 Jun 2015 11:05:00 GMT

We all have one or know someone who does — that old transistor radio that Grandpa used to listen to the baseball games with, or the old game console we had as a kid with graphics we cannot help but laugh at today, yet want to play because of the memories it evokes.

These old, obsolete electronics may be quite valuable to a collector or to the owner for the memories. In the industrial world, however, there is no such thing as collectible or sentimental value, just real production value. As your automation electronics age, the risk of failure increases along with the associated downtime. Downtime that can increase exponentially with each passing year.

For some items, it may only mean a trip to the parts shelf for a quick replacement. Other failures will require a trip to the local distributor or an overnight shipment from the manufacturer. But what about the part that was discontinued years ago? What if that part is a PLC? Do you have a copy of the program? Do you have the software to program a replacement, if one is found? If so, is there a computer that will even run that software? If not, do you have a resource that can quickly help you.

There are many aging systems in operation, and there are a variety of reasons they get overlooked:

Current personnel don’t know or understand the system and its requirements. Knowledge of the system may have left with retirement, downsizing, death of key employees, etc.
Cost of replacement is not in the budget. Components and labor costs are high, so we squeeze everything we can out of the old equipment.
Complacency takes over. “It has never given a bit of trouble before,” or “If we ignore it, hopefully we won’t have to deal with it.”

We all are trying to get the most possible from every system, but do we truly understand the potential problems that lurk within older equipment?

Have you taken the time to really evaluate each system?
Do you have personnel that are truly qualified to determine the requirements for replacement? How many times have we looked at a project and thought, “This is a 20 minute project,” and 2 hours later we are only half way done?
Can upgrading the equipment actually improve our efficiency and/or quality?

The true cost of an equipment failure is not just the cost of the part and the labor, but also the lost down time. It is no secret that planning ahead and scheduling the replacement of aging equipment can save money in all aspects of production and can actually save money with increased efficiency.

Don’t hesitate. Call someone today who can properly evaluate your system and give you a realistic evaluation of your aging equipment. The savings could be huge.

Inventory Tracking – A Real POWER Tool

Thu, 12 Mar 2015 10:55:00 GMT

So what is inventory tracking? It is a tracking system that utilizes software which enables companies to manage and track raw materials and products as they go through different stages of the production process. This software utilizes different tools and methods such as barcode scanners, RFID tags, manually inserting data, and others to collect the necessary data. The data that is collected allows production managers to create reports and view trends on the materials being used and products being made. That information promotes more informed decisions about when and how much of a material to order. It can also help with production scheduling, as well as understanding what products are selling the best.

Inventory tracking utilizes a database to store a wide variety of specific details about raw materials, products being made, and who receives the finished products. Some examples of details that can be useful in the raw materials database include: a complete list of raw materials, who the supplier is, the date and amounts of materials were received, the price paid for each, and even an expiration date if the material is a perishable item.

With this information, production managers can also create a products database. Some useful information that might be stored in this database are: complete product lists, when and where each was produced, what materials were used in making the product, how long a product has been in the warehouse, as well as when and where finished products are shipped. You can also run reports and view details about what raw materials were used to create batches of products. This allows production managers to apply recalls to a more specific range of products should it become necessary. This can significantly reduce the negative impact a recall has on the company.

This may sound like a lot of information to collect and keep track of. But as mentioned previously, there are many different ways to obtain this information and get it into a database. I will discuss two of the best methods: the barcode scanner and RFID (Radio Frequency Identification).

Barcode scanners allow you to simply place a barcode on items as they are received and scan them into inventory. If this item has been received before, scanning each new shipment will add another entry into the database with the current date and time, linking it with the specific material has been received, you will need to enter basic information about the material to the database. Barcodes can also be used during production. Raw materials that become part of a finished product are simply scanned as they are used, and the database is automatically updated.

Inventory tracking is a very important and powerful tool for many industries. Knowing what inventory is on hand and being able to track product trends allows the business owner to better forecast what they need to produce and when. This allows production resources to be focused where they are needed most, eliminates delays, and makes for a more consistent product flow which can lead to higher profits.

Advantages of Ethernet Devices in the Industrial World

Thu, 12 Feb 2015 16:58:00 GMT

The use of Ethernet technologies is penetrating almost every application in industrial automation. The generalized Ethernet communication connection allows the transfer of data through cables composed of multiple twisted wires, similar to a home network. EtherNet/IP is a communication protocol that uses the framework of standard Ethernet data transfer to communicate specific information for manufacturing applications. EtherNet/IP is the industrial Ethernet protocol supported by the Open Device Vendor Association (ODVA), and is becoming the standard of many organizations for full plant data communication.

Many industrial facilities rely on Programmable Logic Controllers (PLCs) to conduct the majority of the automation activities. Ever since its introduction in the 1960s, PLCs have revolutionized the capabilities and space of all applications. All industries including Plastics, Food & Beverage, Infrastructure, Oil & Gas, Pharmaceuticals, and Electronics rely on the common notion of signal transfer from one source to another. In the past, most industrial plants relied on either 4-20 mA or frequency outputs to transmit instrument control. Although this practice has been proven functional, the simplicity of one way signal is a major downfall. Ethernet networks, on the other hand, provide industries with the ability and tools to overcome complex process control and monitoring obstacles. Material flow metering, variable frequency drives, high accuracy scales, and safety control modules, are just some of the tools currently used today that are trending and evolving into more diverse and user friendly models using EtherNet/IP communication.

All flow meters, be it orifice plate, magnetic, or coriolis, need to transmit data through an indicator to be useful. For example, an indicator can be configured to read flow rate, total liquid transferred, or instantaneous flow rate. Due to the limits of one-way 4-20mA signal output, many indicators were previously able to only report one of these readings. However, when indicators are equipped with an EtherNet/IP module, they are able to also report process flow information along with density and temperature of the fluid. Additionally, some meters can provide diagnostics which verifies that the meter is working accurately and within specification.

Variable frequency drives (VFDs) provide the ability to change the speed of a motor by varying the frequency and voltage of the supplied power. While some drives are limited in the number of different speeds they can output, EtherNet/IP embedded drives possess the ability to provide an infinite number of speeds on a common 0-60Hz frequency. All drives operate on a set of given parameters which may include metering, setup, frequency settings, diagnostics, faults, and process display. EtherNet/IP based VFDs allow most of these parameters to be accessed remotely over a network. Full load amps, torque values, energy usage, and reference speed, are valuable information which can be monitored thanks to the help of Ethernet communications.

Industrial scales rely on load cells to monitor weight. A load cell is a unique type of transducer that translates strained force into a measurable electrical output which is then translated into a meaningful measure of weight by an indicator. Many indicators serve as a main display of weight and provide the means for calibration and noise filtration. EtherNet/IP embedded scale indicators take a step further and provide the ability for remote monitoring, calibration, and setup of the indicator and scale. The finalized configuration file can then be transferred from one unit to another.

Another major advantage of EtherNet/IP devices is realized when it comes to installation. Previously, installations that would have required 10-15 wires can now be replaced with a single shielded cable from each device. Many manufacturers of Ethernet embedded equipment also provide the ability to save and export the configuration file which governs the function of a device. This configuration file can then be distributed to any identical unit. What this means to an industrial plant equipped with Ethernet embedded equipment is that the downtime accrued when a device fails is often drastically reduced.

It should be noted that standard continuous Cat5e Ethernet cable has an effective range of approximately 100 meters. Before a cable reaches this limit, the signal will need to be repeated by a switch. Adapters can also be added to a network to transfer information through a fiber optics connection and still use the EtherNet/IP protocol.

EtherNet/IP is one of the leading industrial Ethernet networks used globally. Look at any consumer product used today and chances are, an EtherNet/IP device was used to make it. Because of its many advantages, the use of EtherNet/IP will continue to expand the efficiency and potential of industrial automation.

Allen-Bradley and PowerFlex are trademarks of Rockwell Automation, Inc.

What is a Lot Number and Why Do I Care?

Mon, 12 May 2014 11:09:00 GMT

We hear a lot about product recalls these days. Everything from cars to children’s toys to dog food gets recalled for various reasons. Sometimes you get a notice in the mail telling you that to take your car to the nearest dealer to have them apply a fix for some manufacturing deficiency. Other times you may hear in the news that toothpaste or some other product with a certain code stamped on it has been recalled, etc.

So how does a manufacturer know that a certain bag of chips or a particular vehicle has a manufacturing or safety issue? Of all the tubes of toothpaste made or cars produced, how did they know to recall a certain item? The answer can be found in LOT TRACKING.

Similar to a serial number which identifies a specific item, a lot number is a code (or codes) that identifies a defined quantity of material throughout the manufacturing and distribution process. Product with the same lot number is manufactured by the same equipment using the same raw material components during a specific time period.

Why does this matter?

Lot numbers play a key role in quality assurance. Manufacturers test material for quality. If a material fails to meet acceptable levels, lot numbers are the key to finding and identifying what was potentially affected by the defective product. Product with the same lot number is considered bad, whether the defect is due to a component defect or a manufacturing process equipment malfunction.

For example, consider a tube of toothpaste that fails to meet quality standards because of a contaminated ingredient. Because tubes with the same lot number were made with the same ingredients, all tubes of toothpaste with that lot number are also considered bad. However, the contaminated ingredient could have been used to make toothpaste with different lot numbers as well. The toothpaste manufacturer will have to identify all toothpaste lot numbers that were made with the contaminated ingredient. Using lot number tracking, the manufacturer can alert their customers to the bad products and know for certain which tubes of toothpaste should be recalled even after they have been distributed around the country.

Challenges of lot tracking

As you can see, the traceability of lot numbers can quickly become quite complex. A manufacturer may be tempted to take shortcuts to simplify the process. For example, a company may consider an entire month’s production as a single lot number, but this can result in undesirable consequences. An entire month’s production may have differences in composition and been manufactured on different equipment. In this case, if they need to notify customers about a defective product, the smallest distinguishable group is a whole month’s worth of production. This can be very costly.

Different manufacturing processes require different methods of lot tracking. An item made up of unique, traceable components can be tracked as a single lot number or serial number. A car is a good example of this. Other processes involve mixing specific quantities of raw materials to make batches of product. These batches can be assigned convenient lot numbers for traceability. A third type of process requires mixing specific rates of raw materials together with extensive processing to continuously produce a stream of product. Here, lot numbers typically are assigned to product that is produced over a specified period of time.

Handling bulk materials presents unique tracking challenges. Bulk material can be delivered in small individual packages or placed in large storage silos. A large storage unit can contain material with multiple lot numbers or materials from different vendors. During production, portions of material in a silo or tank can be transferred out to other containers. As a result, bulk material with different lot numbers may become mixed, both purposefully and unintentionally. Even when empty, a storage container may need additional cleaning steps to completely remove trace elements from previous lots, especially for material that could be allergenic, toxic or reactive.

Here’s an example: liquid oil can be purchased in small totes, each with a different lot number. These totes can be pumped into a large bulk storage tank, resulting in a mixture of oil with different lot numbers. In this case it is important to understand how lot numbers are tracked and reported. As liquid is pulled out of the tank, it will be a mixture of all lot numbers added to the tank since it was last completely emptied out. In practice, it may not be practical to completely empty a tank. This causes a continuous buildup of lot numbers in the tank and reduces the effectiveness of the lot traceability program.

To deal with these kinds of situations, manufacturers use different models of how material mixes to determine when the amount of material with a particular lot number becomes a negligible factor. For liquids, assuming a perfectly blended mixture of all the materials is usually the most accurate. When the fraction of material with a particular lot number becomes lower than a certain threshold, it is assumed to be a negligible component. Dry bulk material in a storage silo often tends to rat hole from the top to the bottom. In these situations, a last-in-first-out model of tracking lot numbers is effective. Specially designed mass-flow silos are sometimes used so that material moves through the silo in a first-in-first-out manner.

Understanding the Different Types of Pneumatic Conveying

Wed, 12 Feb 2014 17:07:00 GMT

Understanding the Different Types of Pneumatic Conveying System

Lean phase pneumatic conveying uses a high volume of air at low pressure to move product. Most often a fan is used to create sufficient pressure to move product with an air to product ratio of less than 1:1. Lean phase conveying uses air velocities that are above 4000 FPM and often as high as or greater than 5000 FPM. This combination of high velocity/low pressure allows you to use air to do things other than just convey product. One example of this use of air is to control the temperature of the conveyed product. This could be as simple as cooling the product down to finely controlling the temperature going from one stage to the next. With high airflow velocities, the material being conveyed is actually kept in the center of the pipe with the main air flow in suspension flow. The lower pressures in lean phase systems also have a much less drastic impact on the conveyed material should pressure of any area of the line dramatically decrease.

Understanding the three different types of pneumatic conveying will enable you to keep material flowing at the best possible rate. By utilizing the right form of pneumatic conveying for your material and application, you will be able to move your product in a stable and continuous flow.

Dilute phase pneumatic conveying often uses a PD blower to move less air but at a higher pressure than lean phase conveying. This higher pressure allows dilute phase conveying to move some materials at a product to air ratio as high as 7:1. The pressure is kept at less than 15 PSIG thus allowing this type of conveying system to utilize velocities of 3600 FPM or greater. Dilute phase also uses suspension flow similar to lean phase.

Dense phase pneumatic conveying often uses compressed air to push dense slugs of product along the line. It typically uses pressures less than 60 PSIG but pressures can potentially be much higher. Because compressed air is pushing material along versus keeping it suspended in the pipe, air velocities are typically less than 2000 FPM. Since the air is pushing the product in one slug, the product is not constantly hitting the inside of the pipe, thus dense phase conveying can keep more complex products intact over longer runs. With this type of conveying system, the product to air ratio is very high. In order to stay in dense phase the ratio must be kept above 20:1 and can be as great as 100:1 depending on the type of material being conveyed. If this ratio goes below 20:1, the product will likely enter dilute phase and break out of the neatly packed slug.

The materials you can convey with a dense phase system is limited. Products with particles that are all larger than a half inch in diameter will not work well in this type of system because the air tends to go around the particles instead of pushing them. However, products with particles of varying sizes may work even if some are larger than half an inch. Dense phase systems can utilize very high product to air ratios, but these ratios must be consistently maintained in order to prevent the system from slipping into dilute phase velocities. Though dense phase systems cannot handle many product mixes with larger particles, lean and dilute phase systems can handle almost any material particle size and shape. Also, since the pressure is so great with dense phase systems, the last slug of material going through a pipe will likely burst into its final destination if pressure is not carefully controlled and adjusted at the end.

With so many ways to convey product in a pneumatic system, knowing how each of these systems work as well as their capabilities and requirements will allow you to choose the best system for your application and material so you can move material faster and more efficiently.

Introduction to BatchMATE™ & Its Applications

Sun, 12 Jan 2014 11:45:00 GMT

From the beverages and snacks we consume to the treats we feed our pets, most consumer products are made in large quantities in a manufacturing facility. These industrial facilities can generate thousands of pounds of product per hour to meet consumer demands. In many cases, nutritional components like vitamins and minerals are added to these products. These components are usually weighed manually since they may comprise only a small fraction of the total weight of the ingredients. When any ingredient is scaled by hand, it is fundamentally important to have a system in place that guides an operator through the weighing process and records all pertinent information cleanly and efficiently. Weighing, recording and displaying the information for critical hand-add ingredients is where BatchMATE™ a new product from NorthWind Technical Services, truly shines.

BatchMATE™ is a batching system developed by NorthWind to aid in the scaling of micro ingredients. Many bulk ingredients are weighed with industrial equipment using pneumatic conveying and mechanical handling machinery. While large equipment can handle large quantities of product efficiently, management of “micro” batches can be difficult. Micro mixtures are commonly composed of individual ingredients that weigh less than 15 lbs. BatchMATE™ offers many features specifically designed for accurately working with small mixtures. These include: multi-scale capability, printed labels, barcode integration, user security, Ethernet capabilities, standard reports, and components aimed for different environmental ratings.

Multi-scale capability is important when encountering different ingredients that have strict requirements that differ for each other, factors include scale accuracy, resolution, and size. To illustrate: a target vitamin mixture may require a minimum of 0.5% scale error, the mixture contains a total weight of 10 lbs. and its individual smallest ingredient size is 1 lb. In this specific scenario, a scale platform with a max capacity of 12lbs and 0.005lb resolution will achieve the target. If the same system is also used to weigh a second larger vitamin mixture with a total weight of 50 lbs. and the smallest ingredient size is 15lbs, then a larger scale is required. In this new case, a separate scale with 60 lbs. capacity and 0.01 lbs. resolution would meet both tolerance and size requirements. BatchMATE™ can be configured with multiple scales of different capacities and resolutions to maintain specific ingredient tolerances. This allows for versatile configurations and opens up the system’s use to different sets of ingredients.

Operator guidance plays a crucial role in the accuracy of every batch. The system lists all of the ingredients necessary for the mixture, it allows the operator to gather all of the necessary ingredients prior to operation. The step-by-step instructions will guide the operator throughout the weighing process, messages on the screen will prompt the operator to clean the scale area, scan any ingredients and lots numbers, place the container on the scale, and how much material to place on the scale.

BatchMATE™ displays the material target and deviation away from set point based on user-defined tolerances. When the scale reads a weight outside of the tolerance values, it displays a warning to alarm the operator into adjust the scaled amount. The step sequence that displays the messages is incorporated in the standard version of BatchLOGIX™ and can be manipulated to mimic any production instructions. Printed labels are necessary when it involves quality assurance and ingredient tracking of a product. BatchMATE™ comes integrated with a standard version of BatchLOGIX™, which allows a quality assurance representative to reference a printed label and use it as an entry point to research details on a specific batch. BatchMATE™ is configured to print labels at the end of every batch. The label can be used to search the batch’s date and time, batch ID, ingredient setpoints and amounts, lot information, and final total weight. When applicable, labels can be configured to interface with existing blending systems for full plant-wide lot tracking. Printers can be configured to different label sizes and can accommodate different paper qualities for a variety of applications. For instance, in food grade facilities, it is preferred to have a direct thermal transferred label that contains no tints with an all temperature adhesive

Barcode integration provides ease of access, data collection and security. The BatchMATE™ station allows the user to store ingredient information, including system name, part number, density, manufacturer, and custom description. Once the ingredients have been entered, the user can print a label associated with that ingredient. When the recipe calls for a specific ingredient, the system can request a designated barcode to be scanned before it proceeds to the scaling step. This barcode can either be for the ingredient itself or for particular personnel trained to handle the ingredient. BatchMATE™ can generate barcodes in many formats including some of the most popular such as EAN-13, Ean-8, UPC-A, UPC-E, CODE 128, and Code 39.

User security is integrated with BatchMATE™ as users possessing different access roles. New users can be added by an administrator to identify each operator. Each user’s information includes a username and password, employee first and last name, and an ID number. The employee ID code becomes crucial if a barcode scanner is used for security login or material handling. Each user can be assigned different permissions, tools, and privileges tailored to the individual operator’s functions. Permissions that can be granted include recipe and ingredient management, schedule maintenance, report generation, and batching access.

Ethernet communications is a growing networking tool that has become the industry standard in many plants. Ethernet networks allow for greater distances, faster data links, and detailed equipment diagnostics. BatchMATE™ is available with Ethernet equipped devices such as scanners, scales, interfaces, and printers. Ethernet scanners offer flexibility in location and movement. These scanners are equipped with a charging base that communicates to BatchMATE™ through Ethernet IP protocol. The scanner sends readings to the base through long range radio signal with a typical range of 100m at 910MHz. With a standard label printer, the distance of where the printer can be mounted is limited to the distance of the USB cable. However, Ethernet printers prove useful especially if a printer needs to be mounted in a remote location further away from the BatchMATE™ station. As discussed earlier, BatchMATE™ can be configured to support multiple scales. When these scales are configured though an Ethernet network, they can also be placed further away from each other on standalone platforms closer to the ingredients to be scaled. This is the most efficient configuration when the space and size of the ingredient totes is limiting. In addition, the scanner base, scales, and printers can be mounted further from the BatchMATE™ station since Ethernet’s communication has a distance limit of approximately 100m using a CAT6 cable.

Standard reports provide a history report for each ingredient. BatchLOGIX™ identifies all ingredients to an estimated inventory with lot numbers. As each ingredient is scaled in BatchMATE™, the amount of ingredient remaining gets subtracted from the estimated inventory. This provides the means to track down what each mixture/batch is composed of and which lot it came from. All of the ingredient history is stored in a database within BatchMATE™ which allows for easy generation of reports for a series of batches (referred to a campaign) or for each batch individually. To easily find a specific batch summary, the database can be filtered based on criteria including final product name, ingredient name within a recipe, date/time, and an individual batch or campaign ID.

BatchMATE™ is a new product that greatly expands the possibilities for many micro-batching applications. Integration with plant wide operations as a part of a larger batching system is now possible. It also contains, features involving operator interaction that are more straight forward, and security integration is supported with barcode scanners (RFID reader capabilities will be added soon). Reports enhance monitoring capabilities and record crucial data necessary for quality control and process efficiency. Tailored for many industrial environments and equipped with the latest technology, BatchMATE™ will revolutionize the way micro ingredients are handled.

Legacy PanelView Replacement

Tue, 12 Feb 2013 18:17:00 GMT

Do you lose sleep thinking about the aging equipment in your manufacturing facility, wondering if and when it will cause costly downtime? Last August I wrote an article titled “Aging Equipment” with advice to stop ignoring your aging automation electronics and realize the potential threat they pose to your operation. This time I want to focus on a piece of legacy equipment that can and should be updated — the Allen-Bradley ^® Legacy PanelView™. An upgrade of this particular piece of equipment is both easy to implement and provides real benefits.

These fears about expense, the loss of effort when the control system is upgraded or that operator re-training will be required may not be completely accurate. It is true that some portion of the investment may be lost during future controls upgrades, if the current budget does not allow for a controls upgrade now. However, that cost may not be as high as imagined, especially since the risk of continuing to use the outdated PanelView™, and having an unexpected failure, may be far more expensive. Don’t forget, unscheduled downtime can be very costly.

Some things to consider: What if the majority of the cost for a PanelView™ upgrade was in the new hardware, and the new hardware cost was about the same as repairing the old unit? And, what if that cost included getting a bigger operator screen and more capabilities? Also, new hardware can be used later when the controls upgrade occurs. In some cases, buying new hardware is actually less than repairing the old unit because Allen-Bradley ^® wants you in new hardware.

Converting a legacy PanelView™ program to a new PanelView™ Plus is not as difficult and labor intensive as one might think and will not require operator re-training. The Rockwell Automation PanelView™ Plus programming software can import an old program. Used with a touchscreen PanelView™ Plus, the program conversion can be done in a few hours by experienced personnel, and will look much the same as the old program. Since the look and feel is the same as the old program, no operator training is not required. No conversion is ever perfect, so the areas to address increase with the complexity of the original program and, as is true with any task, the more complex the old program is, the more time will be required to convert. Also, bear in mind that the more complex the program is the longer and more costly the downtime will be, should a failure occur.

The physical installation difficulty varies depending on the replacement model that is chosen. Installation is typically simple, but panel modifications may be necessary. In some cases a bigger opening in the enclosure is required or an adapter plate may needed. Some adapters are available from Allen-Bradley ^® .

It does not matter if you have a simple machine and just need the most basic conversion or have a complex machine that eventually will involve major upgrades, addressing the risk of potential failure in a relaxed time frame is always less expensive and more successful than one implemented while in a rush. Emergency service fees, freight, overtime, unscheduled downtime, etc. can add up quickly. When the conversion to a new PanelView™ is complete, you will have a platform that is easier to use, easier to modify and more capable, while including the added benefit of remote access. Knowing this should help you relax and get some sleep. Until the thought of “What is next?” creeps in, but that is a discussion for another day.
Photo Credit: The Automation Blog

Allen-Bradley and PanelView are trademarks of Rockwell Automation, Inc.

The Allen-Bradley ^® legacy PanelView™, also referred to as the “black bezel”, is no longer available new from Allen-Bradley. The black bezel can be sent in for repair, but repair costs are high and the turnaround time can be significant. These two facts alone make the legacy PanelView™ a good candidate for replacement.

You may be thinking that the investment in developing new graphics may be too great. Updating the controls at the same time may not in be the budget and you fear that the conversion work going to a new PanelView™ could be wasted. You may rationalize that you could just take your chances on a breakdown if it seems you do not have an economical alternatives. Besides, retraining operators on new graphics can be daunting and would just add more expense to an upgrade.

NorthWind Technical Services

Advanced Batching Control System Modernizes Animal Feed Production

Eduardo Martinez

AI for Manufacturers Guide

Ready to explore what AI could mean for your facility? Read the full white paper to get the complete picture, including real-world examples, implementation guidance, and practical advice on where to begin.

The AI Guide for Manufacturers: Improve Uptime, Throughput, and Quality

Quality Assurance Station

A Smarter Way to Measure What Matters: Utilizing Vision Technology to Enhance Product Testing Process

Implementing Vision Technology

Density Measurement

Seamless Integration Into Your Quality Process

Additional Features

The Bottom Line

Ignition 8.3: What We’re Excited About the Most

Jose Pineda

Fairview Mill’s Journey to Data-Driven Manufacturing

Digital Transformation: Fairview Mill’s Journey to Data-Driven Manufacturing

Project Overview

The Impact

Future Outlook

Our Approach

The MES implementation included several key components

Control System Upgrade Streamlines Pet Food Production

Control System Upgrade Streamlines Pet Food Production

Bryan Reinecke

Precision Panel Building in Our UL Certified Control Panel Shop

Precision Panel Building in Our UL Certified Control Panel Shop

Why It Matters

AI & Digital Transformation Seminar 2025

AI & Digital Transformation Seminar 2025 Recap

Technology in Action — Innovation Tours at NorthWind

Real-World Case Studies & Expert Panels

PlantIQ® Alarms Module Troubleshooting Alarms

Control System Troubleshooting on the Plant Floor Faster with PlantIQ® Alarms Module

Control System Troubleshooting on the Plant Floor Faster with NorthWind’s PlantIQ® Alarms Module

Eliminating Cross-Contamination at a Leading Pet Food Manufacturer

Material Validation: Eliminating Cross-Contamination at a Leading Pet Food Manufacturer

Kyle Bell

Developing an Actionable Digital Transformation Journey

Digital Transformation Journey: Guiding a Pet Food Manufacturer to Industry 4.0

Our Approach

Digital transformation recommendations

Aldo Martinez

The Impact

Project Overview

Case Study: Grain Handling Control System

Grain Handling Control System Helps Frontier Cooperative Battle Labor Shortage

Frontier Cooperative

Project Overview

The Impact

Learn more about NorthWind’s Solutions or reach out to schedule a walk through of a system.

Hannah Wenger

Our Approach

Ping Pong Tournament

Battle of the Paddle ﻿

Martha Bray

2024 Thanksgiving Celebration

Giving Thanks at NorthWind

Martha Bray

AI & Digital Transformation Seminar Recap

Educational Sessions

AI & Digital Transformation Seminar Recap

NorthWind Innovation Tour

NorthWind Presents at Palantir’s AIPCon

NorthWind Keynotes at Palantir AIPCon 4: Factory Automation Meets AI

True North Core Value Award

Case Study: Schwan’s Historian Project

Using Data to Implement Process Changes Results in Substantial Savings

Developing the Solution

Implementation

Learn more about NorthWind's Solutions or reach out to schedule a walk through of a system.

Pinnacle Automation Community Partner Award

NorthWind Receives Pinnacle Automation Community Partner Award

Learn More

Automated Project Development Process

Kansas Department of Commerce Merit Award

NorthWind Receives Award of Merit from the Kansas Department of Commerce

Premier Ignition Integrator

Learn more about our MES Solutions and Contact Us today about your project.

Manufacturing Execution System Capabilities

Battle of the Paddle

Join the NorthWind Team – literally! We have several openings, click here for information.