AVEVA (Schneider Electric) Case Studies Woodlands Dairy Improves Production Monitoring and Control with Wonderware System Platform

	Woodlands Dairy Improves Production Monitoring and Control with Wonderware System Platform AVEVA (Schneider Electric)

Woodlands Dairy Improves Production Monitoring and Control with Wonderware System Platform

AVEVA (Schneider Electric)

Technology Category	Platform as a Service (PaaS) - Application Development Platforms Platform as a Service (PaaS) - Data Management Platforms
Applicable Industries	Food & Beverage
Applicable Functions	Discrete Manufacturing Quality Assurance
Use Cases	Process Control & Optimization Real-Time Location System (RTLS)
Services	System Integration Software Design & Engineering Services
Challenge	Woodlands Dairy faced the challenge of integrating a second-hand powder plant from Denmark with an outdated control system into their existing operations. The control system was not suitable for the modifications required to adapt the process to Woodlands Dairy’s specifications. This prompted the company to consider how this expansion could be integrated with the rest of the site. The company needed a single platform that could integrate all the disparate plants on site while preserving past investments in expensive assets and legacy systems while making provision for future expansion. They also needed a centralized environment for process data logging which would allow them to analyze data in real-time and produce reports. The system also needed to comply with ISO 22000 standards and the project had to be completed without any interruptions to production. Read More
About Customer	Woodlands Dairy is a dairy company located in Humansdorp, South Africa. The company is subject to increasingly close scrutiny in the supply of primary foodstuffs such as dairy products. To stay in business profitably in the dairy industry means the consistent provision of quality products and unswerving compliance with ISO standards. The company had a variety of PLCs and no PLC or SCADA standards. They needed a centralized environment for process data logging which would allow them to analyze data in real-time and produce reports. They also needed flexible security facilities that would allow operator access only to designated areas of the plant. Finally, they needed system redundancy to provide for uninterrupted operation as well as the ability to develop and deploy solutions from a central point for ease of maintenance. Read More
Solution	The solution to Woodlands Dairy's challenges was the Wonderware System Platform consisting of the Application Server, InTouch HMI, Historian and Historian Clients trending and reporting tool. The platform was chosen for its universal data connectivity, object-oriented technology, distributed system, easy report creation and retrieval of historical data, full redundancy, scalability, and the level of support available in South Africa. The total implementation took about six months, half of which was spent on the new powder plant which was commissioned first. The standards developed for the powder plant were rolled out for these projects. Other process areas were also upgraded and these included a new Clean in Place (CIP) Station, a new cream pasteurizer/butter plant, an upgrade to the milk pasteurizer, new pasteurized milk silo and milk lines, new pasteurized cream silo and a new milk reception area with its own CIP station. Read More Log in to view content
Contents

Technology Category

Platform as a Service (PaaS) - Application Development Platforms

Platform as a Service (PaaS) - Data Management Platforms

Applicable Industries

Food & Beverage

Applicable Functions

Discrete Manufacturing

Quality Assurance

Use Cases

Process Control & Optimization

Real-Time Location System (RTLS)

Services

System Integration

Software Design & Engineering Services

Challenge

Woodlands Dairy faced the challenge of integrating a second-hand powder plant from Denmark with an outdated control system into their existing operations. The control system was not suitable for the modifications required to adapt the process to Woodlands Dairy’s specifications. This prompted the company to consider how this expansion could be integrated with the rest of the site. The company needed a single platform that could integrate all the disparate plants on site while preserving past investments in expensive assets and legacy systems while making provision for future expansion. They also needed a centralized environment for process data logging which would allow them to analyze data in real-time and produce reports. The system also needed to comply with ISO 22000 standards and the project had to be completed without any interruptions to production.

About Customer

Woodlands Dairy is a dairy company located in Humansdorp, South Africa. The company is subject to increasingly close scrutiny in the supply of primary foodstuffs such as dairy products. To stay in business profitably in the dairy industry means the consistent provision of quality products and unswerving compliance with ISO standards. The company had a variety of PLCs and no PLC or SCADA standards. They needed a centralized environment for process data logging which would allow them to analyze data in real-time and produce reports. They also needed flexible security facilities that would allow operator access only to designated areas of the plant. Finally, they needed system redundancy to provide for uninterrupted operation as well as the ability to develop and deploy solutions from a central point for ease of maintenance.

Solution

The solution to Woodlands Dairy's challenges was the Wonderware System Platform consisting of the Application Server, InTouch HMI, Historian and Historian Clients trending and reporting tool. The platform was chosen for its universal data connectivity, object-oriented technology, distributed system, easy report creation and retrieval of historical data, full redundancy, scalability, and the level of support available in South Africa. The total implementation took about six months, half of which was spent on the new powder plant which was commissioned first. The standards developed for the powder plant were rolled out for these projects. Other process areas were also upgraded and these included a new Clean in Place (CIP) Station, a new cream pasteurizer/butter plant, an upgrade to the milk pasteurizer, new pasteurized milk silo and milk lines, new pasteurized cream silo and a new milk reception area with its own CIP station.

Impact #1	Reduced engineering cost as a result of rolling out the standards that were defined at the start of the project.
Impact #2	Improved quality control with the silo milk release system interlocked with the laboratory InTouch system and CIP reports.
Impact #3	Operators gained confidence now that they have visibility into the entire plant.

Impact #1

Reduced engineering cost as a result of rolling out the standards that were defined at the start of the project.

Impact #2

Improved quality control with the silo milk release system interlocked with the laboratory InTouch system and CIP reports.

Impact #3

Operators gained confidence now that they have visibility into the entire plant.

Benefit #1	Achieved compliance with ISO22000
Benefit #2	Reduced engineering cost
Benefit #3	Improved quality control

Benefit #1

Achieved compliance with ISO22000

Benefit #2

Reduced engineering cost

Benefit #3

Improved quality control

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Overview

Woodlands Dairy Improves Production Monitoring and Control with Wonderware System Platform

Operational Impact

Quantitative Benefit