Bilingual Batch System

Dairy Pipes

Malisko Engineering, Inc. was asked to provide a Control, Data Acquisition and Reporting System for a new dairy-based liquids processing facility in Mexico owned by a global manufacturer of infant and adult nutritional products.

Goals

  • Provide a complete control, data acquisition and reporting system utilizing the most cost-effective technologies available for process automation and reporting, including -
    • ANSI/ISA S88 Batch,
    • Phase Manager-based PLC Programming,
    • Standard Device Control PLC Programming with Spanish-based tag name nomenclature,
    • Event and Data Archiving,
    • Production and Cleaning Reporting.
  • Provide a System where all documentation, nomenclature and programming is in Spanish,
  • Provide the facility with corporate-directed System guidelines to follow on future projects,
  • Reduce product variability due to manual intervention,
  • Reduce production and cleaning cycle times,
  • Reduce time to implement new products.

Design Tasks & Services

  • Developed bilingual Functional Descriptions of Operation and User Manual,
  • Integrated Event Tracking, Alarming, Reporting, and Historical Data Archiving,
  • Created all documentation for System qualification and verification,
  • Provided All System Configuration and Programming:
    • Configured PC’s, File Servers, Remote Operator Stations, Networking,
    • Implemented ANSI/ISA S88 Batch System Standards within Rockwell FactoryTalk® Batch across 8 units (50 Phases),
    • Configured Rockwell FactoryTalk® View SE Server,
    • Developed all HMI screens in Spanish including Spanish naming conventions,
    • Programmed and Integrated Rockwell Allen-Bradley ControlLogix® PLC with Spanish annotation, which included 38 PID Loops,
    • Configured Multiple DeviceNet Networks: InteliCenters, Tuchenhagen PMO 24/7 Mixproof Valves, and Remote Analog/Digital IO,
    • Configured Rockwell FactoryTalk® Historian Server for historical process data collection,
    • Developed historical and real-time process trends visible within the HMI,
    • Configured SQL Server and Data Tables for Rockwell FactoryTalk® Batch Event data, HMI Alarms and Events, Automatically triggered snapshots of process data, and Product formula management,
    • Developed Spanish-based detailed Batch Process, Ingredient usage, and CIP reporting using Microsoft SQL Server Reporting Services, viewable via Internet Explorer, all designed to meet the customer’s specific requirements,
  • Performed Off-Site and On-Site full equipment checkout, startup, and system verification,
  • Provided Operator and Maintenance Training,
  • Provided 24/7 post-startup support,
  • Provided ‘Record Set’ System documentation.

Project Successes

  • Delivered a fully integrated Rockwell/Allen-Bradley Solution on time per the Project Schedule,
  • System is ‘intuitive’ for the Operators,
  • Successfully deployed the project in Spanish providing a maintainable System to the local engineering/technical staff in Mexico.
  • Met both Plant and Corporate Engineering, Production and Management’s needs and expectations.