Batch System Improves Quality And Doubles Production Capacity

Production chart

Malisko Engineering, Inc was asked to provide a Control and Information Management System to a new Batch Process.

Goals:

  • Increasing Efficiency and Speed of Manufacturing
  • Reduce Product Variability Due to Manual Intervention
  • Provide a Flexible System for New Recipe's and Existing Recipe Changes
  • Provide Electronic Batch Records
  • View Real Time Information and the Manufacturing Process from a Control Room
  • Create an Expandable System for Growth to Allow Future Automation of Existing Systems and Equipment

Malisko Engineering, Inc was involved in design, programming, testing and production support.

Engineering Tasks & Services

  • Worked with Production Operators, Supervisors, Plant Engineer and Management to Provide a "Ground-Up" Approach to Design a Flexible System
  • Developed Detailed Design Documents and Description of Operations including Batch Tracking, Alarming, Reporting and Historical Data Archiving
  • Provided all Electrical Design Diagrams and Instrumentation Loop Sheets
  • Designed and Provided a New Control Panel
  • ALL Programming - Traditional Batch System Standards, PLC's, PCs, HMI's, Weighing Devices and Networks
  • Configured and Implemented Data Archiving Database and Batch Report
  • Construction Suggestions for Control Room
  • Performed ALL Equipment Checkout and Calibration
  • System Start-Up Support
  • Operator and Maintenance Training
  • As-Needed Production Support (On-site and Remote Access) After Start-Up

Project Succeses

  • Involved many Stakeholders in the Design from the Beginning
  • Project Met Production & Management's Needs
  • Produce Quality and Consistent Product while Reducing Total Batch Time
  • Fully Automated System and Expandable for Future Growth