Honeywell New Zealand Tom Lewis Plant Automation Solutions

Meadow Lea Foods - Food Solutions Company: Meadow Lea Foods Location: Auckland, New Zealand Process: Manufacturing Margarine, Cooking Oils and processing Dairy Products Needs: Improve Quality & Reduce ‘Human-Error’ Expand Recipe Selection Automate Reports and provide complete component tracing to meet legislation

Meadow Lea Foods - Process Process: Batch Phase 1: Weigh & Blend Phase 2: Transfer (holding tanks) Phase 3: Column (recipe management) Phase 4: Discharge Detailed Batch History reports are created during each Phase. The final product quality and audit report is created at the Discharge phase.

Meadow Lea Foods - Automation

Meadow Lea - Flow Diagram Product Orders Scheduling Weighing & Blend Lab Recipe Download Recipe Calculation to Total Volume (usually 10 tonne batches) Transfer to Holding Column “Cooking” Auxiliary Processes Shipping & Distribution Storage or Packaging Discharge

Meadow Lea Foods - Control Solution

Meadow Lea Foods - Blend Phase Detail

Meadow Lea Foods - Summary The Control System solution has been in operation for 7 years and keeps on expanding With the Batch solution, the consistency of recipe production, operator effectiveness, and quality reporting has improved by 100% The Batch User Interface means minimum training for Operators when introducing new recipes Batch History has provided essential data for Quality reporting, and meeting the strict demands of Food & Beverage Regulations in New Zealand The remote access function improved site support and reduced maintenance costs

Cavalier Bremworth - Carpet Solutions Company: Cavalier Bremworth Location: Auckland, New Zealand Process: Manufacturing of high quality woolen carpet, mainly "Tufted" (stitched on a synthetic backing) Needs: Improve Quality, Reduce Waste Improve Efficiency Identify Operating and Machine Problems (collection of statistical data for analysis)

Cavalier Bremworth - Process Process: Continuous - Semi-Batch Phase 1: Winding Phase 2: Beaming Phase 3: Tufting Each phase is executed as a batch, and is tagged with an ID number, so quality tracking is possible.

Cavalier Bremworth - Winding The wool arrives at the factory in large bales Wool The wool is unloaded and pre-treated Winders 64 Winders spin the wool at 200kg / hour

Cavalier Bremworth - Beaming From the winders, the wool is fed into the beaming machines. 1x Beam, holds about 500kg of wound wool. 200 Winder “Cones”

Cavalier Bremworth - Tufting From the beams, the wool is fed into the tufting machines, producing the finished carpet. Tufting Machine 8 Beams

Cavalier Bremworth - Control Solution

Cavalier Bremworth - Batch Control Batches are specified from the Planning Department, and downloaded to the PlantScape system. Operators login before operating machines. The Batch ID is checked, and the operator productivity and machine efficiency is tracked. Each machine has a selection of “downtime” codes for tracking machine performance. Statistical data is reviewed to determine problem machines, and focus on reducing bottlenecks. Each machine has its own "Batch Control" program that is designed to guide the operator when starting/stopping batches. Each “Batch Control” program has logic steps and plant feedback to minimize error and maximize productivity.

Cavalier Bremworth - Carpet Solutions

Cavalier Bremworth - Carpet Solutions

Cavalier Bremworth - Summary The Control System solution has been in operation for nearly 6 years and keeps on expanding Cavalier Bremworth achieved excellent results: Reducing the number of operators and maintenance staff by 50% Increasing productivity by over 150% (by identifying machine downtime trends, focusing on Operator training, and providing operators with productivity information). This is a unique system, tailored for this application. But the principles can be applied to any industry.