The Magical World of Chocolate Manufacture Let me introduce you to the reality of Chocolate manufacture. Yes we have some interesting almost magical equipment, but at the heart of it is a mass of pipes, valves and electronics controlling it all. So when we at Orley Foods decided to take our factory to the next level of automation as our current systems where no longer suitable we started the project to source a better solution.

Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations) Fiona Byrns (for Orley Foods)

Introduction Project Solution Agenda Benefits Considerations Summary

Chocolate manufacture Mixing Cocoa Butter or Equivalent Sugar or Sweeteners Grinding Cocoa Mass or Powder Emulsifiers Powdered Milk Liquefaction Pressure and Temperature measurement So what is so special about chocolate manufacture Chocolate is an emulsion of Fat, Sugar and sometimes milk products.

Project Scope Orley Foods Manufacturing Raw Material Receiving Chocolate Manufacture Fat Supply Fat Melters Storage Tanks Heat Exchangers Mixing Conches/ Grinding Storage & forming Sugar Manufacture Finished Goods

Background to the Project Seamless and transparent integration throughout the Company manufacturing systems and business system Manufacturing system designed for expandability, ease of integration and contextuality. Information that is important, relevant and contextual to be published to a portal for easy access Ability to trend and trace process issues and speed up trouble shooting. We needed a system that fully integrated with all the other systems and business systems, something that would bring them all together at a shop floor level We needed something that would expand with future growth As the growing need for more and more information grows this system must be able to generate the requirements as they arise, we needed the data to be able to be interpreted by the business system (Syspro) and be database orientated. The system must have the funcianality to trend the processes and provide information which would speed up trouble shooting and process control.

Project Goals Traceability of fat usage and additions against works orders Monitoring / logging of process parameters ERP integration to Syspro Overall system upgraded to latest technologies Network Windows / SQL Server environment SCADA system PLC system Ingredient management of recipes Introduction of expandable reporting infrastructure In the chocolate manufacturing process the different fats are incompatible so it is vital to ensure traceability of the fat used at all times. The chosen system would be used to monitor and track process parameters in the plant and for each recipe batch We wanted one source of the BOM to minimise formulation failures and therefore needed this information to be feed from Syspro to the manufacturing system As our system was outdated we needed to upgrade to the latest technologies As we have over a hundred different recipes for the liquid chocolate, different colours and fat systems we needed a system that would be able to handle this variation seamlessly With the new business environment and the need for information we where developing KPI’s and needed these populated from the manufacturing systems so as to deliver reports from a central area.

Introduction Project Solution Agenda Benefits Considerations Summary

Requirements of integrator and solution Tender process Requirements of integrator and solution Cape Town presence Instrumentation, PLC, SCADA and database development experience Previous experience in food and beverage industry Several solutions investigated Siemens Rockwell Citect We started the project by defining our needs and then drew up a tender process allowing various vendors and systems to be evaluated. It was vital that we had a well know system but equally so we needed to know that they chosen integrator would have a Cape Town presence They needed to have experience in the development of PLC, SCADA and databases especially SQL It was also a prerequisite that they had prior experience in a Food and beverage environment and where acquainted with the complexities of working in a HACCP environment AMR meet these requirements and was chosen

Proven functionality in the Food and Beverage industries Why Wonderware Proven functionality in the Food and Beverage industries Proven integration into business systems (SQL database) Well supported, widely used nationally and internationally Several solution providers / system integrators Development into the future Increased availability of resources (call-outs) As for the solution we evaluated several and found that the Wonderware solution was best suited as it had a proven track record in Food and beverage and was used in many local and international plants manufacturing foodstuffs. We where able to see demonstrated examples of integration into our chosen ERP system Syspro There are also several integrators and solution providers with great knowledge on the platform so we would not be stuck with 1 vendor in an emergency.

Project Design Functional specification prepared Detailed design process Network topology PC/Server infrastructure PLC infrastructure Data flow

Project Description Develop ArchestrA model S95 standard Model includes future upgrades Use model to define data capturing points for EOM

Topology

EOM

Project Design Design Intouch SCADA Dual display AMR’s first project with ArchestrA 3.0 and Intouch 10.0 Converted AMR’s standard valve/motor SmartSymbols to ArchestrA graphics

Project Design

Project Description

Project Description

ERP Integration / WO Management ERP integration to Syspro via holding database WO’s pushed down from Syspro indicating Raw material, tank and equipment allocation/scheduling Operators start and complete WO’s SCADA Intouch SCADA Wonderware Historian Syspro server

ERP Integration / WO Management Example of WO Management at SCADA level

ERP Integration / WO Management

Project Description

Project Description

WO – Modify execution time

WO – Re-allocate

WO – Remove from plan

PLC Allen-Bradley Compact Logix Beckhoff Ethernet/IP remote I/O units Program designed with complete process control management in mind (for future phases) Manufacturing instructions Process parameters (Mixing times, pressure and temperature checks and operator prompts) Fat transfer route allocation Current program only handles fat transfer route allocation

Reporting Wonderware Information Server MS-SQL Reporting services

Reporting

Reporting

Reporting

Introduction Project Solution Agenda Benefits Considerations Summary

Benefits / Goals Achieved Batch size consistency No need for extensive additions to correct recipe failures Raw material allocations tracked What fat goes where Better process control tracking Alarming at SCADA level Trouble-shooting (temperatures, pressure, grinding times) Operators

Benefits / Goals Achieved Significant savings in fat usage Batch processing times where standardized Less usage of resources i.e. power Minimised batch/formulation corrections Savings in additional raw materials to batches.

Introduction Project Solution Agenda Benefits Considerations Summary

Lessons Learned (PLC) User defined data structure always good (duplication of devices similar control) I/O server integration with tagnames instead of address reference Ethernet/IP needs managed switches to handle IGMP Snooping (Internet Group Management Protocol)

Lessons Learned (Wonderware) Domain Security Tighter control with existing business system and network policies Client responsible for user manager/rights (IT department)

Lessons Learned Understanding scope and planning vital Previous projects failures overcome Plant downtime was managed Plant process visibility greatly improved Updated P&ID Operations / process flow Increased speed of data availability

Introduction Project Solution Agenda Benefits Considerations Summary

Project summary / conclusions Phase I successfully completed by AMR using Wonderware technology Increased process control and shop floor visibility Phase II will further utilize the solution into other areas of the plant Future phases will allow for data to be written back to Syspro Automatically closing works orders

Thank you