1. Honeywell New Zealand
Tom Lewis
Plant Automation Solutions

2. 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

3. 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.

4. Meadow Lea Foods - Automation

5. 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

6. Meadow Lea Foods - Control Solution

7. Meadow Lea Foods - Blend Phase Detail

8. 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

9. 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)

10. 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.

11. 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

12. 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”

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

14. Cavalier Bremworth - Control Solution

15. 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.

16. Cavalier Bremworth - Carpet Solutions

17. Cavalier Bremworth - Carpet Solutions

18. 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.