1. 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.

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

3. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

4. 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.

5. 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

6. 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.

7. 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.

8. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

9. 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

10. 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.

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

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

15. Topology

16. EOM

17. 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

18. Project Design

19. Project Description

20. Project Description

21. 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

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

23. ERP Integration / WO Management

26. Project Description

27. Project Description

28. WO – Modify execution time

29. WO – Re-allocate

30. WO – Remove from plan

31. 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

32. Reporting
Wonderware Information Server
MS-SQL Reporting services

33. Reporting

34. Reporting

35. Reporting

36. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

37. 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

38. 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.

39. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

40. 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)

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

42. 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

43. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

44. 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

45. Thank you