We have extensive experience in the dairy industry and have a deep understanding of the process controls of these production facilities. We understand customer requirements and deliver the best results.

In this “Butter Retemp Project” our customer is one of the largest dairy processors in California. As such, they always aim to deliver the best quality products to their customers, which required some process improvements. The purpose of this project was to improve butter production efficiency and reliability with the integration of new logic into the existing Programmable Logic Controller (PLC).

 

This project consisted of two key components:

1. PLC Integration:

• New logic was integrated into the existing PLC based on the customer’s functional description. This ensures seamless communication between various equipment and streamlines the butter production process.

2. Pneumatic Control Panel:

• Our team designed and constructed a custom control panel specific to the customer’s needs.

With these considerations in mind, our team implemented the following process:

1. PLC Programming:

• Programming the PLC to monitor/control:
  • Valves
  • Flow Meters
  • Pumps
  • Motor Starters
• The automated process minimized downtime and eliminated manual labor.

2. HMI (Human Machine Interface) Programming:

• By creating an integrated graphical representation on the HMI, it enabled for more efficient monitoring and management of the butter production process.
• Having a simple and user-friendly graphical representation with standard color coding allowed operators to quickly and accurately monitor and control the system as needed.

To ensure that the implementation of the process improvements was working smoothly, our team conducted the following quality assurance procedures:

1. Factory Acceptance Test (FAT):

• A thorough and detailed FAT ensured:
  • All devices operated as expected.
  • Hardware components were free of damage.
  • The system met the customer’s design specifications and was visually pleasing and comprehensive.

2. Onsite Startup:

• Verified that the control panel functioned as intended on-site.
• Made any necessary addition of user controls during startup to ensure customer convenience and needs were satisfied.
• Led operator training for a smooth user control.

Results

This project resulted in control optimization, reduced labor, and ensured optimal quality in butter production. The rigorous testing and integration of new technology contributed to reliable and efficient processing.

These improvements give the customer ease, knowing that their process control is running efficiently, and their product is being produced with quality and uniformity.

 

To get in touch with us and learn about how we can help you increase efficiency and enhance process controls contact us today!. 

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