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PACE Zenith Awards 2012: Finalists for Food & Beverage

Simplot Australia
Targeting Energy Efficiency Opportunities

Simplot Australia Targeting Energy Efficiency OpportunitiesThe primary objective of the project was to provide a measuring and reporting system that would support the energy reduction program at the Devonport plant.

The task was to identify the key energy sources and install metering equipment that would capture 80% of the electrical and thermal load of the plant and provide a basic report that would quantify the energy usage to the key stakeholders on site.

While there were specific deliverables associated with the project such as energy metering and the creation of basic reports, additional opportunites to help with energy efficiency were explored. Part way into the project a case was presented to expand the scope of the project to move it beyond a purely technical solution to one that would help develop the culture of the site to make the changes more sustainable.

A local automation firm worked to develop a reporting structure based on Citect Historian and MS Reports that would provide real-time data capture and reporting for the key energy consumption points. The reporting system is quite visionary.

It not only meets the needs of plant management to report on high level energy consumption but it provides a useful tool for operators to observe their instantaneous energy consumption against standard values to encourage intervention to conserve where possible.

SAGE Automation
Pressureless Conveyor Control and Singuliser Modular Control

SAGE Automation: Pressureless Conveyor Control and Singuliser Modular ControlThe SMC process involves continuously adjusting the speed of motors based on the measured distance between bottles on the conveyor.

The project also commenced with a review of machine risk by SAGE. This review was used as a basis for the design of the safety system, which was an important factor in reducing the scope creep so often experienced on projects of this type.

Tooheys chose to implement these process improvements on a new automation hardware platform, based on a Siemens S7 programmable logic controller (PLC) system with a Profibus DP network for process communications and an AS-Interface network to implement a Category 4 safety system. A new iFix SCADA system would provide the operator interface.

The impact of the new automation system was immediately apparent. Glass breakage due to bottle crowding has been virtually eliminated, increasing the availability of the bottling line and increasing employee safety. In addition, the PCC and SMC control strategies have contributed to a 20% increase in maximum system throughput.

The bottling machine is now able to run at its highest rated speed, maximising utilisation of the bottling line. The customer has also benefited in the area of engineering practice, with some SAGE engineering standards now being adopted by Tooheys as their site standards.

Lenssen Dairy
One-person milking operation

Lenssen Dairy: One-person milking operationThe project began when Joe Lenssen from Lenssen Dairy approached Global Dairies with the view of maximising the milking process of his herd. He wanted to build a new rotary dairy facility – with a difference.

He wanted to install milking cups in every second bale (stall) and utilise them across two bales – swapped between cows on alternate rotations of the platform.

Each cow would therefore remain on the platform for two rotations (being milked on the first rotation and having time to complete feeding on the second time round).

Each cow has an RFID tag which stores the cow's ID. Additional information from each cow, such as milk yield, temperature and conductivity for monitoring milk flow is recorded by the bale PLC and conveyed via a wireless link to the main herd management system.

All data is captured and logged. The control system has been designed from inception to maintain an operational state even in the event of equipment and/or component failure.

Process Partners

Process Partners: 5amAfter securing a contract to supply a leading Australian supermarket with its yet to be produced organic yoghurt, five:am had a tight timeframe to make its product concept a reality.

Process Partners developed a manufacturing strategy for the plant and worked with five:am to amend and evolve the strategy based on its budget and business objectives.

The sophistication of the automation technologies installed in five:am's plant is not typical for plants of this size.

It contains advanced technologies such as automated cleaning so it can be routinely cleaned when needed with minimal operator involvement.

The automation technologies helped achieve sustainable manufacturing processes by reducing wastage, and ensuring a smooth running of the plant, enabling significant time savings from not having to manually operate and clean machinery. In March 2011, five:am's first products were sold throughout a leading supermarket.

Rescue Foods
Bircher Bars

Rescue Foods Bircher BarsThe objective of Rescue Foods was to create nutritionally complete super-foods for crisis and emergencies.

Rescue Foods is now in trials for a nutritionally complete crisis bar. It is lightweight, low allergen, has a long shelf life, is friendly to vegetarians, vegans, coeliacs, diabetics, as well as meeting halal and kosher requirements.

The convenience and practicality of such a product can impact the shortening of the crisis cycle.

For example when a flood hits this food can be airdropped in and requires no tents, queues or bowls, and aid workers can focus on securing clean water to avert the outbreak of cholera.

Having a nutritious food source has been shown to help manage the stress and energy that is required to rebuild. It is recognised in aid agencies now that people in crisis don't just need calories, they need nutrition, and to just give them calories creates a malnourishment problem further down the line.

Streets Ice Cream upgrade

Unilever Streets Ice Cream upgradeAfter 12 years, a Streets system for manufacturing ice-cream machinery needed updating. A decision was made to replace the obsolete control system with a new generation one.

Streets embarked on a meticulous evaluation process over many months to identify its plant's requirements and expectations for the control system platform.

Siemens SIMATIC PCS 7 process control system and its recipe management system SIMATIC Batch was eventually selected, being identified as the system most capable of meeting the stringent demands of the mix plant.

The Streets plant must produce a wide variety of ice-cream blends to meet the requirements of the company's portfolio so a flexible recipe system was critical. Record high temperatures were experienced in many states and Streets had to increase its output tonnage by nearly 60 percent to cope with the increased demand, something that would have been impossible with the old system.

Siemens believes Australia should be one of the world's industrial powerhousesPACE Zenith Awards 2012: Food & Beverage category is proudly sponsored by Siemens

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