Plantwide Automation System

Customer: Food Customer

Project Type: Matrix provided software design, development, testing, startup and commissioning.

Technical Specs: New 460,000 square foot facility, with an overall investment of over $150MM.

Project Scope: The customer built a greenfield production facility for the production of jams and jellies. Matrix Technologies was responsible for the development, testing, and implementation of Batch, PLC, and HMI software.

The control system Batch, PLC, graphics standard, and software design specifications (SDS) were developed in collaboration with the customer. The SDSs served as the guideline for the development and programming of the FT Batch, ControlLogix PLC and FT View SE HMI systems.

Production schedules from SAP were automatically loaded into the FTBatch system. FactoryTalk Batch was configured to allow control of all FT Batch units in the system. Matrix migrated all existing recipes to the new system and incorporated standard ActiveX controls and executables in the HMI application to allow for local batch control and interface. Matrix tested each system in house, including the Batch, PLC, and HMI via software simulation of each process.

Engineering Challenges: Process design was not complete when software programming needed to start, so an agile software development methodology was employed to ensure production dates were met.

Products and Technologies Used: Rockwell Automation ControlLogix PLCs, FTView and FTBatch software were utilized, along with GE Proficy for the scheduling interface to SAP.

Project Outcome: The project was extremely successful and started up on time.  Much of the commissioning support was provided remotely, allowing customer personnel to become familiar with the system and reducing overall costs of startup.