Yogurt production at a regional grocery chain's LA manufacturing facility had reached maximum efficiency and output given the age of their equipment and process control system. TriCore’s objective was to upgrade the entire system and, ultimately, to provide greater flexibility throughout the manufacturing process, reduce downtime attributed to equipment CIP, and modernize outdated PLC and HMI platforms.
TriCore delivered on all counts, designing and implementing an intuitive, advanced control system consisting of Allen-Bradley ControlLogix processors, distributed Ethernet IP based Flex IO, Ethernet IP based Allen-Bradley Powerflex VFDs, Ethernet IP based SMC solenoid valve manifolds, and DeviceNet based Tuchenhagen mix proof valves.
A new Rockwell FactoryTalk View SE based redundant client server HMI system was deployed to enhance visualization, production and CIP operations and flexibility, with advanced monitoring capabilities. To take full advantage of new real-time reporting capabilities, TriCore developed a new data collection and reporting system, delivering the historical trends, PMO-compliant electronic CIP records, as well as web-based fermentation production reports, CIP reports and operator activity reports, to help them improve plant operations well into the 21st century.