Filling Line revamping

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RealDev consulted one of the market leaders of water filling by assisting in the production and revamping of their bottles filling line. By doing this, the business goal was to achieve decreased production costs and the implementation of modernized tools.

The current technology in the business did not allow for significant production rates to achieve the desired production goals. Initial assessment indicated that the filling capabilities maximized at 11.0 bottles per hour, significantly less than the desired production rate of 18.0 bottles per hour.

Additional constraints involved: Limited intervention time between production slots, short planning period to provide a complete functional analysis and implementation plan, and the expectation of complete maximum production after start-up. To achieve this, we had to develop new features for process implementation and optimization of the existing one, code migration from S5 to TIA-Portal, and hardware configuration.

Using the specific challenges and constraints in this bottle industry, we worked to design a clear and comprehensive strategic plan to help the business complete their project and achieve their goals.

Our solution for this specific case included the implementation of many technological advancements to the businesses current infrastructure. While considering all of the full project detail, we collaboratively set realistic expectations focused on the main objectives while establishing measurable and reportable criteria. To assist in more efficient filling lines, additional implementations of new technology included:

  • 2 IPC
  • 3 SCADA Clients
  • 3 Decentralised PLC's
  • 750 Remote IO on Modules ET200
  • Profinet Network for Instrumentation
  • Historian Server

These new programs and servers assisted in increased operator interfaces, process plants, and machinery enabling the monitoring and issuing of process commands through industrial control systems. The new remote access to local control modules allows for the integrated control over multiple sites and even large distances.

By including 3 decentralized programmable logic controllers (PLC), the assembly production would then experience high reliability automation control suitable for harsh environments, simpler programming, and process diagnosis. Profinet, and other technological advancements allowed for increased technical standards for data communications over industrial Ethernet as well as data collection and equipment controlling. The historian server was also determined to allow for increased strategic decisions based on access to enterprise data sources.

This project yielded undeniably positive results. Processes, beginning with production and continuing on through delivery, improved through the liability of the process control system. To ensure that the full potential of the new processes was utilized, training of the on site operators along with increased responsibility of on site management was established.

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The implementation of the historian server also enabled the potential for big data collection and further operational improvements, combining high speed data acquisition and storage system.
Additionally, historical data management and data accessibility via a web portal and reporting tools allowed us to continuously track and monitor the successful results of this project.