Usability taken to a whole new level – retrofit of the Process Control System and CIP Integration for the perfect mayonnaise.
Reprogramming an aging system is one thing. Making a highly sensitive homogenization process —with limited existing documentation and unclear functionalities—fit for the future is something entirely different. We were commissioned by a well-known manufacturer of mayonnaise and remoulade to perform a comprehensive retrofit of the process control system, as well as the dismantling and reconstruction of a CIP system, including the connection of the media supply line. As is to be expected with old software, we first set out to investigate the system’s history.
Process Control Technology modernized and optimized
As a first step, the existing, overloaded, and outdated control system was brought up to date. It was a truly massive project that involved a great deal of research into the existing code and plant structure, but it also offered significant advantages of the SISTAR® Process Control System in terms of quality assurance and usability.
ongoing documentation
Program sequences, operating procedures, and relevant measurement data are continuously queried, monitored, and stored.
streamlined system
All old system components, recipes, and process screens that had not been in use for quite some time were cleaned up and removed from the code.
optimal usability
Unlike in the past, users can now log in directly at all operator stations. Customized visualizations provide the operator with a much clearer overview.
Due to the outdated CIP control system, the plant manufacturer had to re-pipe the supply lines for liquid egg and egg yolk, and we had to connect them. The challenge here was to ensure communication with the other supply lines as well as the automated connection to the target computer.
”"Everything has to communicate with each other. Almost exactly like in a giant Thermomix."
Tobias GreifProjektleiter
Transparent insights into the process
Customizable process screens and visualizations tailored to specific needs make the user interface intuitive and easy to navigate.
CIP connection with less water loss
Since key plant components—such as the media tanks—had been operated for years on a trial-and-error basis or without proper guidance, it was necessary to adapt the recipes to optimize resource use with the new CIP connection. After all, parameters such as time, the choice of cleaning agent, and, of course, the amount of water required play a decisive role in ensuring an efficient and sustainable process. In this way, we were able to reduce not only water consumption but also cycle time in the cleaning process by up to 15%.
”Thanks to our excellent collaboration with the plant manufacturer, we were able to reduce downtime to a minimum and work together to make the plant future-proof. It paid off to take a closer look at the code and experiment extensively to understand the processes at the program level. By streamlining and properly decommissioning the control system, we were also able to ensure that there would be no unpleasant surprises in any potential follow-up projects.
