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Woodlands Dairy Improves Production Monitoring and Control with Wonderware System Platform
Technology Category
- Platform as a Service (PaaS) - Application Development Platforms
- Platform as a Service (PaaS) - Data Management Platforms
Applicable Industries
- Food & Beverage
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Use Cases
- Process Control & Optimization
- Real-Time Location System (RTLS)
Services
- System Integration
- Software Design & Engineering Services
The Challenge
Woodlands Dairy faced the challenge of integrating a second-hand powder plant from Denmark with an outdated control system into their existing operations. The control system was not suitable for the modifications required to adapt the process to Woodlands Dairy’s specifications. This prompted the company to consider how this expansion could be integrated with the rest of the site. The company needed a single platform that could integrate all the disparate plants on site while preserving past investments in expensive assets and legacy systems while making provision for future expansion. They also needed a centralized environment for process data logging which would allow them to analyze data in real-time and produce reports. The system also needed to comply with ISO 22000 standards and the project had to be completed without any interruptions to production.
About The Customer
Woodlands Dairy is a dairy company located in Humansdorp, South Africa. The company is subject to increasingly close scrutiny in the supply of primary foodstuffs such as dairy products. To stay in business profitably in the dairy industry means the consistent provision of quality products and unswerving compliance with ISO standards. The company had a variety of PLCs and no PLC or SCADA standards. They needed a centralized environment for process data logging which would allow them to analyze data in real-time and produce reports. They also needed flexible security facilities that would allow operator access only to designated areas of the plant. Finally, they needed system redundancy to provide for uninterrupted operation as well as the ability to develop and deploy solutions from a central point for ease of maintenance.
The Solution
The solution to Woodlands Dairy's challenges was the Wonderware System Platform consisting of the Application Server, InTouch HMI, Historian and Historian Clients trending and reporting tool. The platform was chosen for its universal data connectivity, object-oriented technology, distributed system, easy report creation and retrieval of historical data, full redundancy, scalability, and the level of support available in South Africa. The total implementation took about six months, half of which was spent on the new powder plant which was commissioned first. The standards developed for the powder plant were rolled out for these projects. Other process areas were also upgraded and these included a new Clean in Place (CIP) Station, a new cream pasteurizer/butter plant, an upgrade to the milk pasteurizer, new pasteurized milk silo and milk lines, new pasteurized cream silo and a new milk reception area with its own CIP station.
Operational Impact
Quantitative Benefit
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