INSTRUMENTATION • ELECTRONICS
PROCENTEC solutions for permanent PROFIBUS monitoring
How to prevent downtime in a food and beverage production plant In a factory where an impressive 1.5 million liters of juice is produced every day, downtime is not an option. One of the largest producers in the food and beverage industry in the Middle East, teamed up with PROCENTEC and its local partner. This partnership resulted in a spectacular drop to zero (!) downtime during the first six months after installing PROCENTEC’s ComBricks on the PROFIBUS industrial network in the production plant. At a cost of more than € 50,000 per hour downtime, the return on investment was already achieved in the first weeks after installation.
The Middle Eastern company originally started with the production of fresh milk and yoghurt drink. In the years to come the company grew and diversified its products. Entering the bakery products market, the poultry market, and the infant nutrition market.
Today, the company and its sub brands deliver a full range of products consisting of chicken, butter, cheese, bread, wraps, juice, and infant cereal.
Minimize unplanned production downtime The continued growth and expansion were becoming a heavy burden on the production plant, and especially on its PROFIBUS network. In 2017, this production facility had grown up to four times its original size since production started in 2004. In the plant where the company produces juice, long life milk, yoghurt drink and cheese, more than 100 devices are each connected through a PROFIBUS network, with a centralized PLC room. The Senior Auto- mation Engineer of the plant stood for an important task to minimize the unplanned production downtime. With that in mind the Senior Automation Engineer of the plant started his search.
ComBricks: PROCENTEC’s solution for permanent PROFIBUS monitoring His extensive search brought him to PROCENTEC’s solutions for permanent PROFIBUS monitoring and diagnostics: ComBricks. With ComBricks, it would be possible to perform online monitoring over a web browser 24/7, receive alerts over e-mail, and make historical recordings of events happening. If a device, such as a flow meter, would start to fail by sending repeats to the PLC, it is detected before
it could damage (interfere) the industrial network and shut down production. Instead of reacting to a problem, the team would become proactive in their maintenance and troubleshooting with the help of ComBricks.
ComBricks segmented the PROFIBUS network PROCENTEC’s partner designed a fitting solution consisting of ComBricks to prevent downtime in the PROFIBUS DP network. By using ComBricks as a transparent PROFIBUS DP multi-repeater with monitoring function- alities 24/7, the vast PROFIBUS network was segmented. Working with such a solution would give the engineers of the production facility the insights and full control of their industrial network they were searching for. During the design stage, it became clear that this project would be one of the biggest installations of ComBricks in a single plant in the world to date. Due to their long experience and vast knowledge of the industrial networks market, PROCENTEC and its partner were determined to provide the best solution. After PROCENTEC delivered the designed products, the installation took over a month and happened during production downtimes with 10 hours of shut down each. PROCENTEC’s local partner
www.procentec.co.uk |
info@procentec.com
helped with installing the ComBricks, mak- ing sure everything was working properly, and gave on-site ComBricks training to the engineering team. The ComBricks were up and running.
After PROCENTEC’s ComBricks has been im- plemented, not a single downtime occurred The results of the efforts done by the client, PROCENTEC and its local partner were astonishing: during the first six months of implementation of ComBricks, not a single downtime occurred. At a cost upwards of € 50,000 per hour downtime, the ROI was achieved by preventing 3 hours of unexpected production stops.
If you want to trust your industrial network, please call PROCENTEC at +44(0) 753 4307 696 or send an e-mail to
info@procentec.com.
Feel free to visit PROCENTEC’s stand during the SPS in Nurnberg on 26-28 November, where you can be the first to witness one of their biggest releases ever.
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VPInstruments for your fl ow meters and monitoring soluti ons easy insight into energy flows™
More informati on: email to
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www.vpinstruments.com
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www.engineerlive.com
20/09/2019 10:06
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