Automation of Dairy Production

Dairy production 1Upgrading/replacement of control

The project was done based on existing processing plants with outdated HMI and PLC systems (Alert 500) and communication to 330 ALTOP controlled process valves. The solution was a new HMI screen system, Siemens WinCC and ABB PLC with distributed IO and a ASi bus for the process valves.

ALTOP process valves were upgraded with a remodeling kit, replacing electronics in the valve head to the new ASi card. This is a very cost effective way to upgrade valves while retaining the engine and control head. ASi cabling are made in advance so that the change of control can be performed with minimal downtime. Reusing valves ensures there is no need for mechanical modification of valve batteries ol. or purchase of new valve engines.

Fact sheet:

  • WinCC V7.0 Scada system, 3000 tags
  • ABB AC800M PLC
  • 3 operator panels
  • 2 Profibus masters
  • 5 IO boards via fiber link
  • 1 IO board via Profibus
  • 5 Profibus/ASi bus gateways
  • 330 ASi valves
  • 70 IO valves
  • 30 pumps
  • 26 thoughts
  • Remote access

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All existing features were converted to WinCC and ABB PLC. This required knowledge of the solutions previously used on the machine. The new HMI’et communicates with PLC which further communicates  via fiber networks to multiple devices connected to the systems – a distributed IO, Profibus ASi gateways, and 330 ASI nodes.

Object-oriented programming allows fast commissioning due to pre-tested features and simple expandability in program- and WinCC communication.

The plant covers milk reception from a tanker, tank/transportation management in production, bottling, and CIP washing station with cleaning of tanks and rørgnett.

An operator interface provides easy access to functions from the screen, simple menus, faceplates for valves, and pumps for manual control. The control of washing station happens with dosage and temperature, prescription treating tanks, and pipe-cleaning with individual parameter setups in the database.

The plant is expanded in several parts of the dairy. With solutions available for bus communication, it ads new IO cabinets that are easily extended from the existing system. This provides a more comprehensive system and reduces the need for communication to external PLC systems.