Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell...

Honeywell New Zealand Solutions

Honeywell New ZealandProprietary and ConfidentialPage 1

Honeywell New Zealand

Plant Automation Solutions

Tom Lewis

Honeywell New Zealand Solutions

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Meadow Lea Foods - Food Solutions

Company: Meadow Lea Foods

Location: Auckland, New Zealand

Process: Manufacturing Margarine, Cooking Oils and processing Dairy Products

Needs: Improve Quality & Reduce ‘Human-Error’

Expand Recipe Selection

Automate Reports and provide complete component tracing to meet legislation

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Meadow Lea Foods - Process

Process: Batch

Phase 1: Weigh & Blend

Phase 2: Transfer (holding tanks)

Phase 3: Column (recipe management)

Phase 4: Discharge

Detailed Batch History reports are created during each Phase.

The final product quality and audit report is created at the Discharge phase.

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Meadow Lea Foods - Automation

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Meadow Lea - Flow Diagram

Product Orders Scheduling

Lab Recipe

Download

Weighing

& Blend

Transfer to Holding

Column

“Cooking”

Discharge

Auxiliary

Processes

Storage

or Packaging

Shipping &

Distribution

Recipe Calculation to Total Volume

(usually 10 tonne batches)

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Meadow Lea Foods - Control Solution

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Meadow Lea Foods - Blend Phase Detail

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Meadow Lea Foods - Summary

• The Control System solution has been in operation for 7 years and keeps on expanding

• With the Batch solution, the consistency of recipe production, operator effectiveness, and quality reporting has improved by 100%

• The Batch User Interface means minimum training for Operators when introducing new recipes

• Batch History has provided essential data for Quality reporting, and meeting the strict demands of Food & Beverage Regulations in New Zealand

• The remote access function improved site support and reduced maintenance costs

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Cavalier Bremworth - Carpet Solutions

Company: Cavalier Bremworth

Location: Auckland, New Zealand

Process: Manufacturing of high quality woolen carpet, mainly "Tufted" (stitched on a synthetic backing)

Needs: Improve Quality, Reduce Waste

Improve Efficiency

Identify Operating and Machine Problems (collection of statistical data for analysis)

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Cavalier Bremworth - Process

Process: Continuous - Semi-Batch

Phase 1: Winding

Phase 2: Beaming

Phase 3: Tufting

Each phase is executed as a batch, and is tagged with an ID number, so quality tracking is possible.

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Cavalier Bremworth - Winding

64 Winders spin the wool at 200kg / hour

The wool is unloaded and pre-treated

The wool arrives at the factory in large bales

Wool

Winders

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Cavalier Bremworth - Beaming

From the winders, the wool is fed into the beaming machines.

1x Beam, holds about

500kg of wound wool.

200

Winder

“Cones”

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Cavalier Bremworth - Tufting

From the beams, the wool is fed into the tufting machines, producing the finished carpet.

8 Beams

Tufting Machine

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Cavalier Bremworth - Control Solution

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Cavalier Bremworth - Batch Control

• Batches are specified from the Planning Department, and downloaded to the PlantScape system.

• Operators login before operating machines. The Batch ID is checked, and the operator productivity and machine efficiency is tracked.

• Each machine has a selection of “downtime” codes for tracking machine performance. Statistical data is reviewed to determine problem machines, and focus on reducing bottlenecks.

• Each machine has its own "Batch Control" program that is designed to guide the operator when starting/stopping batches.

• Each “Batch Control” program has logic steps and plant feedback to minimize error and maximize productivity.

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Cavalier Bremworth - Carpet Solutions

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Cavalier Bremworth - Carpet Solutions

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Cavalier Bremworth - Summary

• The Control System solution has been in operation for nearly 6 years and keeps on expanding

• Cavalier Bremworth achieved excellent results:

– Reducing the number of operators and maintenance staff by 50%

– Increasing productivity by over 150% (by identifying machine downtime trends, focusing on Operator training, and providing operators with productivity information).

– This is a unique system, tailored for this application. But the principles can be applied to any industry.