AGRANA refines agricultural raw materials into high-quality foodstuffs and a wide range of preliminary products for industrial applications. Roughly 8,800 employees working at more than 50 production sites worldwide generate revenues of around €3 billion. The company was founded in 1988 and is now the leading sugar company in Central and Eastern Europe and is also an important producer of special products and bioethanol in the starch segment in Europe. In addition, AGRANA is the global market leader for fruit preparations and the largest European producer of fruit juice concentrates.

Project description

As in its bioethanol plant and several of its sugar factories, AGRANA installed the SIMATIC PCS 7 process control system from Siemens at its new wheat starch plant. SIMATIC PCS 7 coordinates and optimizes all of the production workflows and processes at the plant.

www.siemens.at/food-beverage

At the same time, the PCS 7 system in the bioethanol plant was upgraded to the latest version.

The SIMATIC IT Manufacturing Execution System (MES) from Siemens was deployed in the new wheat starch plant. During this process, the bioethanol production line was also switched over to SIMATIC IT MES.

Siemens’ SIMATIC IT production control system serves as a data hub, linking all of the information from the AGRANA enter-prise planning system, Siemens’ UNILAB laboratory information system and the SIMATIC PCS 7 process control system. In addition, SIMATIC IT MES controls the internal logistics for the receipt and shipment of goods.

Both systems – SIMATIC PCS 7 and SIMATIC IT MES – allow for close integration with the existing bioethanol plant, which was built in 2008. Thanks to the combination of the two production plants, the raw material employed at the site can be fully utilized.

Food & Beverage

A shared, end-to-end SIMATIC PCS 7 process control system and SIMATIC IT for two AGRANA production plants in Pischelsdorf, Austria

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Scope of delivery and services:

SIMATIC PCS 7 process control system for the wheat starch plant:

• 43 RIO cabinets (24 in stainless steel) including I/O components • 5 PCS cabinets • 5 FO multiplexers • 4 PCS 7 OS servers, redundant • 7 PCS 7 OS clients (2-fold and 4-fold monitor) • 1 PCS 7 OS Process Historian • 1 PCS 7 OS Web server • 3 S7-417H/F units (including fail-safe) • 1 microbox • ET200M, iSP, Scalance • FO cabling (LAN, Profibus) • FO link between the bioethanol plant and wheat starch plant networks

SIMATIC IT Manufacturing Execution System (MES) for the wheat starch plant and bioethanol plant:

• 2 MES servers, highly available, ESX-based • 30 truck and master terminals • 10 lab clients • 14 reporting clients • 2 mobile clients (loading/handling of ancillary materials) • SIMATIC IT Production Suite (MES) including SIMATIC IT Unilab (laboratory information system) • SIPASS RFID system for truck identification • Goods receipt (corn, wheat, special materials) • Goods dispatch (ethanol, DDGS, bran, gluten, starch) • Laboratory management • Tracking, silo management, material management and production data collection • Documentation and reporting • Operating data collection (electrical energy, steam, etc.) • Connection to third-party systems (e. g. SAP, weigh bridges, analysis equipment, alcohol server, bagging plant, etc.) • TIA Integration SIMATIC IT – SIMATIC PCS 7

Costumer benefits:

• The two plants are operated independently of one another but are linked through a uniform operating concept and a centralized control center.

• Significantly higher volume of materials handled with same staff levels in raw materials receiving, laboratory and shipment thanks to the end-to-end automation of all processes and workflows.

• Optimal deployment of staff and synergies in maintenance and training thanks to the shared control center.

• Comprehensive overview at the push of a button – everything from order control in SIMATIC IT to laboratory information and process data to inventory status in the dispatch silo can be accessed thanks to the extensive data integration of the systems.

• Control and execution of the complete goods logistics and production processes with data integration to SAP.

• Reduction of data entry to a minimum thanks to event-driven, automated data transfer from SAP to Transporeon (web-based truck time management tool), SIPASS, SIMATIC IT and SIMATIC PCS 7.

• Energy savings thanks to optimized controller settings.

• Recovery of roughly half of the dryer energy required to heat the new wheat drying plant through the extraction of the previously unused waste heat from the feed drying area of the bioethanol plant.

• No downtimes and thus no impact on the production process during the upgrade of SIMATIC PCS 7 to the latest version (bioethanol plant).

Implementation period:

2012 – 2013 (optimizations and upgrades in 2014)

Siemens AG ÖsterreichProcess Industries & DrivesWolfgang-Pauli-Strasse 24021 Linz, Austria

www.siemens.at/food-beverage

Printed in Austria © 2015, Siemens AG Österreich

Your contact:

Siegmund Scherney Tel. +43 (0)5 1707 65378 siegmund.scherney@siemens.com

Logistical manipulation of starchPlant model

www.siemens.at/food-beverage