Dairy Plant SCADA & Process Automation
High-speed packaging and palletizing cell with 2 FANUC robots, 3D vision tracking, and dynamic recipe management at 120 boxes per minute.
🎯 Challenge / Goal
Legacy PLCs and fragmented SCADA islands prevented line-to-line coordination. Batch traceability had regular discrepancies, HACCP logs were manual creating audit risk, and critical process alarms had no real-time escalation.
⚙️ Solution Applied
All production lines were upgraded to Siemens S7-1500 PLCs. OPC-UA was installed between process islands for recipe handshakes. Ignition SCADA Perspective provided a unified operations dashboard with HACCP auto-reporting module (critical time/temperature logs compiled to PDF automatically). Tiered SMS + email alarm management and MES integration raised batch tracking to 100% accuracy.
📈 Results
- ✓HACCP audits passed with zero findings
- ✓Process downtime reduced by 45%
- ✓Energy consumption reduced by 18%
- ✓Batch changeover time: 2h → 25 min
- ✓Operators reduced from 14 to 8 per shift
🔧 Technologies Used
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