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General Foods

Upgrade Controls for Packaging Machine in Secaucus, NJ

Challenge:

Upgrade electronic controls for rice packaging machine running legacy controls.

Solution:

Electronic controls for rice packaging machine were upgraded to include a new CompactLogix PAC replacing an obsolete SLC 100.  We provided a new consolet enclosure with a Rockwell PanelView HMI screen, and new Electro Cam encoder. We also replaced the main drive single AC gear motor and drive with two servo motors, Stober reducers and a Kinetix 6000 drive.  

Confectionary Chocolate Line Servo Upgrade in Souderton, PA

Challenge:

Upgrade six obsolete motors for a three part mold production line.

Solution:

Our team upgraded six obsolete servos and mold transport motor/actuators for this 3-part mold production line. We upgraded the obsolete PLC to supply the necessary capacity and Ethernet communications, as well as upgraded the VFDs and added them to the Ethernet. For the Ethernet capability, our team upgraded the obsolete pneumatic valve manifolds. We added additional HMI screens, implemented necessary functional safety controls, and provided new and corrected documentation. We upgraded a ControlLogix L55 to a ControlLogix L81, and used Kinetics, Stober and Unimotion hardware.

Cauliflower Mash Process Line in Vernon, CA

Challenge:

Implement a new process line for a cauliflower mash process line, and resurrect a used CIP skid that was missing all controls.

Solution:

This new process line cleaned, mixed, blanched, filtered, sheared, and deposited mashed cauliflower. To complete this solution, we interlocked multiple PLCs, touchscreens, and instruments with upstream, midstream, and downstream unit equipment. We also supplied large custom stainless enclosures for the electrical controls, and supervised the electrical installation. We also brought a used CIP skid that was missing all of it’s controls back to life.

For this solution, we used:

  • Allen-Bradley ControlLogix L81
  • PanelView Plus
  • IFM Efector instrumentation
  • IO Link for instrumentation
  • 2 new control panels
  • Software for multiple new depositors
    • CompactLogix
    • PanelView Plus
    • PowerFlex VFDs controls