Case Study: Upgrading Baker's Best Dough Rolling Machines
Cornerstone Automation delivered a rolling machine automation solution for Baker’s Best by integrating Allen-Bradley Micro 800 PLCs, Kinetix 5100 servo drives, and new servo motors. The upgrade addressed hardware obsolescence, enabled real-time fault diagnostics, and extended the service life of two critical dough processing lines—without disrupting operator workflows.
For over two decades, Cornerstone Automation has provided technical solutions to Baker’s Best, a prominent manufacturer in the baking industry. This case study outlines the benefits of upgrading two industrial dough rolling machines, with a focus on the integration of modern motion control systems.
Since the early 2000s, Baker’s Best has depended on the expertise of system integrators to maintain and improve their production equipment. As their machinery, including the rolling machines, aged, it became increasingly difficult to maintain due to the obsolescence of critical elements like motors, drives, PLCs, and touchscreens.
Challenge: Modernizing Obsolete Dough Rolling Machines
This project’s primary challenge was integrating modern motion control systems into the existing rolling machines. Motion control, a specialized field within control systems engineering, utilizes servo motors and drives to provide precise positioning and speed control—essential factors for efficiently operating rolling machines in a high-demand production environment.
The existing equipment, installed in the early 2000s, had become obsolete. By 2010, the motors and PLCs were no longer supported by manufacturers, and the servo amplifiers had been unavailable for several years. While the touchscreen had been previously upgraded, the overall system could not function effectively without replacing these outdated components.
Solution: Rolling Machine Automation with Servo Drive Integration
Cornerstone Automation began the upgrade by replacing obsolete parts with modern equivalents, including Allen-Bradley Micro 800 series PLCs, Kinetix 5100 servo drives, and new servo motors. These motors offer feedback capabilities that enable precise control and positioning. Ethernet-based digital communication between device hardware simplified wiring and increased data accuracy and volume, further enhancing system performance.
Planning through implementation took about five weeks, with just two days required for installation and testing, minimizing disruptions to Baker’s Best production schedule.
The upgrade focused on addressing obsolescence. The Cornerstone Automation team replaced motors, drives, PLCs, and other outdated components with contemporary versions. The new system was designed to ensure compatibility with current software, extend the end-of-life lifecycle of equipment, and simplify maintenance and troubleshooting—without altering the machine interface that operators used daily.
Benefits of the Rolling Machine Automation Upgrade
Improved Diagnostics and Maintenance
The upgraded system provides more detailed diagnostic information. With real-time fault feedback from servo drives integrated directly into the PLC, precise fault codes allow for quicker identification and resolution of issues, significantly reducing downtime and maintenance efforts.
Enhanced Alarming and Fault Detection
The upgraded PLC features advanced alarming capabilities. Operators and maintenance staff now receive more specific error messages, many tied directly to drive-level faults, streamlining the troubleshooting process and improving overall operational efficiency.
Consistency in Operation
From the operators’ perspective, the machines continue to operate as before, with minimal changes to the Human-Machine Interface (HMI). This approach ensured a smooth transition without retraining or adjustment to workflows.
Extended Equipment Lifespan
The new components are expected to have a lifespan of approximately 20 years. Although this is shorter than some expectations, it represents a significant improvement given the rapid pace of technological advancement. Using the latest hardware also increases the time to lifecycle obsolescence, allowing Baker’s Best to focus on production rather than constant upgrades.
Client Relationship
Cornerstone Automation’s relationship with Baker’s Best has developed into a strong partnership over the years. The trust and mutual respect built through this collaboration have enabled the system integrator to address any operational needs as they arise. Baker’s Best frequently relies on this specialized expertise for planned upgrades and urgent fixes, as demonstrated during a recent commercial freezer upgrade.
The successful upgrade of Baker’s Best industrial rolling machines proves Cornerstone Automation’s capability to manage complex technical projects while maintaining client operational consistency. This project resolved immediate obsolescence issues and improved the machines’ diagnostic and maintenance capabilities.
Looking Ahead: Is Obsolescence Impacting Your Baking Equipment?
At Cornerstone Automation, we understand the importance of keeping your industrial baking machinery running efficiently. If your facility faces similar challenges with outdated equipment, we’re here to modernize your systems. To discuss how we can bring the same level of expertise to your next project, reach out today!
