Background:

National Foods Limited is a leading manufacturer and marketer of natural colors, flavors, and savory blends for the food industry worldwide. To enhance their production capabilities, National Foods established a new processing plant for sauces, ketchup, and mayonnaise. They required a complete automation solution for their culinary plant, including system integration and the installation of field instruments such as level transmitters, control valves, and temperature transmitters.

System Description:

FAIZAL provided National Foods with a robust, technically advanced, and cost-effective automation solution. This comprehensive solution included the design, supply, installation, and commissioning of a PLC-based control system with SCADA, local HMI, Variable Frequency Drives (VFDs), and a complete set of field instruments.

Implementation Approach

The automation system for National Foods’ wet plant featured a rugged and versatile Mitsubishi Electric MELSEC iQ-R Series PLC at its core. The system was customized through programming and configuring the PLC to meet the specific process requirements outlined in the control philosophy provided by National Foods. A Human Machine Interface (HMI) was installed in the control panel, enabling technicians to control and monitor the system locally. Additionally, the control room was equipped with Genesis64 SCADA, providing complete visualization and optimizing operator efficiency while reducing risks.

Key features of the system included:

1. Visual Alarms: The system was designed to generate visual alarms with prioritized visibility based on criticality.
2. Data Logging: Data logging was implemented for designated inputs, with a user-selectable interval time to effortlessly and quickly measure and record data. The data logging feature allowed for thirty days of data storage before automatic deletion of logged charts.
3. Trend Analysis: Trend analysis was included in the SCADA system, allowing users to analyze production data with user-adjustable time intervals.
4. Access Privileges: Access privilege features were incorporated, enabling specific access rights for each user. Depending on the logged-in user and their access rights, parameters such as set points could be adjusted. Access rights and privileges were also set up to manage alarms and process control.
5. Material Transfer: Material transfer between sections of the plant was designed and implemented in the PLC with various process operation modes based on the control philosophy and level-based control.
6. Temperature Control: The system included a product temperature control scheme to maintain the temperature as per set values. Temperature control included hot and cold modes of operation, which were accessible and modifiable through SCADA, thereby enhancing production, packing, and storage processes.
7. Automatic and Manual Modes: Automatic and manual operation modes were engineered with adequate safety interlocks. In automatic mode, parameters were controlled according to set values entered in the SCADA or HMI setting pages, while in manual mode, equipment was operated manually.

Project Outcomes

The implementation of this automated control system provided National Foods with a reliable and stable solution, with potential for future expansion and adaptation. The system improved production efficiency, enhanced monitoring and control capabilities, and ensured a safer operating environment. The flexibility and reliability of the upgraded system have made FAIZAL the preferred choice for National Foods’ automation needs.

Overall, the new automation system has significantly boosted operational efficiency and process reliability, positioning National Foods Limited to meet its production goals effectively while maintaining high standards of safety and quality.