Batch solution reduces administrative workload

Edited by the Engineeringtalk editorial team Aug 29, 2005

At its factory in Jarna, near Stockholm in Sweden, Cerealia produces such famous brands as Gyllenhammars havregryn, Start, Kungsornen pasta and AXA muesli products.

Cerealia is one of the largest food and beverage companies in Scandinavia.

It develops, produces and markets cereal-based products for the domestic markets in northern Europe and for export to other parts of the world.

At its factory in Jarna, near Stockholm in Sweden, Cerealia produces such famous brands as Gyllenhammars havregryn, Start, Kungsornen pasta and AXA muesli products.

"When our batch system for FruitMusli became too old, we started looking for a new solution and found CitectScada Batch".

"At that time we knew nothing about Citect, but after talking to a number of their customers we got nothing but good feedback".

Ingvar Malm, Automation Engineer, Cerealia, Jarna, said: "It took no more than 10 minutes to swap from the old to the new system".

Originally a pasta production site, the factory produces approximately 21,000 tonnes each year.

However, since the move of the AXA grain-mill to the Jarna site in the late 1970s, the focus for this site has moved more towards being an outright cereal producer with current production of grain products almost equaling that of pasta at 20,000 tonnes, and production of cereal products standing at 6000 tonnes.

At the Jarna factory, which comprises a grain-mill, an extruder (crushing and forming/sizing facility), and a mixing plant for muesli, a total of 180 different products are produced by 150 people, using over 700 raw materials.

In 2004, Cerealia started a major project to increase the production capacity throughout the entire plant for similar products.

To handle the increase in capacity, a central storage facility was built next door to the production plant.

This facility is capable of storing 25,000 pallets at the same time, and these are shipped and replaced with new products every month.

In the Jarna factory, 10 different batching solutions were being used, a number of which were becoming outdated and inefficient.

In turn, this was making it increasingly difficult for Cerealia to get access to spare parts and product support.

"When you get to a situation like that, you have no choice but to start looking for new solutions", said Ingvar Malm, Automation Engineer at the Jarna factory.

Cerealia had two major requirements for the new batch system.

"It was imperative that the batch solution be built and designed to handle the ISA S88 standard", said Malm.

ISA S88 defines terminology and models for batch control.

The standard comprises of two parts: ISA-S88.01 Part I: Models and terminology and Part II: Data structures and guidelines for languages.

"The second requirement was that we had to be able to keep our existing PLCs and weighing equipment that was already working properly on the FruitMusli production line".

"This meant that a hardware independent solution was important".

"After seeing a presentation and a product demonstration of CitectScada Batch we felt that it was a solution that met our requirements and we decided to use it in a pilot project".

"The new system was surprisingly easy to get going", said Malm.

"It took no more than 10 minutes to swap from the old to the new system, and it is still very easy to swap back to the old system if required".

"Another surprise was the reaction from the operators, they were all happy with the new system".

"I was expecting to get complaints from them during the initial period, as the structure and operating procedures are different in the new system, but this did not happen".

According to Malm, the CitectScada Batch system is now in full production and is performing very much to his satisfaction.

"The analysis we have done so far has shown significant reductions in administrative tasks needed".

"It is easier for the operators to empty tanks and make sure that tanks are filled with the correct raw material", said Malm.

Talking about his expectations for production efficiency improvements using CitectScada Batch, Ingvar Malm concluded: "It certainly looks very good and Beijer Electronics should be praised for its skilled and engaged staff".

"They have been very helpful and approachable".