Digital Transformation in Process Distributed Control Systems (DCS) Discover how our customers and some of your process skids builders realized significant benefits through digitalization of their production processes.

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Therefore, we have assembled a mix of different examples in different industries showcasing how customers’ issues turned into an improvements for their business. To achieve our customers’ goals, it’s clear that a digital plant is no longer contained within the walls of the plant itself, but instead stretches to the complete supply chain – from raw materials to the shops where consumers can order or buy their products. When looking at a digital plant, it is clear that a separate DCS system is no longer an option, instead an integrated digital DCS is required to I’m inviting you to discover how we, at not only quickly meet these flexible production Rockwell Automation, are enabling the industry demands, but also to play a much larger role in to realize the benefits from digitalizing their the digital factory of the future. This is backed factories and process skids. up by one customer, who told us “doing the The need to adopt digitalization in the face same we did five years ago would set us back of ever-changing consumer behaviour puts 20 years, so we need to digitalize our plants increased pressure on manufacturers of tomorrow.” products and their suppliers. While we provide a better insight in some A key market trend is that consumers demand key industry trends, we trust you also find it greater variety and more intuitive tailored beneficial to read through the different blogs Product selection combined with instant highlighting our solutions to respond to delivery. market trends. While in the past consumers would select only Thanks you for taking the time to read through what they wanted based on what was available our joint achievements and do not hesitate to on the shelf, now we are seeing them check all contact me for any question. the options online before getting confirmation on availability and then ordering from multiple Friendly yours sources – at the best available prices. Alain Hermans Indeed, our customers are telling us that demand for higher variability by consumers is Process Business Leader, EMEA accelerating the adoption of new technology at Rockwell Automation. for process control. Email: [email protected]

3 Contents Introduction 3 Need to Need to modernize Need to address growing aging systems 5 customer demands 27 modernize Anchor Glass 6 corosys 28 Azov Controls and Zaporizhstall 7 DELIN Elettronica 29 College Station Water Services (CSWS) 8 KCC 30 aging systems Columbia Pipeline Group 9 ProLabNL 31 Du Pont 10 Quimikao 32 Energy Control Technologies (ECT) 11 Blog: Gelatine production 12 Stemming the Next Pandemic 33 Kraft Heinz 13 Optima Control Solutions 14 Tata Steel 15 Tereos France 16 Blog: Time to Move Beyond Aging Assets 17 Need for open, Process skid solutions 35 scalable and secure Bausch+Ströbel 36 solution that meets Dinnissen Process Technology 37 all the requirements 19 Feluwa 38 Frames 39 AB electric 20 FrymaKoruma 40 Liquid Petroleum Distributor 21 IMA Automation 41 Prodesa 22 IMA Automation 42 Petroecuador 23 Zellwag 43 Tradebe 24 Zeton 44 Blog: Zippe 45 Peace of Mind 25

4 5 Anchor Glass Azov Controls and Zaporizhstall

Food & Beverage In addition to serving the beverage Metals Zaporizhstal PJSC turned to Ukraine- industry with a variety of shapes, colors based Rockwell Automation. and sizes of glass bottles, Anchor Glass Recognised System Integrator, also produces glass containers for jams, Azov Controls LLC, to not only replace sauces and salsa for food and beverage and build the control systems for its companies around the world. fifth and sixth sinter strands, but also Anchor Glass facility in Minesota, US design and populate a brand new produces up to 600 bottles per minute. central control room.

Challenges Solutions Challenge Solutions PlantPAx® Modern DCS A Rockwell Automation Integrated Process An aging furnace was causing • Single, scalable, plantwide process control Ageing control infrastructure at control system was installed, which included: energy inefficiencies and threating system Ukrainian sinter plant unable to • OWS stations productivity at a Minnesota Anchor • Process historian improves access to real- leverage modern data-driven • EWS Stations with integrated design tools Glass facility. time and historical data, and automated process advances. • Industrial Ethernet switches reporting capabilities • Multiple EtherNet/IP-based device level rings The inability to see more than two • System tracks most frequent alarms and (DLR) prioritizes for easier operator response weeks’ worth of production data • Integrated Safety • Internal model control system improved limited monitoring and trending • Connected variable speed AC & DC drives capabilities. management of furnace thermal operations • Stone Technologies implemented virtualized Results PlantPAx® modern DCS • Modern connected automation solution for Results sinter plant • Brand new central control room To read the full Improved Energy Efficiency Read our process application story visit application stories here • Greatly enhanced process data capture • Improved operator flexibility and ability to monitor temperature variables through • More efficient energy control PlantPAx® system • Remote access • Better handle 18 changeovers each month • Automated management of automation • Estimated reduced energy costs of over assets $1 million

6 7 College Station Water Services (CSWS) Columbia Pipeline Group

Water & Wastewater Pumping groundwater from wells Oil and Gas Columbia Pipeline Group (CPG) recently around the county, the College Station modernized its operational environment Water Services (CSWS) cools the water by implementing a modern distributed and transports it through water lines control system to improve reliability, gain to a second pump station for further better insight into its production data, treatment. and ease maintenance. From there, water is transported into the distribution system and two elevated storage tanks.

Challenge Solutions Challenge Solutions PlantPAx® process automation system Virtualization Aging control system was putting • Virtualized solution provides improved Modernize the operational • Virtualized PlantPAx® process control system a strain on staff and providing little access to process data, updated alarms and environment to improve reliability, shares information across facilities and up to to no access into real-time process events, and easyto- interpret production gain better insight into production executive level dashboards data. data, and ease maintenance. Information-Enabled • Rockwell Software applications enable Results system control, monitoring, reporting and Improved process control data recording over EtherNet/IP • Increased production from 8.1 million gallons Long-Term Maintenance per day to 11.8 million gallons • FactoryTalk AssetCentre software helps Reduced operations costs securely control user access in the field. • Reduced energy costs by $65,000 annually Results • Reduced spare parts inventory from $250,000 to less than $20,000 per year • Reached 99.5 percent reliability at To read the full Reduced downtime To read the full 100 percent capacity application story visit application story visit • Standardized solution eased troubleshooting • Provided information to the Enterprise and maintenance Analytics group to make business decisions based on real-time and historical data • Decreased downtime through remote troubleshooting capabilities and virtualized • Saved approximately $2.3 million in servers maintenance costs in 2014

8 9 Du Pont Energy Control Technologies (ECT)

Food & Beverage The Du Pont plant in Brazilian city of Oil and Gas Energy Control Technologies Esteio, Rio Grande do Sul, founded in (ECT), an OEM member in the 1958, was the first to manufacture Rockwell Automation PartnerNetwork™ margarine in the country. program, is one of the companies Currently, it provides protein solutions for helping drive this relatively recent major players in two primary markets: energy boom. meat (which uses it for processed meats, The Iowa-based company designs, for example) and nutrition (shakes, juices, builds and supports turbomachinery- cereal bars, among others). plant control systems for oil and gas production.

Challenge Solutions Challenge Solutions Deployment of the PlantPAx® Distributed PlantPAx® DCS Perform the migration of obsolete Control System (DCS) with support from Replace multiple proprietary • Technology based on open-communications DCS and PLC systems, at the end of technical consultants and Engineering from systems used in turbomachinery standards serves as common automation Rockwell Automation. their service life and unsupported control with one open, integrated platform by connecting multiple control systems by the manufacturer, with large platform. Results • Integrated HMI gives workers visibility into all number of I/O points and within Increased operational availability, faster systems from one screen three weeks. maintenance agility, better control of operating AADvance Fault-Tolerant Control System costs, and gains in flexibility in the control • Provides SIL-3 hardware process control for system. auxiliary systems; manages overall system trips, interlocks and permissives

Results Reduced Costs Read our process To read the full • Integrated platform speeds deployment, application stories here application story visit reduces spare-parts inventory and enables end user to keep maintenance activities in-house Simplified Operations • Workers can initiate operations with two button pushes and view all aspects of operations from single HMI

10 11 Gelatine production Kraft Heinz

Food & Beverage Gelatine is a multitalented ingredient Food & Beverage Since 1952, Ore-Ida, a part of the for countless applications. Gelatine Kraft Heinz Company brand, has manufacturers must adhere to stringent appealed to people’s appetites with ­national and international food process- dozens of frozen-potato varieties. ing requirements.To help safeguard fu- Its production operations are based in ture production of a large-scaled gelatine Ontario, Oregon, where Ore-Ida was manufacturing plant, an innovative risk founded. management approach was ­undertaken The facility produces all of Ore-Ida’s to identify and subsequently replace frozen potato products, about legacy equipment with assistance from 800 million pounds every year. Rockwell Automation.

Challenge Solutions Challenge Solutions • Integrated plant-wide control – PlantPAx® Model Predictive Control To upgrade legacy DCS system distributed system delivers integrated plant- Identify cost-saving opportunities • Rockwell Automation team identified innova- to mitigate production risk with wide control to justify cost of upgrading aging tive solution to identify process improvements minimal disruption to production • Innovative project execution – FEED control infrastructure. and maximize production using data analytics mitigated project risks and reduced processes and output. • Pavilion8 MPC software assesses current and execution time predicted operational data, compares it to • FAT and operator training reduced project desired results, and optimizes process control risks • IO adaptor card significantly reduced Results integration time Increased Production Capacity • Process integration and optimization led to Results 10 percent increase in production capacity • Minimal downtime to A-grade product – on production line – more than doubling Careful planning, operator input, FEED and project’s goal

To read the full FAT prior to commissioning minimised To read the full Prepared for Long-Term Growth downtime at the plant during changeover application story visit application story visit • Savings provided opportunity to upgrade • Safeguarding production – New system aging control system infrastructure and helps secure gelatine production for many modernize plant automation years to come Reduced Product Variability • Variability issues are detected and addressed throughout production to help produce consistent food products

12 13 Optima Control Solutions Tata Steel

Food & Beverage The dangers of obsolescence were Mining, Metals & Cement Tata Steel’s limestone quarry and lime identified early on at a leading British kilns, located in Cumbria in the UK, biscuit manufacturer in its mixing plant, have been producing quicklime and where older hardware was showing its limestone products since 1962. At the age in terms of performance and failures. plant in Shapfell, the company produces To address this issue, the biscuit high-performance lime products created manufacturer approached to meet the requirements of a wide Rockwell Automation, the manufacturer range of applications. Lime products of the ageing legacy system, who include ­CE-marked fine lime, other size collaborated with Optima Control grades and ground limestone in flexible Solutions Limited. quantities and at short notice.

Challenge Solutions Challenge Solutions A Rockwell Automation solution was installed, A Rockwell Automation solution was installed, Optima Control Solutions was which included: Tata Steel needed to upgrade the which included: tasked with replacing an ageing • Allen-Bradley ControlLogix programmable control solution on four of its kilns • Dual redundant Allen-Bradley ControlLogix recipe-control system with a automation controllers in Shapfell, but the window for PACs modern batch control solution. • Migration/conversion solution replacement per kiln was just 16 • 5,000+ Allen-Bradley POINT I/O nodes • Batch servers hours. • FactoryTalk View site edition (SE) SCADA • Rockwell Automation integrated-display • FactoryTalk Historian computer running FactoryTalk View Site • FactoryTalk VantagePoint Edition (SE) • EtherNet/IP Network • Rockwell Software FactoryTalk Batch software • VMware-based virtualisation solution • EtherNet/IP device-level ring network Results topology • Technical implementation from a • Far less risk of failure To read the full Rockwell Automation batch specialist To read the full • Full off-line virtual testing prior to install application story visit application story visit • Off-line virtual training prior to install Results • Modern communication network enabling • Reduced obsolescence risk data capabilities in The Connected Enterprise • Reduced downtime • Real time visibility of manufacturing/process data • Quicker and easier migration • Connectivity with other site activities

14 15 Tereos France Time to Move Beyond Aging Assets

Food & Beverage Tereos France is a leading company in the French sugar industry with nine sugar factories, five distilleries and four packaging facilities, producing an annual total of 1.5 million tonnes of sugar and 500,000 cubic metres of alcohol and bioethanol from beet.

Challenge Solutions Chemical producers face many A Rockwell Automation solution was installed, business challenges – from Tereos’ objective: to modernize which included: PlantPAx® Process Automation stiff competition and reduced System The connected production technologies and optimize control of boilers margins, to limited human capital, available today are far beyond what was and integrate these within a single • The solution, based on the Logix Control regulatory compliance and supply available just 10 years ago. Advanced Platform with Control Logix PAC, replaced an technology gives chemical producers control and command system for outdated DCS and provides a flexible process chain digitization. While trying the whole factory. to juggle these challenges they immediate relief from the constraints of control system with excellent reliability obsolete equipment and limited human • New I/O platform eases system upgrades also face the day-to-day realities capital and domain expertise. It can also help • Services of dealing with aging assets and merge IT and OT systems to provide seamless • Turnkey project approach managed by growing support costs. connectivity to manage production and Global Solutions team supply chain data into actionable real-time Decades-old chemical plants across the U.S. are information. working to address a wide range of equipment Results This connected, information-driven approach challenges, including obsolete equipment and to chemical production can be called a • Boiler control has been improved, in particular unplanned downtime, and limited visibility into connected chemical plant. critical-asset performance. To read the full in terms of monitoring reheating; it has been Building a connected chemical plant doesn’t application story visit possible to link the boilers together, and pow- With the digital landscape changing rapidly, have to be daunting. Think of it like this: By er matching is now carried out automatically chemical producers are looking to technology strategically prioritizing investments around • Increased reliability of boiler operations to help solve their issues with a quick ROI. That’s smarter technologies, a connected chemical why it’s important to rethink business decisions • The boiler control and command system is plant offers nearly unlimited opportunities to and consider technology investments that will now totally integrated with the other factory monitor and improve production performance. deliver both incremental and long-term ROI. units, allowing traceability to be centralised So, what does this mean for you in everyday for the entire production site. operation?

16 17 Need for open, scalable and secure solution that meets all the requirements

Increased asset utilization: Optimizing specific needs. Additionally, pre-engineered SIS asset utilization begins with being able to solutions are also available to fill capability gaps measure asset performance and identify and address specific business challenges in production problems in real time. A modern older plants in the most cost-effective manner. DCS can integrate all aspects of automation Improved maintenance and support: and information into a single, plant-wide Many producers struggle to support the infrastructure. Simultaneously, integrated mix of automation technologies that they power control systems can capture the accumulated from multiple vendors over electrical data from aging production assets to many years. Standardizing and consolidating monitor their performance and help minimize technologies in a connected chemical plant unexpected downtime and predict equipment reduces the number of systems with which issues. It’s a win-win for chemical producers. maintenance technicians and support teams Improved operations flexibility: A connected must support and stock spares. chemical plant can make batch production With these capabilities in place, chemical more agile and flexible by allowing operators producers can better monitor and upgrade to more easily make changes and bring new aging assets as needed. You can reduce the products online faster. Difficult to measure support costs associated with unplanned batch to batch variability causing quality and downtime and myriad systems. Then, you can throughput issues? No problem. focus newfound opportunities to improve Reduced risks: Operational and regulatory operations and boost production. risk facing producers can be easily understood and managed with a connected chemical plant. Scalable safety instrumented systems (SIS) allow chemical producers to apply various levels of risk mitigation as required by their

18 19 AB electric Liquid Petroleum Distributor

Water & Wastewater In a recent green field clean water Oil and Gas One of the largest, independent treatment project in Denmark, Danish liquid petroleum distributors in the system integrator AB Electric A/S was United States operates a marine oil tasked with developing and installing a terminal that occupies 250 acres on the comprehensive control and monitoring East Coast. solution for a facility spread over several The tanks at the acquired terminal can sites and locations that are kilometres hold more than 4 million barrels of apart. petroleum products, and are strategically located in a major U.S. harbor for easy transportation access.

Challenge Solutions Challenge Solutions A Rockwell Automation PlantPAx® solution was • Virtualized PlantPAx® System With Production AB Electric was tasked with installed, which included: United States liquid petroleum Intelligence – Intuitive modern DCS platform developing and deploying a state- • PlantPAx® operator workstations with distributor needed to automate a that integrates with simulation software for pre-testing and training of-the-art PlantPAx® solution advance diagnostics newly acquired major oil tank farm. • Process automation controllers • Pre-configured objects and faceplates for at a four-site Greenfield water easy integration • Distributed I/O treatment plant in Denmark, with • System provides production intelligence by • Variable-Frequency Drives connection to a central control collecting and reporting plant-wide data • EtherNet/IP, fibre-optic, internet and room. • MAVERICK Technologies, a integration of 3rd party devices/protocols Rockwell Automation company, designed Power consumption optimisation • Stratix switches and routers and implemented the systeml was another important part of the • 19 inch integrated stainless steel panel brief. computers Results • WIN-911 remote alarming platform • Decreased Implementation Costs – PlantPAx® DCS and the Rockwell Automation library To read the full Results To read the full application story visit application story visit of process objects eased implementation, • Robust process control solution exploiting cutting costs in half off-the-shelf hardware • Rapid Operator Training – The intuitive • Highly scalable and highly flexible for future system platform and simulation software expansion reduced operator training to one day • Strong scalable foundation for other water • Eased Troubleshooting industry projects

20 21 Prodesa Petroecuador

Power generation Prodesa, an engineering company based Oil and Gas Supervisors of the EP Petroecuador in Zaragoza (Spain), improves biofuel Balao terminal decided to carry out a production technologies with innovative complete renewal and updating project processes by providing comprehensive of the pumping station operations, solutions for solid biofuels production which included the development of and environmental protection. Prodesa an automatic control system for the is committed to the development based management of the maritime terminal. on knowledge and technology with the aim of contributing solutions that aid in resolving social and environmental problems and improving the quality of life.

Challenge Solutions Challenge Solutions Rockwell Automation PlantPAx® distributed • PlantPAx® modern distributed control system Automate all systems, equipment control system Development of an automatic • PowerFlex 7000 medium voltage AC drives and processes in the world’s second • Library of Process Objects control system to optimize biggest pellet production plant. • EtherNet/IP network management at the EP Results • Allen-Bradley GuardLogix SIL 3 safety Petroecuador Balao terminal. • Tripled their capability of loading and controller unloading ships • Distributed I/O over EtherNet/IP • Reduced the down time of a freighter, • Operator Stations (OWS), Engineering which means significant cost savings for the Stations (EWS) company • Optimized delivery to the Esmeraldas Results refinery for processing and distribution of fuel • Straightforward installation and commissioning of more than 6,000 I/O points To read the full • Time savings in design, engineering and To read the full application story visit application story visit simulation • Remote management and maintenance • Reduce training time for the operators • Higher productivity and high energy efficiency

22 23 Tradebe Peace of Mind

Waste Management Tradebe is a leading international company on industrial waste management with annual turnover of €400 million in 2014. The company operates more than 60 fixed plants in Europe (Spain, United Kingdom, France) and in the United States. Tradebe employs 2,130 people worldwide.

Challenge Solutions Some decisions are incredibly easy A Rockwell Automation PlantPAx® process to make, like which restaurant to go Tradebe needed an open, scalable control solution was installed, which included: to, or which movie to watch. Others, and secure process control solution • High performance controllers which attract greater – for want A couple of years ago, my company Alfasigma made a decision to evolve its operations, to • Low density distributed I/O for a new hydrocarbon terminal of a better word – risk, can take a give us the capabilities to address upcoming near Barcelona. • Virtualized servers and operation little longer, such as which car to legislation and more stringent pharmaceutical workstations in a centralized control room buy. If you scale this up to a new industry demands. The questions were, where • Integrated safety systems house purchase the risks become do we start and who do we get to help us? This is where peace of mind and capabilities come • Communication backbone based on commensurately larger. EtherNet/IP into play. • Transaction management with ERP Now imagine this decision is based on We knew we needed a package that covered you making the best possible use of your every facet of our operations – from HVAC, company’s money for a new asset purchase through batch control and onto serialisation Results or a revised operational approach. Here the across our supply chain – and delivered the • Scalable and flexible system that adapts to challenge requires an incredible amount of data we needed for dissemination both the plant structure investigation and due diligence. internally and externally. This all-in-one To read the full technical solution is something in demand application story visit • SIL safety level accomplished In all of the personal instances, there is one all across the industry but, surprisingly, is not • Easily integrated with different terminal common factor – peace of mind. A restaurant offered by too many companies. subsystems or movie may have five stars, a car might be Car of the Year and the new house is in a popular To compound the complexity of the decision- • Connectivity with Terminal ERP system up-and-coming area. The question is, how do making process we also identified the need you attach this type of perception and, of course, for a supplier that already had a significant peace of mind, to an industrial environment? pedigree in this market and understood

24 25 Need to address growing customer demands

international demands. And, just to make them In terms of deliverables we are expecting work really hard, we modular and scalable efficiency gains, far greater data integrity, more solution – we weren’t going to jump in with stringent adherence to industry and legislative both feet, we wanted to see a pilot project requirements, better process control and, of that could be scaled up and migrated across course, better quality levels. We can now show our existing infrastructure. We needed an our customers and the industry in general that organisation that would hold our hand and we are in line with GMP guidelines and that lead us towards an optimum solution. we can offer traceability and serialisation for all Each stage of this planning process saw more production parameters. and more suppliers falling by the wayside as There aren’t many suppliers that could offer we culled the list of potential suitors down what we needed, even fewer had the necessary to a select few. I am pleased to say that we industry experience and only one gave us the eventually opted for one that said the right peace of mind we were looking for all along. things, had the right solutions, knew precisely This is a complicated process and, sure, it has what we wanted and knew the pharmaceutical its risks, but find the right supplier and life industry inside out. More importantly, they give becomes immeasurably easier. us the all-important peace of mind. So, where are we know? This process started two years ago and we have made huge strides. From the very first step of knowing the best time to start the evolution, we have since developed a pilot project based in a new development at one of our plants, which is running in parallel with an existing line, so we can compare results.

26 27 corosys DELIN Elettronica

Food & Beverage corosys Prozeßsysteme und Sensoren Oil and Gas DELIN Elettronica is a system integrator GmbH (corosys Process Systems and headquartered in Modena, Italy. Sensors plc) is a manufacturer and Established in 1983 as a distributor supplier of sensors, components and of electronics systems for industrial complete process systems for the automation, the company has since worldwide brewing, beverage, chemical/ moved its focus from sales to engineering pharmaceutical and biotechnology and now offers its system integration industries. capabilities in both automation and process control applications.

Challenge Solutions Challenge Solutions A Rockwell Automation solution was installed, A PlantPAx® distributed control solution from corosys needed to adopt a new which included: Technical specifications imposed Rockwell Automation has been installed. control system for the US brewing • Integrated Architecture by the end-customer demanded This includes: industry, which entailed a complete • Allen-Bradley CompactLogix programmable a considerable evolution of the • High End process controllers in standard and SIL2 configuration redesign of its existing architecture. automation controller (PAC) control system architecture, • Allen-Bradley PanelView HMI • Rockwell Automation Library of with safety management at SIL 2 Process Objects Level, full redundancy and smart Results • Remote I/O in redundant configuration equipment management on • EtherNet/IP Infrastructure with • Engineering time cut from four to two days Foundation Fieldbus. DLR technology • Simpler deployment and integration due to • Foundation Fieldbus hardware and software running in a single platform • HART protocol • Single, open communication protocol offers • Redundant OPC interface more streamlined access to wider control To read the full infrastructure and remote maintenance To read the full Results application story visit channels application story visit • Project standardisation • All hardware already certified for US market • Availability of real-time information on • Simpler programming than incumbent equipment diagnostics supplier • Smart equipment management on • Ability to offer remote maintenance for Fieldbus Foundation customers (already put into practice)

28 29 KCC ProLabNL

IndustryChemical For over half a century, KCC has been Oil and Gas ProLabNL, located in Arnhem in a technology innovation in building The Netherlands, is an independent test materials such as glass windows, doors, facility for oil and gas process equipment. exterior/interior materials and flooring. The company offers state of the art, They moved into the silicone business, large-scale test facilities that operate with an area ripe for the creation of high- live hydrocarbons (natural gas and crude value products in the fields of specialized oil) at high pressures in order to simulate paints and next-generation precision real oilfield conditions. Its flow loops chemical engineering. In April 2014, have been used extensively for subsea KCC was named the No. 1 brand in the technology qualification programs of windows and doors material segment. major oil and gas companies.

Challenge Solutions Challenge Solutions • Standardized system enabled by PlantPAx®, A Rockwell Automation PlantPAx® DCS was Increased market demand required The Modern DCS ProMotion BV was tasked with installed, which included: new line at new facility. • Integrated Architecture based on finding a replacement process • Rockwell Automation Library of Process ControlLogix L7x, Motion and EOI control system that could address Objects Increased engineering • PlantPAx® library and pre-designed multiple technical- and time-related • High-level process automation controller development time and cost. faceplates engineering issues coupled with • SCADA software • Historian software Unplanned downtime and Results stringent customer demands. increased maintenance. • Asset-management software • Improved efficiency 20 % for consistent cost • Data collation and trend presentation Outdated machines, devices and savings software components. • Reduced engineering time from 14 months • TechConnect support contract to 11 months (through simultaneous • Knowledge and support resources electrical design and program development) • Reduced two-hour downtime to one- Results To read the full hour recovery; with 50 % cost savings for To read the full application story visit maintenance application story visit • 50 % reduction in set up • Significantly reduced engineering effort • Easier-to-use software • Better information presentation using multiple displays • Far more flexible system

30 31 Quimikao Stemming the Next Pandemic

Household & Personal Care Quimikao was established in Mexico more than 35 years ago. Today Quimikao produces products for the North and South American, Asian and Australian markets. The company primarily produces cationic surfactant derivatives of fatty acids for use in a wide range of products, from fabric softeners and fragrance compounds to asphalt emulsifiers and corrosion inhibiters used in petroleum.

Challenge Solutions At the iBio plant in College Station, • PlantPAx® Process Automation System Texas, living plants are used as Construct a greenfield facility in • Single platform controls every phase of the bioreactors to produce vaccine- Mexico to meet growing production nitrile production process. grade protein. plant) are seeded per tray and sent to one of • Advanced networking, monitoring and two grow rooms. The 55-ft-high laminar air- demand. They grow 330,000 kg of plants in one year, diagnostics help increase preventive flow room where germination takes place was and the biopharmaceutical company’s facility is Model design of new facility after maintenance and reduce repair costs. designed using computational flow dynamics more than 100,000 sq. ft., stands more than five and temperature-controlled within 2 °F. The a chemical plant in Japan, but use • Virtualized Infrastructure stories high and sits on a 21-acre site. second, larger growth room stands 14 layers a North America-based control • The higher availability and faster disaster The iBio Vertical Pharming manufacturing high with a capacity of 1.2 million plants. recovery compared to conventional system supplier to reduce language process involves three steps — plant Agroinfiltration is where the magic happens. infrastructures reduces equipment and time-zone barriers. production, plant infiltration and downstream It’s where iBio infects the plant with the vector downtime. purification in autonomous cleanrooms. for a transient expression of new protein. The Everything is automated that can be plants are placed upside down in an infecting Results automated— they don’t allow people to touch liquid, evacuated to one-third of atmosphere, the plants. • Successful Technology Transfer and brought back to atmospheric. All of their The process was originally developed in protein-synthesizing DNA is hijacked. To read the full • Increased redundant control and visibility a challenge from the Defense Advanced application story visit into all aspects of processing Once the plants are fully grown, their proteins Research Projects Agency (DARPA) and are extracted in one of the seven autonomous • Performance Improvements involved being emailed gene sequence and a clean rooms. Built as portable pods, each clean • Increased production efficiency, and request to make 50 million doses in 12 weeks. room has 100% redundancy, are fully moveable improved product quality and consistency It’s what stops a pandemic in America. via air bearings and are controlled using the Some 1,200 plants of vacuum-infiltrated PlantPAx® distributed control system. Nicotiana benthamiana (an Australian tobacco They used some very advanced techniques.

32 33 Process skid solutions

And now, they’re currently working in Brazil In the pharmaceutical industry, the final and South Africa to transfer the technology to customer is the patient. Mistakes are not other countries. allowed. Their strategy is that improvement should be They have to be 100% correct each time, which iterative, not retrospective. For iBio, that means is a daunting task. Quality by Design includes starting with baseline equipment and software, assessment, quality target product profile, risk then improving on it. With the initial layers of analysis, process development and validation. automation already in place, the next step will As one of the most regulated industrird on be to add the manufacturing execution system the planet, iBio is thinking inside the box. (MES) to the top layer. And they must have a constantly improvable environment. Find out more about the PlantPAx® modern DCS from Rockwell Automation.

34 35 Bausch+Ströbel Dinnissen Process Technology

OEM Bausch+Ströbel, from Baden- OEM Dinnissen Process Technology was Württemberg, has been focusing on founded in 1948 as a machine specialist special-purpose machines for the global for the compound feed industry. Rapid pharmaceutical industry for the last regional growth and development of 51 years. this sector continually challenged the Its product offering ranges from semi- company to apply all of its innovative automatic machines for labs, through talent and expertise. fully automated single machines, on to The company’s customer list now highly complex facilities for the industrial includes many of the world’s leading processing. foodstuffs, chemical, pharmaceutical and feed manufacturers.

Challenge Solutions Challenge Solutions • Allen-Bradley ControlLogix® programmable • An Allen-Bradley GuardLogix® programmable Development of VarioSys a automation controller (PAC) Catering for all customer demands, automation and safety controller maximum flexibility, user-friendly • Allen-Bradley Kinetix® 5700 servo drives including those enforced by local, • Allen-Bradley PowerFlex® 525 modular system, in which a SKAN • Allen-Bradley servo motors national or international legislation variable-speed drives standardized isolator system • EtherNet/IP™ network and developing new, tailor made • Allen-Bradley PanelView™ HMI manufactured by the company solutions. • Allen-Bradley POINT I/O™ can be combined with a wide Results • Stratix® 2000 Unmanaged Ethernet Switch range of machine modules from • Nested vials can now be processed • EtherNet/IP™ network Bausch+Ströbel on the basis of a with 100 % in-process control (IPC) at full machine output Results lock-and-key principle. • Maximum flexibility • Designing of a new mixing concept • Seamlessness that is as lean as possible • Addressed specific customer demands

To read the full To read the full • Easy programming application story visit application story visit

36 37 Feluwa Frames

OEM FELUWA Pumpen GmbH originally focused OEM The Frames Group describes itself as on the manufacturing of combustion, air providing the vital link between the well and water technology equipment, but and the pipeline in the international soon switched to concentrating on pump oil and gas industry. It designs, builds technology. In the meantime it joined the and delivers separation technology, oil ranks of the leading suppliers of technology and gas treatment, flow control and in this field. In this context, the company safeguarding systems and modules and covers the entire spectrum, starting with integrated solutions, such as total plants, their development, construction and working directly with its customers to manufacturing, right up to global sales and optimize upstream, onshore and offshore encompassing services. processes.

Challenge Solutions Challenge Solutions • Allen-Bradley PowerFlex 525 A Rockwell Automation PlantPAx® DCS solution Continuously changing variable-speed drives Frames Flow Control & was installed, which included: requirements regarding modern • Allen-Bradley PowerFlex 753 Safeguarding was challenged with • ATEX-certified Controllers & I/O pump systems. variable-speed drive constructing nine autonomous • ATEX-certified managed Ethernet switches well-site control and safety skids • ATEX-certified panel PCs and OWS Results that could operate effectively in • AADvance safety controllers and software • Major efficiency a remote location with minimal • In depth industry and application knowledge • High degree of availability operator interaction. • Low wear and tear Results • Fully autonomous, solar-powered well-site control and safety skids • Fully integrated control and safety solution • Simpler integration with ESD and third-party

To read the full To read the full equipment application story visit application story visit • Easier programming due to the Rockwell Automation Library of Process Objects l • Simpler installation due to open integrated environment • All on single skid – real estate and cost savings • Low power demands suitable for solar power

38 39 FrymaKoruma IMA Automation

OEM FrymaKoruma is among the world’s OEM IMA Automation comprises leading leading suppliers of process engineering companies in the assembly industry. machines and process facilities for the This group has proven itself as one of the cosmetics, chemical and pharmaceutical most innovative world leaders in the field industries, as well as for food of assembly solutions. manufacturing. IMA’s philosophy is based on research and innovation and, as a result, owns more than 1,700 patents and patent applications.

Challenge Solutions Challenge Solutions • Allen-Bradley® CompactLogix™ • MagneMotion independent cart technology Development of Dinex machine, programmable automation controllers Design of the newest modular • Allen-Bradley® ControlLogix programmable which is an all-rounder, capable of • Allen-Bradley® FLEX™ I/O modules platform for the automation automation controller manufacturing everything from • Allen-Bradley PowerFlex® AC drives industry, which had to meet the • Allen-Bradley PowerFlex® variable-speed pharmaceuticals to toothpaste. • Allen-Bradley PanelView™ graphics terminal need for speed and flexibility in drives • Allen-Bradley VersaView® industrial computer manufacturing. • Allen-Bradley Kinetix® servo drives • Allen-Bradley PanelView™ Plus HMIs Results • FactoryTalk® View • Highly diverse scope of functions • EtherNet/IP™ network • Increased flexibility – machines are easily • Stratix™ switches adapted to customer’s requirements • Fast support from Rockwell Automation Results • Streamlined design and programming times

To read the full To read the full • Reduced wiring application story visit application story visit • Easier troubleshooting, testing and validation • Lower TCO • Incredible machine flexibility • Reduced maintenance, changeover and training times • Minimized installation and start up times

40 41 IMA Automation Zellwag

OEM IMA Automation comprises leading OEM Based in Frauenfeld, Switzerland, Zellwag companies in the assembly industry. AG was founded in 1990 as Engineering This group has proven itself as one of the & Sales company. In 2015 Zellwag most innovative world leaders in the field Pharmtech AG was founded and became of assembly solutions. part of Rychiger a world leader in filling IMA’s philosophy is based on research and sealing solutions. and innovation and, as a result, owns The company focuses on machines more than 1,700 patents and patent and customised solutions that deliver applications. affordable Swiss quality, high flexibility and striking simplicity.

Challenge Solutions Challenge Solutions • Allen-Bradley® ControlLogix™ programmable • Allen-Bradley® Compact GuardLogix™ Development of EVO FLEX ROTARY, automation controllers Design of a fully automated programmable automation and safety an assembly-indexed rotary • Allen-Bradley GuardLogix® safety controller robot-based filling and closing controller platform based on space-saving • EtherNet/IP network machine which complies with • Studio 5000® programming environment design, which is ideal for the • Allen-Bradley POINT I/O™ pharmaceutical and biotech • Allen-Bradley Kinetix® 5700 servo drives assembly of large quantities of • Allen-Bradley PowerFlex® 525 manufacturers’ regulations. • Allen-Bradley VersaView 5400 IPC Panel PC complex, market-ready products, variable-speed drives • EtherNet/IP™ network such as medical devices and caps & • Allen-Bradley Kinetix 5700 servo drives Results closures. Results • Fast product change, • Increased flexibility • Easy cleaning of the machine • Streamlined design and programming times • Compact design and high flexibility • Reduced wiring • Easier maintenance and troubleshooting

To read the full • Easier troubleshooting To read the full • Reduced training time application story visit • Reduced maintenance and training times application story visit • Quicker changeovers • Enhanced safety • Reduced format costs

42 43 Zeton Zippe

OEM As the world’s leading designer and OEM Within the international glass industry, builder of innovative lab scale systems, ZIPPE is renowned as THE contact of pilot plants, demonstration plants and choice for batch and cullet plants. small modular commercial plants, Owner-operated in its fourth generation, Zeton BV helps its customers bring new the company was formed in 1920 and technology and processes to market, supplies everything from one source – faster, with less risk and lower cost. from planning up to commissioning. 45 experienced individuals are responsible for the realization of modern, high-performance automation and control systems at ZIPPE.

Challenge Solutions Challenge Solutions • Allen-Bradley ControlLogix A Rockwell Automation solution was installed, Zeton works hard to understand • programmable automation controller (PAC) Erection and commissioning of a which included: specific customer requirements • Allen-Bradley PanelView Plus HMI high-availability and extremely • PlantPAx® ready system from Rockwell and its unique solutions at • FactoryTalk® View Site edition (SE) powerful batch plant within the • Allen-Bradley PowerFlex AC drives the laboratory, pilot plant and • EtherNet/IP™ alongside Modbus and Profibus timespan of only one year. • EtherNet/IP Network demonstration plant scale provide Connection of external systems exceptional value in the most Results Results such as a special electronic challenging process development • Cross-discipline solution • Engineering time for software developments weighing system and bar code niches. reduced by 30 % • Integration readers. • Hardware and software are easy to learn, • Simple and quick implementation of external operate and maintain Setting up of a fully redundant systems system. • High availability • Simple scalability

To read the full Read our process • Uniform look and feel for users application story visit application stories here • Visibility of ongoing processes • Simple fault diagnostics

44 45 Facility of of the the Future Future Achieve a new a new level oflevel efficiency of efficiency and flexibility and flexibility Biotech solutions from Rockwell Automation are built on a scalable automation platform, delivering fully integrated,Biotech solutionsflexible systems. from Built-in Rockwell plug & Automationplay technology allowsare built you to on easily a scalableconfigure automationand control mobile orplatform, disposable delivering equipment. fully integrated, flexible systems. Combined with our Manufacturing Intelligence and MES solutions, the solution provides flexible multi-product manufacturingBuilt-in plug with & play real-time technology visibility and allowstraceability. you to easily configure and control mobile or disposable equipment. Combined with our Manufacturing Intelligence and MES solutions, the solution provides flexible multi-product manufacturing with real-time visibility and traceability. Book your seat for Single Use Biotech Demo at our booth at the Achema show June 11–15 in Frankfurt, Germany

Allen-Bradley, LISTEN. THINK. SOLVE. and Rockwell Software are trademarks of Rockwell Automation, Inc. Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Learn more about our Biotech solutions

Allen-Bradley, LISTEN. THINK. SOLVE. and Rockwell Software are trademarks of Rockwell Automation, Inc. Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. How Do You Keep up with the Industry Challenges?

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Publication:Publication PROCES-BR034A-EN-PPROCES-BR049C-EN-P –– AprilMay 20182015 Copyright ©2018 Rockwell Automation, Inc.Copyright All Rights ©2015 Reserved. Rockwell Printed Automation, in the EU. Inc. All Rights Reserved. Printed in USA.

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