1 (Formerly India Ltd.) plant is automated to achieve high quality product with optimum batch-time.

PROJECT AT A GLANCE

Project type Processing

Location India (Rewari-Haryana)

Application Bournvita – Malted Food Drink

System Components Cadbury India Ltd. is a part of Mondelez International. • UAG • M340 PLC Cadbury India operates in five categories – Chocolate • X-80 Remote I/O confectionery, Beverages, Biscuits, Gum and Candy. In  Vijeo Citect SCADA the Chocolate Confectionery business, Cadbury has  Vijeo Historian maintained its undisputed leadership over the years.  SUPERBatch Batch Management Some of the key brands are ,  Magelis HMI Bournvita, , Perk, Bournvita, Celebrations, Gems,  Altivar 32/ 71 VFDs  MCC , Éclairs, , and . It today has six company-owned manufacturing facilities at Thane, Customer Benefits Induri (Pune) and Malanpur (Gwalior), Bangalore and • Flexible Manufacturing Baddi (Himachal Pradesh) Hyderabad with the • Advanced Batch Process Management corporate office is in Mumbai. “Bournvita” – the Malted based on ISA S88 Batch Standard • High and consistent product quality Food Drink is their main product in the Milk Food drinks • Easy diagnostics segment. • Energy Management • Batch and Management Information Reports

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The Challenge

The liquid ingredients – Malt, Liquid Glucose, Cocoa Liquor, Caramelized Syrup etc. are charged in the in wet mix tank. Dry ingredients – Cocoa Powder, Crystal Sugar, Skimmed Milk Powder, Vitamin Mix, Mineral Mix, Whey Powder etc. are charged in the hopper. Both the liquid and dry charging process are working in parallel. Both the wet mix tank and hopper materials are charged in paste mixer and mixed. Paste mixer outlet called “magma” is transferred to magma heating tanks. The magma is separated in two parts. One part of the magma product is transferred to Chocotech system and other is transferred for the oven system. The output of Chocotech system is sent to Band Dryer. Band dryer is a long tunnel with four temperature zones under vacuum. The Chocotech product is distributed on ten conveyor belts which pass through the four zones. Dried cake coming out of the band dryer is crushed and the crushed product falls in a series of hoppers. The other part is dried in ovens and then crushed into powder. The Band Dryer and oven products are then mixed in certain proportion to get the final Bournvita product. Finally the product is sent to packing section for packing in different sizes of packages.

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The challenges involved in the process control were: 1. Accurate charging of liquid raw materials 2. Accurate charging of solid raw materials 3. Accurate Mixing time in mixers 4. Precise Temperature Control of liquid ingredients 5. Integration with “Chocotech” system used for cooking of Magma for Band Dryer 6. Temperature and Vacuum Control in Band Dryer 7. Conveyor speed and material flow control in Band Dryer 8. Integration with Parker Swivel system used for uniform cake width on the belts 9. Integration with CIP system 10. Recipe based flexible manufacturing 11. Management Information Reports and ready for integration with SAP in future.

The Solution:

Batch/Historian Engineering + Engineering SYSTEM CONFIGURATION Server Station Operating Station

SUPERBatch Modules 1. SUPERBatch Manager 2. Plant Editor 3. Recipe Engine

Ethernet TCP/IP 100 Mbps

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HMI EL0.0M HMI EL5.5M Ethernet TCP/IP 100 Mbps

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Remote I/O- 1 0.0 M Remote I/O- 2 5.5 M MCC Process Utility RIO C MCC BV Process RIO A LOCATION: Remote I/O- LOCATION: Remote I/O- 1 Panel N LOCATION: MCC BV Panel 2 Panel LOCATION: MCC Process O Utility Panel p e n OFFERED IO's DI DO AI AO Main Plant PAC 192 96 24 8 Process Utility MCC MCC BV Process RIO 192 96 16 16 MCC Process Utility RIO 192 96 16 16 LEGENDS : Remote I/O- 1 0.0M 128 64 32 8 ETHERNET TCP/IP 100 MBPS Remote I/O- 2 5.5M 128 64 32 8 CANOpen

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The system consists of 3 no. M340 Controllers - Main PAC, BV Process, Utility and 4 nos. Remote I/O stations - RIO1, RIO2, RIO3, PMCC RIO. There are two MCC panels – Process MCC and Utility MCC consisting of conventional motor starters and Altivar 32/ 71 VFD based starters. Conventional motor starters are connected with the PLC on remote I/O and VFDs are connected on Canopen bus. The PACs and remote I/O communication is Ethernet TCP/IP. One Engineering cum Operating Station and one Operating Station has been provided in the main control room. Two 10.4” Magelis HMI have been provided in the field for local operation. A Batch/ Historian Server has been provided for ISA S88 based Batch Management System - SUPERBatch and Vijeo Historian. Flexible recipe based operation is achieved through SUPERBatch, a Batch Management software based on ISA S88 Batch Standard developed by Supertech. SUPERBatch is tightly integrated with PlantStruxure components – UAG, Unity Pro, Vijeo Citect SCADA and Vijeo Historian. It uses the MS SQL Server data base integral with the Vijeo Historian for batch data as well. Various Batch reports and Historian based Management information reports are generated by the system.

For precise temperature and vacuum control standard PID control blocks from UAG library have been used. Special program was developed for complex control involved in Band Dryer according to the logic provided by the German OEM.

Following are the solutions provided for the key challenges: = 1. Accurate weighing of raw materials are achieved through load cells based weighing system which was developed by using material charging functional block, designed by Supertech. During auto charging through SUPERBatch every raw material (liquid and solid) is added accurately, following screen shows the comparison between set quantity and actual charged quantity.

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2. Solid raw materials are conveyed to Dry Batch hopper one by one as per the instructions provided in HMI, after every Dry material is charged acknowledgement is done through HMI as shown.

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3. Chocotech system (make: Allen Bradley) was integrated with Schneider-Electric control system. The SCADA screen is developed so as to provide supervision for chocotech system, controlling the main feed pump.

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4. Formation of cake with uniform width is critical parameter needed for appropriate product formation, for these two parameters were considered – Belt speed and swivel stroke. a. Belt speed: belt speed of band dryer is automatically calculated based on residence time provided on SCADA which decides period for which the material will be exposed to different temperature zones. b. Swivel stroke and speed: CANopen based communication is done between Parker Drive and Schneider control system, which enables the input options either through SCADA or through HMI. Furthermore resulting in control of stroke and speed of swivel.

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5. Modbus based communication CIP (clean in place) cleaning system is integrated with Schneider system which provides selection of appropriate equipment. Moreover it also indicates the CIP cycle status.

9 SUPERBatch – ISA S88 Based Batch Management System Advanced Batch Management is achieved by using “SUPERBatch” which is a Batch Management software developed based on ISA S88 Batch Standard and fully integrated with “PlantStruxure PES” architecture. It consists of six modules viz. Plant Editor, Recipe Engine, Batch Scheduler, Batch Execution, Online Batch viewer, Reports Viewer. SUPERBatch has enhanced the value of the Control System to the customer in following ways: Product Consistency with best use of Recipes Management comprising of SOP and formulations Automatic generation of Batch Reports, raw material consumption, comparison with Golden Batch, Aborted batches etc. Batch Based Data Availability for analysis that may result in KPI improvements such as optimum utilization of resources and achieving level of maximum production using improved Batch cycle Time etc. Provision is provided for back-to-back auto downloading of batches which saves time, provides accuracy and avoids unwanted adulteration/excess use of raw materials, which may occur during manual operations. And Many more…

Vijeo Historian Based KPI Reports

Process and Energy data from VJC and Batch data from SUPERBatch are recorded in MS SQL Server integral with the Vijeo Historian. Based on customer requirements, about 15 KPI reports were developed using Report Development Tool of VJH. Some examples are – Oven Cycle Time, Pasteurizer/ Sucrofilm/ Holding Tank Temperature, Dried Material Weighing, Vertical Silo Weight, No. of PSM Batches, Energy Consumption, etc. These reports can be viewed from any machine on Mondelez network through

Internet Explorer.

This system was designed and supplied by Supertech - Alliance Partner of Schneider Electric : Supertech Instrumentation Services (I) Pvt. Ltd. 12, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE – 400601 (Maharashtra) India Phone: +91-22-41550100 e-mail: [email protected] URL: www.supertech.co.in

[Grain Processing]

Navasasyam Processing Equipments 4 TPH Pigeon Peas Processing Plant is automated to achieve high quality product with minimum breakage and waste

PROJECT AT A GLANCE Project Type Grain Processing

Location Samay Agro, Latur, Maharashtra

Application 4 TPH Pigeon Peas Processing Navasasyam Processing Equipments is a team of experts in various field such as Process Design, Product Design & System Components Development, Engineering and Project management. • Modicon M580 Processor They are experts in planning and delivery of projects for • EcoStruxure Hybrid DCS the Grain & . They apply the latest • Specially Developed Templates technology and knowledge within key areas such as food safety, hygiene, process equipment design and CUSTOMER BENEFITS Selection, operational setup and controls, as well as efficiency in all processes including optimizing of energy • Higher Yield consumption and minimizing waste i.e. by-products • Continuous and consistent generation in process. production This project was executed by Navasasyam for M/S • Efficient Control System Adds to Samay Agro Dal Processing Mill at Latur in Maharashtra. highest level of productivity

• Reduced errors due reduced manual Supertech provided user friendly graphics and operating intervention faceplates in the DCS for the complex material handling • Increased Safety and Reliability of operations. They provided excellent support during Operation commissioning by adapting to the frequently changing • Optimum utilization of the mill process requirements. The project was completed within capacity, lower power consumption the desired project schedule” per ton of production Janardan Pawar Director, Navasasyam

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[Grain Processing]

The Process

The process consists of pre-cleaning the raw material with drum sieves and pre-cleaner machines to remove coarse foreign particles. Fine cleaning process removes fine dust, mud etc. Next the material passes through grading section in which it is classified into Bold, Medium and Small. The classified material undergoes hulling process in which peas are scratched to loosen the skin. Water and Oil is added to the hulled peas and kept for resting in the resting bins for 8-16 hours. The bins are then passed through heaters to achieve de-skinning. The process repeated till the complete skin is removed. The de- skinned whole peas then undergo splitting process. The split peas i.e. the Dal passes through the colour sorter. Colour sorter sorts the product into three types – Accept, Re-sort and Reject. The accepted product is sent for polishing in buff polishers or polishing conveyors. The finished Dal product is sent for bagging and packing.

Some of the pictures of the plant are as follows:

Dal Processing Plant Classifier

The Challenge

• To produce Quality product like- sharp edges, graded dal, reduction of powder • Minimizing grain breakage and waste • Reduce manual operation • Low operator skill levels • Complex Material Handling due to large no. of equipment

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[Grain Processing]

The Solution

The Automation system consists of EcoStruxure Hybrid DCS with 1250 objects license and M 580 Level 3 processor with 1200 nos. X-80 I/O.

The process involves charging and discharging of material and conveying by means of a series of conveyors and elevators, control of heating, water and oil addition etc. The plant consists of approx.. 450 motors with conventional starters and a few of them with VFD. All motors are controlled through DCS auto sequence. Customized Hybrid DCS templates were prepared for sequential operation, charging and discharging. Auto start-up, fault, stop and emergency shutdown sequences were developed. The auto sequences have a facility of PAUSE and RESUME. Operations are repeated multiple times depending on the quality of raw material.

DCS operating screens of some of the important operations are as follows:

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[Grain Processing]

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[Grain Processing]

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[Grain Processing]

The Benefits

• Unique innovative automated process reduces mechanical stresses and heat buildup in the grain, thereby minimizing grain breakage and producing uniformly polished grain, with higher Yield

• Automation allows multiple operations to be carried out at different stages simultaneously and results in consistent quality and higher throughput.

• Efficient Control System Adds to highest level of productivity

• Reduced errors due reduced manual intervention

• Increased Safety and Reliability of Operation

• Optimum utilization of the mill capacity, lower power consumption per ton of production

This system was designed and supplied by Supertech – Master Alliance Partner of Schneider Electric: Supertech Instrumentation Services (I) Pvt. Ltd. 12, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE – 400601 (Maharashtra) India Phone: +91-22-41550100 e-mail: [email protected] URL: www.supertech.co.in

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