Success Case - Modernizing Production Through Automation: A Success Case for Ingrain’s Carbon Plant Upgrade

Ingrain, a leading player in the food and beverage industry, recognized the need to modernize its production processes to stay competitive and improve efficiency. With outdated automation systems limiting performance, the company embarked on a major upgrade to enhance its carbon plant's capabilities. The primary goal was to replace old technologies with state-of-the-art solutions that would boost performance, reliability, and maintainability, positioning the company for long-term success.

Customer Requirements

At the core of Ingrain's upgrade was the need to overhaul its Supervisory Control and Data Acquisition (SCADA) system, which had become obsolete. The key requirements were clear:

1. Upgrade SCADA System: Replace the existing SCADA system with the latest Siemens WinCC software.
2. PLC Replacement: Swap out the outdated Programmable Logic Controllers (PLCs) for Siemens S1500 PLCs, ensuring uniformity in hardware and software across the plant.
3. Enhanced Functionality: Leverage improved function blocks to boost system performance and simplify ongoing maintenance.

Solution Design

To meet these requirements, 4Sight OT Automation designed a comprehensive solution, blending cutting-edge hardware and software to meet Ingrain’s modernization objectives.

Hardware

• PLC: Siemens S1500 PLCs and I/O cards were selected for their superior performance and flexibility.
• I/O Configuration:
  • 32 Digital Inputs (DI)
  • 16 Digital Outputs (DO)
  • 24 Analog Inputs (AI)
  • No Analog Outputs (AO)
• Communication Protocol: The system relied on ProfiNet for seamless communication between PLCs.

Software

• SCADA System: The Siemens WinCC Runtime (RT) with 512 tags in a standalone configuration was chosen to oversee plant operations.
• Additional Equipment: The solution included a desktop PC equipped with a 27-inch monitor for enhanced user interface experience.
• Software Versions:
  • PLC Programming Software: TIA Portal V16
  • SCADA Software: WinCC 7.5 SP2

The new SCADA system was optimized to handle all internal tag archiving, eliminating the need for external communication with other PLCs or Manufacturing Execution Systems (MES). This approach streamlined the setup and focused resources on core operational needs.

Implementation

4Sight OT Automation managed the entire implementation process, ensuring a smooth transition for Ingrain’s carbon plant:

• Supply of Equipment: Provision of Siemens PLCs, SCADA software, and Yaskawa drives to equip the plant with the necessary hardware.
• PLC Program Conversion: The existing PLC program was upgraded using 4Sight’s standard blocks, improving functionality and making troubleshooting more efficient.
• On-Site Commissioning: Comprehensive testing and validation of the new system were conducted to ensure that the plant was ready for full operational capacity.
• Handover and Training: Ingrain's team received thorough training on the new system, ensuring smooth operation and confidence in handling the upgraded technology.

Customer Benefits

The carbon plant upgrade delivered several significant benefits to Ingrain, providing a strong return on investment and enabling the company to remain competitive in the evolving food and beverage industry:

• Enhanced Performance and Reliability: The upgraded system operates more efficiently, leading to increased production capacity and reliability.
• Improved User Interface: The modern SCADA system offers a more intuitive and user-friendly interface, improving operational oversight and usability.
• Scalability: The system is designed with future growth in mind, allowing for easy expansions or modifications as needed.
• Better Integration: Standardizing hardware and software promotes seamless integration across various operations, streamlining workflows and reducing complexity.
• Support & Updates: By utilizing the latest Siemens technologies, Ingrain can access regular updates and comprehensive technical support.

Conclusion

Ingrain’s carbon plant upgrade is a prime example of how investing in modern automation technology can significantly enhance operational efficiency. Through their partnership with 4Sight OT Automation, Ingrain successfully modernized its production capabilities, replacing outdated systems with the latest innovations. This upgrade not only enhanced performance and reliability but also positioned the company for future expansion and continued success in the highly competitive food and beverage industry.