Automation and control
The control room is the heart of the plant, since it is the operating center to monitor and control the whole technological process.
A DUE develops internally all management software for processing rooms making use of the most important and popular platforms (e.g. Wonderware/System Platform, Siemens WinCC TIA Professional, Rockwell Factory Talk, etc.)
The automatic management of the specific recipe of each drink, the continuous monitoring, recording and storage of all the main process parameters, are the operations that ensure quality and traceability of the finished product.
All this is only possible with a high level of plant automation.
With 50 years of experience in the beverage industry, A DUE has developed its own automation and process control philosophies based on the following principles:
data sharing through networks;
The above-mentioned concepts are applied to PLC and supervision system programming, which, suitably integrated with the main fieldbus, form the basis for complete automation of the process systems.
SCADA (“Supervisory Control And Data Acquisition”) information systems are used to monitor and control the industrial processes.
The purpose of the Supervisory system is to control a complex reality, where the acquisition of a large quantity of data in real time, their processing, interpretation and presentation are essential for an activity to function.
In fact, the decisions concerning the running of the plant itself are taken on the basis of these data and they cannot be collected manually.
The Supervisory software is active in each processing phase to historicize the data coming from all the machines being used and adjust their functioning.
The Supervisory system consists of one or more PC connected to the PLC of the plant through an ethernet network, where the main software is installed to allow the plant functioning, to guarantee its protection and monitoring.
The Supervisory system is supplemented with the assistance through remote access (VPN), provided in standard configurations of all our plants.
By means of the ethernet network the Supervisory system exchanges all data relating to the plant with the PLC of each machine, making the information available in real time.
Besides this, the data are also saved in the system HD and displayed in historical trends, lists of events, alarms and reports.
The Supervisory system allows to display interactive mimic charts of the plant.
The following charts can be displayed:
devices activation status (pumps and valves),
field analog values (pressures, flow rates, levels, etc.),
alarms and messages subdivided according to the processing areas,
digital sensors and limit switches,
coloured visualization of the plant piping, according to the type of fluid (water, syrup, washing solution, steam, etc.),
state of the various cycles with a specific indication on the ongoing phase,
All the above data can be accessed quickly and intuitively through simple surfing within the available in the Supervisory System pages.
The Supervisory system is able to command the whole plant, by operating utilities and cycles and modifying the system parameters and all the recipe data that are present.
The main feature of the Supervisory system is data historicizing.
Alarms: there is an alarm history archive containing the alarm detailed indications.
Events: there is a log-event management, which records such events as: the cycle start/stop, the password login/logout, the manual/automatic switching of various devices, system parameters variations.
Analog signals (Trends): the field analog values are recorded and can be displayed in trend curves.
The data relating to Alarms, Events and Analog signals can be directly accessed from the Supervisory System. Alternatively, the above data can be exported in a CSV-format.
Reports: the files are generated in CSV-format and contain the key data relating to the specific system activities, such as: execution of recipes, washing, pasteurizing etc.
By way of example, the data stored and grouped according to the concerned machine types are the following:
Batch Control: recipe data, quantities actually dosed, batch start/end date and time.
CIP UNIT: recipe data, collected process parameters, washing start/end date and time, washing cycle result.
Blender: recipe data, collected process parameters, start/end date and time of the blending cycle..
Pasteurizer: recipe data, process phase start/end date and time, recirculation times.
All operations controlled by the Supervisory System are subject to log-in of individual Users who have a multi-level access to the system through the dedicated passwords.