Greenfield Process Control Installation at Ice Cream Manufacturer

A major global food manufacturer needed greenfield installation to create the largest ice cream manufacturing facility in the world. Cybertrol led the project to create a new robust facility capable of running 24/7 with zero downtime.

Challenge

Components had to be specified to keep the operation running 24/7/365 with minimal staff support. Programming standards had to allow for commonality between the systems throughout the facility. Ease of upfront installation and of any additions was a top concern as well.

Solution

The new facility required a flexible batching solution that could handle dynamic equipment arbitration across more than 100 source tanks/batch processes/destination tanks. The solution featured:

• Ability to integrate with a corporate formulation and costing system
• Seamless scheduling of plant production
• Utilization of FactoryTalk Batch in a virtualized, fault-tolerant environment
• Application that imported corporate formulas and allowed site-specific recipe parameters and production scheduling via a web interface 

Results

The result was the largest ice cream manufacturing facility in the world. The web-based application was tied to the corporate database and interfaced to FactoryTalk Batch for ease of use at the operational level. The entire server system was made highly available, with functionality built into an email or text support personnel in the case of a hardware failure or resource utilization issue.