Delivering the Most Automated Corn Processing Facility in the World

A new corn processing facility enlisted the help of Cybertrol Engineering to become the most technologically advanced, flexible, and efficient plant of its kind in the world.

Challenge

Corn processing facilities are typically run with a hodgepodge of OEM (Original Equipment Manufacturer) equipment with manual interconnects and manual sequencing, leading to less flexibility and more time-consuming changeovers. The goal for this facility was full automation and flexibility.

Solution

Cybertrol developed streamlined designs for the DCS (Distributed Control System), MCCs (Motor Control Centers), control panels, and software designs by implementing several design features, including:

• Rockwell Automation PlantPAx® Distributed Control System (DCS)
• State-of-the-art OT (Operational Technology) network design to to enable an IIoT (Industrial Internet of Things), and a digitally transformed facility
  • Thousands of plant floor connections to devices, OEM Equipment, MCC equipment, control panels and HMI’s
  • OT Infrastructure design of IDFs (Intermediate Distribution Frames) and wireless network
  • Best practice security design integrated with IT (Information Technology), MES (Manufacturing Execution System), CMMS (Computerized Maintenance Management System), and plant floor MCCs integrated with Ethernet
• Formulation system with over 200 recipes for products
• Flexible operation with options for over 600 routings of product
• KPI (Key Performance Indicators) and OEE (Overall Equipment Effectiveness) reporting systems for:
  • Quality reports
  • Yield reports
  • Shift production dashboards
  • Lot reports for material management and tracking
• Software designed with modular concepts utilizing PackML (Packaging Machine Language) programming design
• OEM equipment integration
  • Dozens of OEM sub-systems from global suppliers
  • Standardized integration design
  • All controlled from the distributed control system (DCS)

Results

As a result of this project, this facility is now the most automated corn processing facility in the world with the industry’s best ship time, reduced staff, increased yield, low cost of production, and expansion into new markets.