A new corn processing facility was built to become the most technologically advanced, flexible, and efficient in the world.

Challenge

Corn processing facilities are typically run with a hodgepodge of OEM 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, MCCs, control panel, and software designs by implementing several design features, including:

• Rockwell Automation PlantPAx Distributed Control System
• State-of-the-art OT network design to to enable an IIoT, digitally transformed facility
  • 1000’s of plant floor connections to devices, OEM Equipment, MCC equipment, control panels and HMI’s
  • OT Infrastructure design of IDF’s and wireless
  • best practice security design integrated with IT, MES, CMMS, Plant Floor
  • MCCs integrated with ethernet
• Formulation system with over 200 recipes for products
• Flexible Operation with choices for over 600 routings of product
• KPI and OEE Reporting systems for:
  • Quality reports
  • Yield Reports
  • Shift Production Dashboards
  • Lot Reports for material management and tracking
• Software designed with modular concepts utilizing PackML programming design
• OEM equipment integration
  • dozens of OEM sub-systems from global suppliers
  • standardized integration design
  • all controlled from 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.