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.
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.
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)
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.