Interplastic Corporation, a leader in specialty resin production, sought to modernize the batch processing system at its Fort Wright, Kentucky, facility. The goal was to enhance product quality and consistency through total automation while addressing inefficiencies and streamlining operational challenges.
Interplastic partnered with Cybertrol Engineering to implement a cutting-edge solution employing Rockwell Automation's PlantPAx® 5.0, FactoryTalk® Batch, and Cybertrol's BatchWorks, a comprehensive MES software enhancing recipe management and integrating seamlessly with the ERP system. The success of this project at their Fort Wright location has since led to repeat business and requests for implementing similar solutions at Interplastic’s other facility locations.
Overcoming Legacy System Limitations in a Tight Downtime Window
At Interplastic, a resin manufacturing facility operating 24/7/365, the challenges were multifaceted. Their primary issue was an outdated, manual batch process software system that created the core component for all their products. This system relied heavily on operator knowledge and was highly repetitive, with operators essentially “reinventing the wheel” with each batch. The manual nature of the system resulted in inconsistencies, unintentional errors, slow production, and elevated operational costs due to product waste and scrap. These problems were exacerbated by the facility's continuous production schedule, where even minor downtimes or product errors could lead to significant financial losses. Additionally, the previous system experienced up to a two-minute delay between commanding a function and the system responding, leading to a significant lack of trust by employees.
Apart from the operational inefficiencies stemming from the software, Interplastic faced significant challenges with their hardware setup. Their existing control system was technologically obsolete and lacked a distributed or redundant environment. The entire plant's operation relied on a single desktop computer, which frequently encountered issues, leaving them dependent on an aging, unreliable 20-year-old computer as a single point of failure. This setup meant that any malfunction could halt the entire production, leading to significant downtime and financial losses. Additionally, outdated PLCs and I/O modules further complicated their operations.
Given the complex chemical nature of the resin production process, it was crucial for Interplastic to simplify system operation without compromising quality. The previous system required operators to tend the HMI nearly 100% of the time, making them “slaves to the HMI” and limiting their ability to perform other meaningful tasks.
With the need to overhaul both their software and hardware while working around tight time constraints, Interplastic required a robust solution that could integrate seamlessly with minimal disruption to ongoing operations. Cybertrol was able to address these unique challenges by developing a total automation solution featuring a fully distributed, modern control system. This upgrade provided redundancy, modern server technology, and a new network, significantly improving stability and instilling confidence in both the hardware and software systems.
The most challenging aspect of this project was the time constraint. Cybertrol had only a narrow seven to eight day window of scheduled downtime to perform the hardware cutover. This limited timeframe demanded precise planning and execution to ensure both the hardware cutover and the semi-automated deployment could be completed without extending the plant's downtime, thereby avoiding profit losses.
Integrated Automation with PlantPAx, FactoryTalk Batch, and BatchWorks
Cybertrol Engineering implemented a comprehensive automation solution that integrated seamlessly with Interplastic's existing manufacturing execution system (MES). The solution featured:
Integrated Automation
PlantPAx 5.0 Integration
BatchWorks MES Software
Batch Analytics and Reporting
To strategically make the most of the limited time available for implementation, a phased commissioning approach was utilized.
Phase 1: Electrical Cutover and PlantPAx SCADA Implementation
Phase 2: Semi-Automated Operation with PLC Equipment Modules and Equipment Phases
Phase 3: Total Automation with FactoryTalk Batch and Cybertrol's BatchWorks
Significant Improvements in Production Control, Quality, and Efficiency
Interplastic's automation journey culminated in a state-of-the-art system that not only reduced errors and increased production but also empowered their team with improved data visibility and process control. This enhanced control not only justified the cost of the project but also promised increased profitability through improved efficiency and reduced errors. The plant gained greater flexibility and a higher degree of confidence in the new system compared to the old manual processes. The newly installed PlantPAx 5.0 platform, combined with Cybertrol's BatchWorks, revolutionized how Interplastic could monitor, adjust, and report on their production processes. Results included:
Scalable Automation Across Facilities
The success at the Fort Wright production facility sets a foundation for future rollouts across other Interplastic locations. Interplastic has four main production facilities: Fort Wright, KY, Minneapolis, MN, Hawthorne, CA, and Pryor, OK. The positive outcomes at Fort Wright have led to plans for similar projects in Minneapolis and Hawthorne with discussions about revisiting the Pryor, OK, facility to implement the strategic ideas developed at Fort Wright.
Want to learn more about our partnership with Interplastic? Check out this featured article in Control Engineering: Lessons for Manufacturers in the Digital Transformation Journey