Green Plant Farms Selects PlantPAx to Achieve Automation Scalability for their New Patented Food Process Facility.

Transcription

1 Insert Photo Here Green Plant Farms Selects PlantPAx to Achieve Automation Scalability for their New Patented Food Process Facility Presenters: Steve Schiedemeyer Vice President of Engineering ESE, Inc. Tim Foster Vice President of Engineering Green Plant Farms Copyright 2009 Rockwell Automation, Inc. All rights reserved.

2 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 3 of 42

3 Executive Summary Green Planet Farms is a company dedicated to a legacy of environmental stewardship. Producing organic and nongenetically modified soy protein isolates for use in functional foods. GPF sought partners sharing similar core values. For its new facility, GPF partnered with ESE, Inc. (system integrator), using Rockwell Automation for its PlantPAx Process Automation System to successfully create a full-scale Greenfield manufacturing facility. This session will explore how GPF and ESE developed and then implemented the control solution utilizing: ControlLogix platform in a distributed control architecture Redundant FactoryTalkView SE wireless thin client based HMI architecture Endress+Hauser instrumentation Hardy Instruments weight controllers Integration to third party proprietary equipment and processes Multiple Allen Bradley IntelliCenter Motor Control Centers FactoryTalk Transaction Manager based acquisition with Microsoft Reporting Services 4 of 42

4 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 5 of 42

5 Green Planet Farms The earth is a gift......of which we are stewards 6 of 42

6 Green Planet Farms The founders of Green Planet Farms were executives, innovators, and consultants in the global foods industry They shared strong desire to create, brand, and market nutritious and environmentally responsible foods and ingredients Green Planet Farms: a company dedicated to a legacy of environmental stewardship and emerging as a global leader in the organic and non-gmo food ingredient industry 7 of 42

7 Green Planet Farms Green is a beautiful color Plant design & construction takes into consideration maximized use of recycled materials, natural lighting, energy efficiencies, waste reduction GPF recovers 80% of all the heat from steam use NE DEQ did not require an air permit from GPF due to superior air quality remediation engineering Working with industrial neighbor to take GPF s sugar water and convert it into bio gas to create methane and reduce their nitrogen contamination in waste water discharge 8 of 427

8 Green Planet Farms Green Planet Farms (GPF) a $40 million, 195,000 square-foot Soy Protein Isolate (SPI) manufacturing facility in South Sioux City, NE. 9 of 42

9 Green Planet Farms Unlike other SPI manufacturers No hexane a gasoline byproduct during the extraction process. Only soy protein manufacturer: Able to utilize full fat soy flour Proprietary water process Nutritious, High quality proteins Hexane free. GPF s main focus is to serve organic and non-genetically modified protein isolates to food and beverage producers worldwide. 10 of 42

10 Green Planet Farms Soy Extraction To transform soybeans into a 100 percent soluble protein isolates, Green Planet Farms process includes: Milling soybeans into a full-fat soy flour Patent-Pending water based extractions process separating fiber, fat, and sugar. Extracted liquid protein is spray dried Packaging 11 of 42

11 Green Planet Farms Company Green Planet Farms proprietary process has introduced a breakthrough product line a dry soybean protein with a more stable nature something the market has not previously seen. Soygeia TM Breakthrough Product Line Soygeia TM Beverage SPI Soygeia TM Meat & Meatless SPI Soygeia TM Bakery & Snacks SPI Soygeia TM Nutra-Macro TM Foods This means when drinking a protein beverage, for example, the protein doesn t sink to the bottom of the glass and require frequent shaking or mixing. The protein also has no detectable flavor, a significant advantage over other proteins that carry a distinct soy aftertaste. 12 of 42

12 Green Planet Farms Company Green Planet Farms stands out from other producers due to its passion to leverage a highly sustainable production process. Triple bottom line people, planet and profit. Founders of the company help keep sustainability a leading Our entire company principle warehouse for every decision employees that s to top made. management shares the same core value system when it comes to sustainability. We pride ourselves on partnerships The with company s organic farmers, sustainability as well as clean commitment: processes and facilities. Sustainability goes Small the way farmers from who the air are we growing breathe organic to the energy produce and methods we deploy for the safety and health of our employees. Ingredient processing, are completed using organic Susanne Stoeger-Moore, Board Chairman and Chief Marketing Officer, Green Planet Farms. methods Quality products with a minimal footprint on the environment. 13 of 42

13 ESE, Inc Company Profile Innovative Food Processing Solutions Advanced Plant Automation System Best In Class Control Systems Rockwell Automation Solution Provider Rockwell Automation Process Industry Partner CSIA Certified 2005, recertified 2008 Integrated UL 508A Panel Shop 14 of 42

14 ESE, Inc. Company Profile Since 1981 at the forefront of delivering advanced plant automation Nationwide reputation for blending top-of-the-line analytical solutions with best-in-class control systems and sophisticated software for data collection, reporting, and lot tracking Solid reputation among leading food and beverage manufacturers for providing: Innovative Q5 analyzers fast, accurate food analysis using near infrared technology Smooth system commissioning and quick process retrofits improve ROI High-quality electrical design and control panel fabrication ensure consistency In-depth knowledge of fluid, batch, and blend processes provides optimized processes Advanced process design and best-in-class control systems assure the right system at the right price 15 of 42

15 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 16 of 42

16 Business Situation Green Planet Farms Nebraska facility was only a concept before Back then, the team of three knew they needed a large facility for their growing business. As a small growing business, Green Planet Farms needed: Cost-effective solution Maximum design and manufacturing flexibility Sustainable focus through prudent utilization of used equipment Timely delivery The selection process involved two primary phases: Selection of the automation hardware platform Selection of the system integrator 17 of 42

17 Business Situation Precise Process Control was Imperative Control system must be extremely advanced Fewer total employees, but more highly qualified Require minimal training and maintenance System Cost was a Concern Cost effective solution Accurate project estimates As a pilot, our primary challenge involved migrating from a lab environment to a full-scale, automated manufacturing facility. There were general ideas for how the production process should run, but as with most pilots, transitioning from a lab environment requires maximum design and manufacturing flexibility. Susanne Stoeger-Moore, Board Chairman and Chief Marketing Officer, Green Planet Farms 18 of 42

18 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 19 of 42

19 Finding a Partner Why Rockwell Automation/ESE? Strong commitment toward environmental stewardship Experience implementing innovative manufacturing processes Rockwell Automation is a recognized leader in corporate responsibility ESE is a recognized industry solution provider GPF engaged ESE for the initial process design with special emphasis on the control strategy ESE designed the process control system using the PlantPAx process automation system from Rockwell Automation and Partners Allen-Bradley ControlLogix programmable automation controllers Allen-Bradley IntelliCenter motor control centers Rockwell Software FactoryTalk View SE HMI environment Endress+Hauser process instrumentation ProSoft Technology wireless access topography Hardy Instruments weight controllers 20 of 42

20 Design Collaboration Project success nurtured from the beginning ESE and Green Planet Farms worked jointly Development of the initial process flow schematics Defining the critical process control points Instrumentation requirements Control system functional and operational requirements Functional Description Defined the process from a equipment level; defined the purpose of each equipment Control parameters of the equipment Fault conditions Control modules associated with the equipment HMI requirements Alarming parameters 21 of 42

21 Friendly Side of HMI HMI Design Criteria Mobile Enhanced Graphics Graphical Process Overviews Process Control Operations Manual Control Override Capability Process Variable Trending Intuitive Alarming Multiple level security levels 22 of 42

22 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 23 of 42

23 Technical Details Rockwell Automation s PlantPAx process automation platform System architecture is centered on Rockwell Automation s Integrated Architecture strategy ControlLogix platform Processing power and memory required to meet continuous and batch operations Redundant Configuration Add-On-Instructions Allen Bradley Flex I/O Distributed throughout the process area Minimized the electrical and pneumatic installation costs PowerFlex VFDs with ControlNet Motor Contactors with DeviceNet 24 of 42

24 Technical Details FactoryTalk View SE SCADA solution Distributed Redundant Robust computing system to drive the HMI applications Secure the process data Wireless FactoryTalk View Clients on the production floor Data Historian and Reporting System FactoryTalk Transaction Manager Microsoft SQL server Microsoft Reporting Services Dell rack-mount servers and computers Environmentally controlled control room Multiple uninterruptable power supplies Automated tape back-up system 25 of 42

25 GPF Patent Pending Process 26 of 42

26 Control and Data Networks The plant transfers data across three different networks Ethernet /IP PAC-to-HMI communication Peer-to-peer communication to other third party equipment Integration with the front office ControlNet for the processor and I/O platforms DeviceNet for motor control center communications 27 of 42

27 Managed Ethernet Network Server Room Control Room Wireless HMIs Managed Ethernet Switch for Control System Network (CSN) CLx CLx CLx CLx CLx Proprietary Equipment PLCs Managed Ethernet Switch for Control System Network (CSN) Proprietary Operator Interfaces Weight Controllers 28 of 42

28 Wireless HMI Installation Wireless HMI Technology was a key component of the GPF project. Wireless = State of the Art production capability for sales and marketing benefits Labor cost savings Quicker operator response to issues Implementation support provided by ProSoft Technologies Mesh topography More than two dozen access points With the ProSoft Technology wireless capabilities, our operators can go anywhere in the plant where there is a problem. While they are assessing one problem, operators don t lose the ability to monitor the rest of the process. Tim Foster, Vice President of Engineering, Green Planet Farms 29 of 42

29 Panasonic Wireless Displays Powerful small handheld operator interface was a critical success factor. Selection criteria included: Display size Touch Screen IP rating Case material Vibration and shock resistance Battery life Weight 30 of 42

30 ESE Batch Optimizer Integration ESE implemented its Batch Optimizer programming strategy Flexible recipe management and batch system. Graphical HMI environment Phase-based programming Recipes based on the extensive process equipment capabilities Facilitates quick system and recipe adjustments Extremely beneficial during initial start-up and new product Development Modify the operations without outside assistance from ESE More than 100 batch and continuous process phases 31 of 42

31 PlantPAx Solidified Automation Assured interoperability by integrating Endress+Hauser process instruments and Rockwell s PlantPAx system Seeing how well ESE was able to integrate the Rockwell Automation systems with Endress+Hauser instrumentation and ProSoft Technology wireless gave us a high level of confidence in how our plant would function. The partnerships and experience offered through this partnership rivaled other vendors because we had more flexibility in the areas we chose to incorporate. Tim Foster, Vice President of Engineering, Green Planet Farms 32 of 42

32 Data Collection and Reporting During the design phase ESE demonstrated multiple levels of data acquisition and reporting Requirements: Ability to pull real-time data directly from the process Ability to export data to other applications, if needed Ease of generating meaningful reports tailored to the user Ease of report distribution and archiving Implementation: Rockwell Software s FactoryTalk Transaction Manager Rockwell Software s RSLinx Microsoft SQL Server Microsoft Reporting Services 33 of 42

33 Project Management System design standards Integration with OEMs Instrumentation, motor, and valve schedules Operator/User manual System functionality Contributed to a successful project commissioning Project documentation and Project Management Key to a successful installation and support of the system On both sides of this project, everyone knew what was going on with the project at all times, and that is the most effective way for a new project like this to be executed, said Foster. In addition, the standout customer service by both companies was a huge bonus. The people that we had on-site were highly capable of doing any task that was needed. Tim Foster, Vice President of Engineering, Green Planet Farms 34 of 42

34 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 35 of 42

35 Operational Benefits Flexibility and plant-wide integration PlantPAx system ties seamlessly to proprietary plant processes and equipment Integrated Architecture solution between control system and partner technologies helps enable faster configuration New technologies and processes are easier to incorporate with open, standardsbased control platform One platform controlling all segments of the facility reduced training required Standardization ESE is very familiar with the Rockwell Automation portfolio Process, discrete, safety, and drive control applications Reduced cost of ownership, training, downtime 36 of 42

36 Operational Benefits Support of sustainability programs Automation systems support sustainability goals with integration into climate control, energy recovery, and track and trace systems. Process energy recovery was incorporated into the facility to measure the outgoing waste materials. Byproducts are now able to be used in later stages of development to shrink the carbon footprint. Computer controlled lighting Mobility Wireless system allows operators to leave the control room and be an active participant on the plant floor System requires ½ of the normal staff to operate Engineers remotely monitor all elements of the process, and very quickly make any modifications necessary 37 of 42

37 Operational Benefits Batch Optimization The new control system now manages more than 100 batch and continuous process Controlled adjustments for Optimization User-expandable Track-and-trace requirements No translation, routing or special programming required between networks Real-time information throughout the enterprise 38 of 42

38 Financial Benefits Process control system enabled Surpassing annual production goals by 15 percent almost immediately Testing and reporting capabilities confirmed complete product integrity Plant operates a continuous process for 20 hours per day (four hours for cleaning) Remote access To monitor all elements of the process Quickly make any modifications necessary 39 of 42

39 Agenda Executive Summary Green Plant Farms & ESE Company Profiles Business Situation Finding a Partner Solution/Technical Details Operational/Financial Benefits Results 40 of 42

40 Reliable/Robust PlantPAx system This was the best start-up I ve ever seen. ESE, Inc. saved two weeks of engineering time just by leveraging Rockwell Automation add-on instructions, and the reusable code will help us as we expand our operation. Tim Foster, Vice President of Engineering, Green Planet Farms At the end of the day, ESE, Inc. and Rockwell Automation really exceeded our expectations. Both companies share our core values and were our real partners in this project. That is so refreshing in a world where customer service is often forgotten. Susanne Stoeger-Moore, Board Chairman and Chief Marketing Officer, Green Planet Farms This new system also allows our workforce to leave the control room and be an active participant on the plant floor. As a result, all members of our team can fully engage in making safety a priority. Tim Foster, Vice President of Engineering, Green Planet Farms 41 of 42

41 Insert Photo Here Questions Copyright 2009 Rockwell Automation, Inc. All rights reserved.