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Golden Wonder
Nik
Nak packing line and flavour stations upgrade
(Omron to Rockwell SLC PLC upgrade)
Project Decription: Golden Wonder needed a Specialist Systems Integration Contractor who could successfully integrate new process and packing equipment, whilst modifying an existing crisps packing line to produce Nik Naks or crisps with minimal business disruption. This was a turnkey project encompassing project management, control panels, SCADA/PLC software, installation and commissioning. The project also included the replacement of 6 obsolete business critical Omron PLC's controlling the crisp distribution and flavouring.
Approach: The main challenge was the main crisp distribution line PLC transplant. After verification, the Omron PLC software was converted to SLC504 and tested internally at MCS's offices. The client was invited to witness the software test, using in this case a bespoke switch box. This allowed the functional testing and exception handling of the software and tests were signed off by the client against an approved test specification.
The new control panel c/w PLC & HMI were electrically installed and the Omron PLC panel was used as a remote junction box to reduce downtime. Over a planned weekend the Omron PLC was stripped out and the panel wiring re-terminated to remote I/O previously installed. The full line was tested for functionality and exeption handling and put in service in readiness for the 06:00hrs start. No production losses were logged against MCS for the PLC transplant.
The second part of the project was to replace 5 off Omron PLC's used for the flavour stations. Each "new" flavour station included a Panelview HMI to enable the operator to set up flavouring parameters and flavour types, i.e. oil basedfor Nik Naks or powder flavour for flat crisps. These 5 flavour stations were phased in over a period of 2-3 weekends.
Results: Golden Wonder's project engineer commented: "I would like to thank MCS Control Systems for the professional approach to this business critical project. This was a high risk project, which included the replacement of 6 obsolete PLC's without loss of production. The quality of work and communication was excellent throughout and start up was achieved against very tight timescales, without loss of production. The PLC transplants were always a concern to Golden Wonder but these concerns proved to be unfounded due to the clear expertise MCS have in transplanting obsolete PLC control systems in a live operational environment."
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