The timing sequence was originally controlled by manual potentiometers using specially designed relays that were expensive and difficult to find. We removed all the old controls and replaced with touch screen HMI and PLC which not only allowed for easy and cheap replacement but also added functionality such as a recipe list where settings could be saved, therefore reducing human input and error. Each product that runs through this machines now has its own recipe to ensure the correct settings are used.
The water management system was controlled with buttons, switches and outdated notification software that required the company to maintain a stand-alone computer that was unable to receive security updates. We replaced the controls with touchscreen HMIs and PLCs that not only made the system more user friendly and understandable, it also increased the types and frequency of emergency notifications and allowed the company to adjust setpoints that reduced the amount of chemicals needed to maintain the water within regulations, saving the company large amounts of money that was wasted in the past. It also allowed the company to discontinue the use of the stand-alone PC which was a security risk to their network.
Check back soon to see some more of the projects we have completed.