Confectionary Control System Upgrade

When it comes to high quality chocolate, Our client is up there with the best. Our client is a household name and is known for producing beautiful, mouth-watering creations.

 

During the summer of 2009 a master chocolatier awarded Datastor Systems Limited a contract to upgrade the centre boil manufacturing control systems. This project included enhanced software functionality and management reporting together with upgrading the existing obsolete hardware.

 

 

Customer Profile

Our client is one of the best loved and oldest names on the high street. For almost a century they have been producing a delicious range of chocolates that are almost impossible to resist.

 

The Project Scope

A control system was originally installed by Datastor in 1992. Throughout this time it has effectively controlled the process for producing the liquid centre's for a delicious range of chocolates. During 2009 the decision was made to upgrade the system to take advantage of a range of new functionality and enhancements.

 

System Functionality

The key functional requirements included;

• Recipe control
• Mixing and boiling
• Clean in Process (CIP)
• Data capture and analysis
• Stock control
• Error alerts
• Process visualisation
• Traceability
• Label printing

 

The Benefits

The upgrade was completed in March 2010, the master chocolatiers are delighted with the end result. The system now provides our client enhanced control of their operations, improved flexibility and information management reporting.

Project Overview

 

Datastor’s PC Batch Control Software was originally installed in 1992 to control the batch production of the chocolate centres. The system also comprised of an Intel Modbus based system utilising Pamux I/O that was nearing the end of it’s life and needed replacing. This also applied to their operator PC’s which were replaced with Rockwell’s Panel View Plus Terminals. They also wanted to extend the existing software functionality and this could only realistically be achieved by up-grading both the software and hardware.

 

The Production Process

 

Datastor’s PC Batch Control system provides automated control of the centres production process up to the filling operation. This includes; recipe management, hand weigh of ingredients, product labelling (traceability), mixing and boil operations. The whole process can be seen and monitored by the operator’s via Tilcon graphics. The system alerts operators to error conditions and also controls the CIP process. Real-time data is captured and provides instant production analysis.

 

Strict Time Scales

 

A crucial requirement was to keep production downtime to a minimum. This was achieved by careful detailed planning utilising a weekend shutdown to maximum effect. In all, it took Datastor’s engineers 4 days to complete the upgrade process which included pre-upgrade testing and simulation.