Production Line Modernisation
Obsolete controllers, single channel safety circuits, and drives nobody could source parts for. This Victorian infant formula line needed to be brought up to current standards without losing a production season.
Industry
Infant Formula, Food & Beverage
Location
Victoria
Duration
Aug 2023 to Nov 2023
Safety Rating
PLd SIL2
Scope of Works
The line was running on discontinued SLC programmable controllers with old single channel safety circuits. Spares were getting harder to find, and the safety system no longer reflected what a line like this is expected to meet.
The brief was to replace the controllers with current technology, merge two discontinued controllers into one line controller, upgrade to a SIL2 safety rated processor, and rewire every legacy safety circuit to PLd SIL2. All design, installation, and integration was handled in house.
The Electrical Delivery
Alongside Scope Automation
Scope Automation carried out the Allen Bradley integration in Studio 5000, merging the two discontinued controllers into a single SIL2 safety rated line controller. Because the same team handled the wiring and the code, safety functions could be proven end to end during commissioning rather than argued about afterwards.
Key Technologies
From the Job
Compliant, Supportable, Documented
The line came back with modern hardware that can actually be sourced and supported, a safety system rewired and validated to PLd SIL2, and drives reporting over Ethernet instead of hard wired analogue.
The site also gained accurate as-built documentation, which matters as much as the hardware. When something does go wrong at 2am, the person on the tools has drawings that match what is in front of them.
Have a Project Like This?
From switchboards and site cabling to safety systems and control integration, we deliver the electrical side of complex industrial work. Let's talk about yours.
View all projects