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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 1
Honeywell New Zealand
Plant Automation Solutions
Tom Lewis
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 2
Meadow Lea Foods - Food Solutions
Company: Meadow Lea Foods
Location: Auckland, New Zealand
Process: Manufacturing Margarine, Cooking Oils and processing Dairy Products
Needs: Improve Quality & Reduce ‘Human-Error’
Expand Recipe Selection
Automate Reports and provide complete component tracing to meet legislation
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 3
Meadow Lea Foods - Process
Process: Batch
Phase 1: Weigh & Blend
Phase 2: Transfer (holding tanks)
Phase 3: Column (recipe management)
Phase 4: Discharge
Detailed Batch History reports are created during each Phase.
The final product quality and audit report is created at the Discharge phase.
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 4
Meadow Lea Foods - Automation
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 5
Meadow Lea - Flow Diagram
Product Orders Scheduling
Lab Recipe
Download
Weighing
& Blend
Transfer to Holding
Column
“Cooking”
Discharge
Auxiliary
Processes
Storage
or Packaging
Shipping &
Distribution
Recipe Calculation to Total Volume
(usually 10 tonne batches)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 6
Meadow Lea Foods - Control Solution
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 7
Meadow Lea Foods - Blend Phase Detail
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 8
Meadow Lea Foods - Summary
• The Control System solution has been in operation for 7 years and keeps on expanding
• With the Batch solution, the consistency of recipe production, operator effectiveness, and quality reporting has improved by 100%
• The Batch User Interface means minimum training for Operators when introducing new recipes
• Batch History has provided essential data for Quality reporting, and meeting the strict demands of Food & Beverage Regulations in New Zealand
• The remote access function improved site support and reduced maintenance costs
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 9
Cavalier Bremworth - Carpet Solutions
Company: Cavalier Bremworth
Location: Auckland, New Zealand
Process: Manufacturing of high quality woolen carpet, mainly "Tufted" (stitched on a synthetic backing)
Needs: Improve Quality, Reduce Waste
Improve Efficiency
Identify Operating and Machine Problems (collection of statistical data for analysis)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 10
Cavalier Bremworth - Process
Process: Continuous - Semi-Batch
Phase 1: Winding
Phase 2: Beaming
Phase 3: Tufting
Each phase is executed as a batch, and is tagged with an ID number, so quality tracking is possible.
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 11
Cavalier Bremworth - Winding
64 Winders spin the wool at 200kg / hour
The wool is unloaded and pre-treated
The wool arrives at the factory in large bales
Wool
Winders
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 12
Cavalier Bremworth - Beaming
From the winders, the wool is fed into the beaming machines.
1x Beam, holds about
500kg of wound wool.
200
Winder
“Cones”
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 13
Cavalier Bremworth - Tufting
From the beams, the wool is fed into the tufting machines, producing the finished carpet.
8 Beams
Tufting Machine
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 14
Cavalier Bremworth - Control Solution
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 15
Cavalier Bremworth - Batch Control
• Batches are specified from the Planning Department, and downloaded to the PlantScape system.
• Operators login before operating machines. The Batch ID is checked, and the operator productivity and machine efficiency is tracked.
• Each machine has a selection of “downtime” codes for tracking machine performance. Statistical data is reviewed to determine problem machines, and focus on reducing bottlenecks.
• Each machine has its own "Batch Control" program that is designed to guide the operator when starting/stopping batches.
• Each “Batch Control” program has logic steps and plant feedback to minimize error and maximize productivity.
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 16
Cavalier Bremworth - Carpet Solutions
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 17
Cavalier Bremworth - Carpet Solutions
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 18
Cavalier Bremworth - Summary
• The Control System solution has been in operation for nearly 6 years and keeps on expanding
• Cavalier Bremworth achieved excellent results:
– Reducing the number of operators and maintenance staff by 50%
– Increasing productivity by over 150% (by identifying machine downtime trends, focusing on Operator training, and providing operators with productivity information).
– This is a unique system, tailored for this application. But the principles can be applied to any industry.