Experience example
Helping an Aquaculture Feed Manufacturer Increase Their Production Capacity
“Once we accept our limits, we go beyond them” - Albert Einstein
Industry
Food
Sector
Aqua Feed
Segment
Production Control System
Project
- The client has 19 facilities around the globe supplying annually over 2 million tons of feed to the aquaculture industry.
- To meet demand the clients Tasmanian plant needed to double production (70,000 to 140,000) tons within 12-months.
- The new production line needed to be built in parallel to the existing line to avoid significant production interruptions.
- Cromarty were engaged by the client to work collaboratively with the clients international team to provide the control and automation solution, incorporating site SCADA and PLC then integration into the materials/stock handling system.
Solution
The project was split into two phases:
Phase 1 - remove and install new intake and batching system
- Ground up redesign of new CitectSCADA whilst maintaining legacy SCADA.
- Modify control system, maintain production, move and install equipment
- PLC code simulation providing control system test environment, preventing waste of material waste and production time while speeding up commissioning without personnel risk
- 4-week plant shutdown to install and commission the new control system
Phase 2 - install new extruder line
- Ground up re-design for the new extruder control system
- Installation of the new extruder line without stopping the existing extruder
- The new program was installed and commissioned within a 1-week window
- Removal the redundant code and de-commission the legacy system
Outcome
Despite the size and complexity of the project, the challenging development and commissioning time frames and the need to maintain production during the upgrade, the new facility started on schedule, was on budget, was almost immediately in production. The site now has a future proofed control system and Cromarty were also able to optimise the original equipment to provide more stable production. This not only met but exceeded the original target of doubling production capacity.