Design new control systems for two unique Flexi malthouses. Eliminate and replace obsolete control products (Honeywell Controller and I/O, PLC5 and associated 1771 I/O) with new control elements (Allen-Bradley ControlLogix processor and current supported I/O). Modify the existing iFIX SCADA application to accommodate and use the new ControlLogix processor in place of the PLC 5 processors, and to provide a recipe system for the Flexi 1 & 2 Kiln operation. Implement the new controller hardware, logic, safeties and recipe management while the plant continues to run its normal production schedule in "manual" mode.
Multiple site visits to generate / verify electrical and control installation information. Preparation of a functional specification of the kilning process aided by key Prairie Malt staff. Discussion regarding safeties and interlocks, recipe structure and control functions. Development of a detailed risk analysis plan and manual operations checklist to ensure proper processing prior to commencing the control conversion. Execute the first Flexi malthouse conversion and learn from any issues before planning and executing the second Flexi malthouse conversion.
Our project managers have extensive malting industry experience, and we ensured that all operational issues were understood and discussed prior to implementation.Our malting knowledge combined with Flexi system experience enabled us to complete the project efficiently and effectively.
Both outdated Flexi kiln control systems were upgraded, providing improved reliability and operator visibility. The enhanced recipe structure allows the client more control and options for programming its Flexi malthouses in the future.