IDM | Site report
By using EtherNet/IP as the primary communication
protocol, Fonterra has given itself
the opportunity to move easily into The
Connected Enterprise, an approach manufacturers
are adopting to leverage the use
of connected machines, supply chains and
customers. Manufacturers are able to establish
manufacturing processes that are data/
information rich, supported, secure and future
ready for market demands.
Ultimately, a Connected Enterprise approach
for manufacturers will create a more
competitive, innovative enterprise that can
deliver insights to improve productivity,
sustainability and economic performance
through faster time to market, lower total
cost of ownership, improved asset utilisation
and enterprise risk management. Other benefits
of access to real-time, contextualised
information, include minimised downtime, improved
technology and process optimisation,
greater workforce efficiency and smarter expenditure.
Because EtherNet/IP is based on
standard, unmodified Ethernet, it means that
there is very little that needs to be done for
these connections to be established; and full
security solutions are also available for user
control and to prevent unwarranted access.
From a product perspective, Fonterra has
deployed multiple Allen-Bradley ControlLogix
programmable automation controllers (PACs),
working in conjunction with Allen-Bradley CENTERLINE
2500 motor control centres (MCC),
complete with Allen-Bradley E300 Electronic
Overload Relays and more than 250 Allen-
Bradley PowerFlex variable-speed drives, some
with dual-Ethernet capabilities. Arranged in 42
cabinet columns, the MCC installation is 50 m
in length. As well as providing intelligent centralised
motor control, the CENTERLINE MCCs
also offer advanced energy management capabilities
and integration into the Rockwell Automation
Integrated Architecture – delivering
true plug-and-play capabilities.
According to Alex van Dalen, the General
Manager from Beenen BV: "Beenen worked
very hard to win this project and was initially
bidding against two other local system integrators.
We go for quality and the best solution,
therefore Beenen employed Rockwell Automation
to design and develop the MCC solution,
while Beenen undertook the remainder
of the electrical and automation work based
around other Allen-Bradley solutions. We built
up a real team ethic with Rockwell Automation
and the positive effects of this cooperation
was evident in the dealings with Fonterra and,
of course, the success of the project."
8 · 9 2017 | international-dairy.com
Arranged in 42 cabinet columns, the MCC installation
is 50 m in length (photo: Rockwell
Automation)
FactoryTalk View
The software installation is just as impressive:
FactoryTalk View offers overall visibility into
the processes and interface with the ERP and
process-control systems; FactoryTalk Historian
is used for collection; and FactoryTalk VantagePoint
is used for information, visualisation
and dissemination. By making data freely available
in an easy-to-read format, when you need
it, in the specific format required for each job
role; operators and managers are able to make
much more informed decisions, much quicker
and with greater positive effects on the line
optimisation. FactoryTalk AssetCentre gives
Fonterra the ability to centrally secure, manage,
version control, track and report automation
related asset information across its entire
facility. AssetCentre also provides automatic
scheduled backups of controllers thus supporting
"disaster recovery". Rockwell Software
CPG Suite delivers value-based applications
that can help Fonterra achieve operational excellence,
increase supply chain effectiveness,
adhere to regulatory compliance guidelines
and meet sustainability goals.
Completing the installation is a number of
value-added service offerings, which include
a parts-management contract providing critical
spare parts, a TechConnect upport contract
and in-depth training for the Fonterra
operatives.
Results
According to Alex van Dalen: "The Fonterra
team was particularly enthusiastic about the
benefits of Premier Integration in relation to
the motor control offering from Rockwell
Automation. They found the diagnostic software
very useful to 'see' into the contactor
from the MCC and also in the frequently con-
trollers. The Connected Enterprise approach
will also allow them to leverage their manufacturing
data far more effectively and then
share it with all those that need to see both
historic and real-time information."
Hans Berghorst, Operations Director at
Fonterra, explains: "Rockwell Automation is
the Fonterra standard in the Netherlands
and by deploying a complete Rockwell Automation
solution, we only have one supplier
instead of two, which also offers benefits in
terms of maintenance and spares. We also
selected our suppliers based on total cost of
ownership (TCO). Rockwell Automation came
out well; we not only looked at the CAPEX,
but also at the life costs over 10 years and
determined that the Rockwell Automation
approach developed by Beenen was the best
solution. Our engineers are also enjoying the
benefits of the integrated approach. The
MCC IntelliCENTER solution allows them to do
restarts from the HMI in the control room;
they don’t have to go to the MCC."
Discussing the creation of the new faceplates,
Berghorst adds: "It’s a mixture of
Fonterra, Beenen and Rockwell Automation
engineering. Our plan was always to have a
standardised solution and we do have our
own in-house libraries that we use as standard
within Fonterra, which are all the same
worldwide. But of course now that the motor
drives are from Rockwell Automation, we
jointly developed new faceplates, based on
Fonterra’s engineering standards.
"We knew from the start that we wanted
to use Allen-Bradley PACs and control solutions.
We do a lot of joint development with
Rockwell Automation back in New Zealand,
so it is easy to copy and paste routines and
programmes. In addition, we have specialists
in our process control department in New
Zealand who know and understand Rockwell
Automation solutions very well. Also, from
a support point of view, it’s always better
when you have a standardised solution."
Discussing the five year service contract,
Berghorst continues: "I think within Rockwell
Automation there are some very knowledgeable
advisors, who know the systems inside
out. We also saw very good co-operation
from Beenen who undertook most of the direct
interactions with Rockwell Automation.
"It is the first time we have built a new facility
in Europe," Berghorst concludes, "so it is
difficult to compare the performance characteristics
compared to other sites and other
technology, however, so far we are very
satisfied with the performance."