The Challenge
Lakeland wanted an automation control system and associated MES modules for a new Lactose extraction and drying plant. They used the project as a pilot for a new Wonderware System Platform SCADA and MES, that would eventually be rolled out across the rest of the plant and other plants in the group.
NeoDyne was tasked with providing a turnkey solution including detailed design, supply, testing and commissioning of the new system. The main project challenges included interfacing with existing site systems, including ERP and LIMS as well as paperless operator log sheets.
Our Approach
The process control component was built on a central Siemens S7 PLC with ET-200 remote I/O units and Festo solenoid blocks in various locations around the plant.
The SCADA/MES component of the system was built on the Wonderware System Platform software suite, with a Wonderware InTouch operator interface. The software was hosted in a virtualised environment and delivered to the plant floor through industrial grade thin client hardware. The MES components were built on a Microsoft SQL database and presented to the user through .NET objects embedded in the InTouch application. Interfacing to the existing ERP and LIMS systems was via standard OLE-DB interfaces and robust handshaking for transfer of data.
About Lakeland Dairies
Lakeland Dairies, a major dairy processing co-operative, operates within a nineteen-county catchment area across the northern half of the island of Ireland. The Group processes about 1.8 billion litres of quality milk annually into a range of value-added dairy foodservice products and functional dairy food ingredients.
NeoDyne has been Lakeland’s Automation and MES integration partner at their Killeshandra and Lough Egish plants since 2012. NeoDyne has worked closely with Lakeland’s IT team to build an enterprise SCADA and MES platform, built on Wonderware System Platform, Information Server, Thinmanager Terminal Services and a secure network of Siemens PLCs.
Customer Requirements
- New Siemens control system
- Pilot project for Wonderware System Platform
- Introduction of MES functionality
- Integration with ERP and LIMS
- Paperless Operator Log sheets
Challenges
- Complex control logic for the crystallisation process
- Robust interface with ERP and LIMS
- Scalable enterprise-grade infrastructure
- Business process changes to paperless plant
Outcome
- Stable and consistent control of the new Lactose extraction and drying plant
- Successful pilot of Wonderware System Platform
- Full integration to ERP and LIMS
- Paperless plant with new business processes in place
- Scalable server infrastructure ready to migrate the rest of the site over to System Platform
- Introduction of a new .Net web reporting portal built on Wonderware Information server
Other Case Studies
See other System Integration projects below to see our solutions in action
Huhtamaki
Design, configuration and delivery of a multi-lingual, paperless shop floor MES.
MSD Brinny
Design, supply and commission of a new Clean Utilities and Process Control System for a brownfield contract manufacturing plant.
