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The Bega site in Strathmerton was chosen to host a new natural cheese production line.

IAL supported Cheese Solutions NZ Limited (CSL) as an OEM provider of the majority of the machinery used to construct this production line, with CSL handling mechanical design, and IAL providing the electrical design and automation, and a combined commissioning effort.

The result was a turn-key prototype system that was specially engineered to meet the customer’s site specifications and performance requirements.

Line Summary

• CSL Log Cutter
• CSL Continuous Slicer
• CSL Line Control System
• CSL Anaconda Cheese Reforming System
• 2 x Checkweighers
• 2 x CSL Robotic Clamshell Loaders

Project Features

The CSL 240 Line Control system manages the conveyors that run between the various machines, as well as co-ordinating the flow of product and handling machine-to-machine communications.

Interfacing between systems provided by the different manufacturers was provided entirely by IAL for this project, and not only covers basic handshaking (ready to receive, ready to send, etc.), but also more complex management of demand and accumulation control, relaying of machine alarms, and automatic adjustment of upstream machines based on feedback from downstream (changing slice thickness according to checkweigher measurements).

Results

This project resulted in the creation of the fastest natural cheese block line in Australia and New Zealand.

LHF (Life Health Foods) required an upgrade to their existing chick pea cooking system for the hummus line.

This involved upgrading an obsolete touch panel HMI, improving the process and performing fault-finding on the software and electrical system, and commissioning the installation of the 5^th cooking vessel.

Project Features

• Upgrade HMI hardware from obsolete Proface screen to Allen-Bradley PanelView Plus.
• Redesign screen to improve operator interface and incorporate 5^th cooking vessel.
• Modifications and additions performed on existing PLC program to improve performance.
• Software design and commissioning to add new 5^th cooking vessel with improved sensor feedback and control.
• Provide design options for improving the system hardware.

Results

Following the above improvements resulted in improved production capability and reliability.

Huhtamaki operate a variety of plastic thermoforming, paper forming and labelling machines which they use to manufacture a number of different food packaging products. IAL has been involved with many jobs to fault-find, improve process performance or upgrade hardware on these machines.

Of particular note is the complete rebuild of Browns Thermoformer 2, which at the time of the job, was approximately 20 years old.

Project Details

• Complete replacement of obsolete main control system – new PLC, I/O, HMI.
• IAL completed the electrical design, electric drawings, HMI and PLC programming.
• Upgrade from crude proximity position switches to Temposonic linear position transducers for platen position control.
• Accurate motion control and synchronisation required for effective operation.