Most large scale food processing plants have already grasped automation but some small and medium-sized enterprises (SMEs) remain reticent about the process of implementation, particularly how the latest technology will combine with existing installations.
One of the common misconceptions about introducing automation is that the entire manufacturing process has to be revised at once. Clearly, this has some considerable financial implications. For many, this level of investment, added to the cost of lost production during the installation, makes the concept non-viable.
However, one of the most fundamental principles of automation is scalability. With sufficient planning during the initial stages of an automation project, it is possible to develop a plan that can be deployed in one area and then gradually rolled out to include other processes in due course.
This way, business owners can set aside smaller budgets and also see the improvements in productivity.
What is automation?
The term automation covers a wide spectrum of technology; everything from a level sensor opening and closing a valve, to PLC-controlled pneumatic valve stations working with robots to deliver micro–accuracy in production.
For most, the solution will be positioned in the middle ground, with a possible eye for additional development in the future.
Provided the communication protocols are maintained, it is relatively easy to install standalone control systems based on a centralised control concept that contains all of the necessary components to operate valves, including a PLC, input/output systems and valve islands.
For those looking to start from scratch, the possibilities are constrained by the size of the business and the extent of the processes to be automated.
Upgrading to automation
As the scale of any business grows and the level of automation increases, it should be possible to add a new module without interfering with the existing installation.
For example, in craft brewery, it is not possible for the brewmaster to be on site 24 hours a day, yet he would still need to be informed of any anomaly in the process.
Adding an Ethernet module allows access to the process control system from remote locations and if necessary, the ability to change parameters.
Introducing automation can be a daunting prospect for those who have no experience of it, but with the proper foundations, it is possible to create a process control system that can deliver both the needs of the business now and those in 10 years time.
This article was based on writing by Mark Lilley, Field Segment Manager, Hygienic Food and Beverage for Burkert Fluid Control Systems.
Burkert manufactures more than 100,000 different process control products, all of which can be used as part of a bespoke control infrastructure specific to hygienic applications.