TBL in Dar es Salaam recently embarked on a transformative journey to enhance the efficiency and reliability of its production systems. Faced with aging infrastructure and the need for a scalable, future-proof solution, TBL partnered with IAES to upgrade its PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) systems. The project also integrated 12 condensers into a unified automation system to optimize performance based on discharge pressure.
What we did
The upgrade began with a comprehensive assessment of the existing systems. IAES replaced TBL’s outdated S7-200 controllers with the advanced S7-1500 series, known for superior processing power and robust reliability. We also converted the Step 7 v5.5 programming environment and WinCC Flexible 2008 visualization platform to TIA Portal v13, providing a unified engineering framework for seamless integration and enhanced system efficiency. A key challenge was integrating the 12 condensers into the upgraded system. This required configuring automation to enable ramp-up operations based on discharge pressure. The IAES team developed custom programs, reconfigured inputs and outputs, and adapted communication protocols to ensure flawless operation.
To minimize operational downtime, IAES meticulously planned the implementation, decommissioning legacy hardware and installing new Siemens PLCs and HMIs. Rigorous on-site testing during commissioning ensured that all components worked seamlessly and integrated smoothly with the existing infrastructure. The final phase involved training TBL’s technical team, equipping them with the necessary knowledge and skills. This will ensure effective operation and maintenance of the upgraded systems.
The scope of work included replacing S7-200 controllers with S7-1500 series, converting Step 7 v5.5 and WinCC Flexible 2008 to TIA Portal v13 or above, and integrating the 12 condensers to ramp up based on discharge pressure, along with the supply, installation, and commissioning of all hardware and software components.
Benefits of the Upgrade
The successful upgrade has delivered significant benefits for TBL Dar es Salaam. Transitioning to the S7-1500 controllers has greatly enhanced system performance and reliability. The new TIA Portal environment offers a centralized and efficient engineering platform, simplifying future modifications and maintenance. Integrating the 12 condensers into the automated system has optimized energy efficiency and operations, adjusting based on real-time discharge pressure.
This project showcases TBL’s commitment to adopting cutting-edge technology to maintain a competitive edge in the brewing industry. It also highlights IAES’s expertise in delivering tailored automation solutions that help industries modernize operations, reduce downtime, and embrace Industry 4.0 innovations. With this upgrade, TBL Dar es Salaam is now well-positioned for sustainable growth and operational excellence.
