Tanzania Breweries Limited (TBL) in Arusha recently completed a comprehensive PLC system upgrade to resolve ongoing operational problems. Specifically, they faced frequent issues with their belt press systems and outdated control modules. Therefore, TBL partnered with IAES to implement a complete Siemens automation transformation. This strategic move modernized their control systems and brought back reliable brewing operations.
Comprehensive System Assessment
First, the project began with a detailed review of TBL’s existing systems. Our team found key connection points and possible challenges to ensure a smooth changeover. Then, the old S7-200 and S7-300 controllers were replaced with advanced Siemens S7-1500 controllers for better performance and efficiency.
Strategic Implementation Process
Controller Modernization
First, we replaced the outdated S7-200 and S7-300 controllers with the modern S7-1500 series. This important change in the PLC system upgrade provided better processing power and stronger system reliability for TBL’s brewing work.
Filter Press Integration
Another key task involved connecting the filter press system to the new controller. This step required changing inputs and outputs, updating communication methods, and creating custom programs to ensure perfect operation.
Careful Installation Planning
We carefully planned the installation to reduce production stops. After removing the old modules, we installed new Siemens PLC/HMI systems and connected the filter press for central control and monitoring.
Thorough Testing Process
Commissioning involved complete testing to check all parts worked correctly. Additionally, the IAES team conducted overnight on-site testing to ensure smooth changeover and fix past operational issues.
Complete Staff Training
Finally, we trained TBL’s technical team on running and maintaining the new systems. This knowledge sharing ensured long-term operational success with the upgraded PLC system upgrade.
Important Upgrade Benefits
Better System Performance
The PLC system upgrade brought major improvements in processing speeds and system reliability. Moreover, advanced fault-finding tools greatly reduced downtime and maintenance needs.
Future-Ready Features
The new system works perfectly with Industry 4.0 technologies, thereby positioning TBL Arusha for digital changes in the competitive brewing industry.
Smooth Operations
The filter press connection ensured continuous operations during the changeover. This careful planning kept production running while updating important control systems.
Conclusion: Sustainable Growth Achieved
In conclusion, this successful PLC system upgrade shows TBL Arusha’s dedication to modern technology. By using Siemens S7-1500 controllers, TBL has updated operations and built a foundation for continued growth. Furthermore, the project highlights IAES’s commitment to providing smart automation solutions that help brewing industries reach operational excellence and future readiness.
