Revolutionary Upgrade: TBL Arusha’s PLC Revamp
Tanzania Breweries Limited (TBL) in Arusha, faced persistent challenges with their existing belt press systems. The equipment frequently experienced faults and errors, leading to declining performance. Moreover, the aging modules in use had become obsolete, making it increasingly difficult to source spare parts. In light of these issues, TBL Arusha then decided to undertake a comprehensive upgrade of the system’s PLC and integration of other systems in the new architecture (Programmable Logic Controller) and HMI (Human-Machine Interface) systems, engaging IAES to carry out the upgrade.
What we did
The project began with a comprehensive assessment of TBL’s existing systems, identifying integration points and potential challenges to ensure a smooth transition. The outdated S7-200 and S7-300 controllers were replaced with the S7-1500 for better performance and efficiency. Another critical aspect of the project was the integration of the filter press system into the new controller. This required reconfiguring inputs and outputs, adapting communication protocols, and developing a new program to ensure the system operated flawlessly.
We meticulously planned the installation process to minimize industry downtime. Decommissioning of the old modules was done and then installed the new SIEMENS PLC/HMI. Integration of the filter press was then done to the new system to be controlled and viewed from one point. Commissioning involved rigorous testing to ensure that all components functioned correctly and integrated seamlessly with existing machinery. The IAES team conducted overnight testing on-site to ensure a smooth transition and resolve past issues. They then trained the staff on operating the new machines.
Benefits of the upgrade
Following the successful deployment of the new platform, TBL’s technical team received comprehensive training, equipping them with the knowledge and tools to efficiently operate and maintain the upgraded system. The upgrade delivered significant benefits, including enhanced system efficiency through faster processing speeds, reduced downtime due to advanced diagnostics, and future-ready capabilities compatible with Industry 4.0 technologies. The seamless integration of the filter press system ensured uninterrupted operations, marking a smooth transition to the new platform.
This successful project highlights TBL’s commitment to leveraging cutting-edge technology to remain competitive in the brewing industry. By adopting the Siemens S7-1500 controllers, TBL has modernized its operations and positioned itself for sustained growth. This achievement also underscores our dedication to providing innovative automation solutions that empower industries to achieve their operational goals and prepare for the future.