SUCCESSFUL PACKER/UNPACKER MACHINE PLC/HMI UPGRADE
Tanzania Breweries Limited (TBL) in Arusha, faced persistent challenges with their existing packing and unpacking machinery. The equipment frequently experienced faults and errors, leading to costly shutdowns and production inefficiencies. 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 Packer/Unpacker Machine’s PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) systems, engaging IAES to carry out the upgrade.
Need for an Upgrade
The Packer/Unpacker process faced recurrent faults and errors in packing and unpacking of the goods. These issues affected the overall productivity and efficiency of the brewery as well as a significant downtime. Unplanned shutdowns due to equipment failures were becoming a regular occurrence. Each shutdown resulted in lost production time, increased operational costs. This led to delayed deliveries, impacting the company’s bottom line and its ability to meet customer demands.
Reprogramming of the process would have been an option but there was another issue. The control modules in use had reached the end of their life cycle (obsolete). As technology advances, these modules become outdated, and finding compatible spare parts becomes increasingly difficult. The lack of available parts meant that repairs were often delayed, further exacerbating downtime issues. These issues led to the need for an upgrade of the Packer/Unpacker Machine PLC/HMI.
The Upgrade Process
Recognizing the urgent need for modernization, TBL Arusha enlisted our expertise to upgrade the PLC and HMI systems of their Packer/Unpacker Machine. It started with a thorough assessment of the existing system, drawings so as to understand the operational challenges faced by the team and know how to overcome them in the new systems. The newly chosen system offers greater reliability and compatibility with modern systems. Key factors in the selection process included ease of integration, availability of spare parts, and support services.
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. 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.
Benefit and Conclusion
The new systems have reduced faults and errors, ensuring more stable and reliable operations with fewer unexpected shutdowns and a consistent production flow. Modern, reliable equipment and available spare parts dramatically reduced downtime, increasing uptime and productivity. Additionally, the advanced PLC and HMI features enabled precise control and monitoring, improving quality control, and cycle times, and reducing wastage. The transition from obsolete modules to modern, reliable systems has resolved these issues and positioned the brewery for enhanced productivity and growth. This successful upgrade serves as a testament to the importance of timely investments in technology to maintain operational excellence in the competitive brewing industry.