Since 1999, coolback stands for taste and freshness in high-quality baked goods. At the factory in Nuthe-Urstromtal in Brandenburg south of Berlin, 270 employees produce more than 500 million frozen bakery products per year, using traditional and innovative recipes. To this end, the factories must be available around the clock, 24/7.
It is intended to replace the factory operation control, built on the basis of Siemens MP277 1” touch panels, with a modern, future-safe operating concept. The operating control should be designed for continuous use 24/7 and permanent operator intervention.
This involves a baking line that consists of two factory components
• The line with 3 fermentation cabinets, converters, paternosters and cutting systems
• The conveyor oven with two baking levels and feed and delivery systems. The entire baking line contains approximately:
• 103 drives
• 60 actuators/cylinders
• 8 burners
• 220 sensors
A decision was made to use a slim, 100% web-based control system as a touch panel solution. It should be possible to operate this in a platform-independent manner. The solution shall include the following service properties; Complex user management, recipe management, recording of user actions and alarm management.
For automatic and manual operation, there are integrated interlocks for process pumps and valves. This prevents the switching of a process pump in manual operation, when the associated media flow is not free due to open valves. Valves, on the other hand, cannot be switched when a pump is turned on in the associated process cycle. In maintenance operation, the individual agitators and process pumps can be switched without any monitoring. It is also possible to switch the valves on site without monitoring. If an open valves leaves the final position, the associated process pump is immediately switched off automatically, since every on-site intervention can lead to damages and must therefore be undertaken with the utmost consideration and care!
The actuators, especially agitators and process pumps, can have three operating states, which interlock each other:
In addition, the operating hours are shown in each operating element. In the case of a malfunction of the actuator, the operation is always on service.
The entire system is password-protected. There are 4 hierarchies in runtime mode, which can be provided with any number of users:
Due to an intelligent user and client management, company-internal and company-external user hierarchies can be established in infOmatic. Besides the user with administrative authority (this applies for each plant), it is possible to grant or refuse any other user plant-specific access to selected functions with a single mouse click.
This gives plant operators the option to individually integrate external service providers such as consultants, laboratories or electricity traders in the portal in a cost-neutral fashion, in order to grant access to selected plant data.
This leads to a reduction of administrative costs, while at the same time increasing the reaction speed at the plant.
The daily use of the individual components in your plant leads to wear and tear, thus making your overall plant susceptible to faults and repairs. The higher risk of failure is exacerbated by an increasing energy requirement. This leads to higher costs and a reduced efficiency of your overall system. With regular maintenance, you can ensure the smooth and long-lasting operation of your plant.
Tailored to our customers’ needs, the ORmatiC team developed a maintenance tool that is integrated in the plant operation. Our maintenance tool contains the following building blocks:
Early reporting and correspondingly fast reaction times enable the optimisation of your plant’s smooth operation. →Optimisation
With the ORmatiC control centre – a new building block in our service package – we always keep an eye on your plant. Make use of our service with central alarming and a reduced reaction time – this will prevent higher losses and damage to your plant! Our employees offer immediate support when trouble-shooting your system. We will gladly inform you about our individual service offers.
You want to stay in control of monitoring your plant and yet use the full functionality of a control centre? Whether you operate a biogas plant, a wind turbine or any other decentralised system, with infOmatic, we can set up your own control centre in just a few days.
OPC is a Client Server Architecture by Microsoft. OPC is used where sensors, regulators and controls by various manufacturers form a common, flexible network; today, it is the standard in manufacturer-independent communication in the automation technology. An unlimited number of clients can access a server.
Virtual Private Network (VPN) is used to create a safe, encrypted network via public communication channels by employing tunnel technology. Computers connected via VPN (e.g., in biogas plants) are linked in a network with secure access.
Use of the Melsys product with the following properties:
The infOmatic server constitutes the heart of the system. Therefore, the infOmatic server is installed in a computing centre with the highest security requirements. The ORmatiC GmbH assumes the maintenance for the portal-specific software tools. The maintenance of the hardware and the operating system’s software is carried out by IT specialists. Professional IT workers ensure the availability and security of the data.
We distinguish 2 types of alarms:
In addition, a message or event overview can also be integrated. This differs from the alarm overview in that the messages need no confirmation.
Use of the Melsys alarm manager product with the following features:
We offer the following services for regulator optimization:
As independent observers, we can inspect your processes with “open eyes“, analyze them in an unbiased fashion and develop new solutions in collaboration with you. This is where ORmatiC’s “Time to Solution“ strategy comes in. We will analyze your process, develop new solutions with you and implement them. If required, we will also collaborate with your automation partners.
Regulation means that a system possesses a feedback loop with information about the system’s behavior. That means that the system’s reaction to any manipulated variable is monitored and evaluated directly by comparing this reaction to a preset nominal value. The determining factor for the regulator’s structure and the values of the regulator parameters is the process that needs to be regulated. Various routes can be distinguished, based on different criteria such as linearity, time variance, static and dynamic transfer behavior. The literature on the basics of regulator technology normally assumes a linear system with no time variance, since this is the only system that can be handled through relatively simply mathematical equations.
Biological consultants and analytical laboratories may participate in infOmatic free of charge. If the operator of a biogas plant employs a biological consultant, he may be given access to the system. This lowers your costs while at the same time increasing the reaction speed. The consultant can access plant data and lab analyses at all times without the use of tools such as PCAnywhere and can make timely suggestions for the adjustment of the operating style of your biogas plant. If the consultant wishes to integrate a biogas plant, we will make a timely offer for the setup expenses.
