Honeywell New Zealand

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Honeywell New Zealand
Tom Lewis
Plant Automation Solutions
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Meadow Lea Foods - Food Solutions
Company Meadow Lea Foods Location Auckland,
New Zealand Process Manufacturing Margarine,
Cooking Oils and processing Dairy
Products Needs Improve Quality Reduce
Human-Error Expand Recipe Selection Automate
Reports and provide complete component tracing to
meet legislation
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Meadow Lea Foods - Process
Process Batch Phase 1 Weigh Blend Phase
2 Transfer (holding tanks) Phase 3 Column
(recipe management) Phase 4 Discharge Detailed
Batch History reports are created during each
Phase. The final product quality and audit
report is created at the Discharge phase.
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Meadow Lea Foods - Automation
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Meadow Lea - Flow Diagram
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Meadow Lea Foods - Control Solution
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Meadow Lea Foods - Blend Phase Detail
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Meadow Lea Foods - Summary

• The Control System solution has been in operation
  for 7 years and keeps on expanding
• With the Batch solution, the consistency of
  recipe production, operator effectiveness, and
  quality reporting has improved by 100
• The Batch User Interface means minimum training
  for Operators when introducing new recipes
• Batch History has provided essential data for
  Quality reporting, and meeting the strict demands
  of Food Beverage Regulations in New Zealand
• The remote access function improved site support
  and reduced maintenance costs

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Cavalier Bremworth - Carpet Solutions
Company Cavalier Bremworth Location Auckland,
New Zealand Process Manufacturing of high
quality woolen carpet, mainly "Tufted" (stitched
on a synthetic backing) Needs Improve Quality,
Reduce Waste Improve Efficiency Identify
Operating and Machine Problems (collection of
statistical data for analysis)
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Cavalier Bremworth - Process
Process Continuous - Semi-Batch Phase 1
Winding Phase 2 Beaming Phase 3
Tufting Each phase is executed as a batch, and
is tagged with an ID number, so quality tracking
is possible.
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Cavalier Bremworth - Winding
The wool arrives at the factory in large bales
Wool
The wool is unloaded and pre-treated
Winders
64 Winders spin the wool at 200kg / hour
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Cavalier Bremworth - Beaming
From the winders, the wool is fed into the
beaming machines.
1x Beam, holds about 500kg of wound wool.
200 Winder Cones
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Cavalier Bremworth - Tufting
From the beams, the wool is fed into the tufting
machines, producing the finished carpet.
Tufting Machine
8 Beams
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Cavalier Bremworth - Control Solution
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Cavalier Bremworth - Batch Control

• Batches are specified from the Planning
  Department, and downloaded to the PlantScape
  system.
• Operators login before operating machines. The
  Batch ID is checked, and the operator
  productivity and machine efficiency is tracked.
• Each machine has a selection of downtime codes
  for tracking machine performance. Statistical
  data is reviewed to determine problem machines,
  and focus on reducing bottlenecks.
• Each machine has its own "Batch Control" program
  that is designed to guide the operator when
  starting/stopping batches.
• Each Batch Control program has logic steps and
  plant feedback to minimize error and maximize
  productivity.

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Cavalier Bremworth - Carpet Solutions
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Cavalier Bremworth - Carpet Solutions
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Cavalier Bremworth - Summary

• The Control System solution has been in operation
  for nearly 6 years and keeps on expanding
• Cavalier Bremworth achieved excellent results
• Reducing the number of operators and maintenance
  staff by 50
• Increasing productivity by over 150 (by
  identifying machine downtime trends, focusing on
  Operator training, and providing operators with
  productivity information).
• This is a unique system, tailored for this
  application. But the principles can be applied to
  any industry.