Commissioning in the
food industry
W
hen adding an extension to a house, an architect
will often use computer assisted design (CAD)
software to visualise what the extension will
look like. Similarly, commissioning a new system for a food
manufacturing plant requires software assistance to plan
effectively and with digital twinning, manufacturers can
optimize its ongoing operations. Here, Brith Isaksson, of ABB’s
food and beverage business, explains.
Planning can be time-consuming, but when adding to an
existing building like a house, it could be the differ-ence
between a crumbling foundation and your dream home. To
make the process smoother, architects em-ploy specialist
software that allows them to draw the designs and integrate
the electrical and plumbing ele-ments of the existing structure
into the plan.
Architects can then review the plans to ensure compliance
with regulations, the practicalities of the design and eliminate
any potential issues. However, while CAD plans are often used
for planning system installations in manufacturing plants, the
software is often limited by the variables that arise during
operation.
As a result, we’re seeing a shift towards virtual commissioning
technology and other forms of simulation software in the
industrial sector.
Virtual commissioning allows manufacturers to build and
run a new factory process line virtually, before building it in
the physical world. This includes simulating an exact replica
of the line with its current auto-mation system and network
in a virtual realm, which is then modified to add in any new
equipment. Virtual commissioning allows plant engineers to
program robots and automation systems in the virtual world.
They then run virtual tests, and any discovered issues can
be resolved in advance to significantly reduce costs and the
system’s start-up time.
For example, if a plant manager plans to install a new robotic
cell to pick product from a conveyor and place the product in a
box at a certain rate per minute, the line can be choreographed
and tested virtually. This ensures that the robot can perform
the movements and required manoeuvres in conjunction with
the flow of product and packaging. With a virtual process
architecture, various scenarios can be run, and the automation
software programmed without having to stop production on
the physical line.
By using virtual commissioning, manufacturers can also
eliminate operational inefficiencies in their existing lines to
boost productivity. ABB’s Ability™ RobotStudio, can simulate
the different processes in a food and beverage plant so that
managers can identify what strategies should be revised to
provide better quality and increase output.
www.stonejunction.co.uk
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