CONTROL & AUTOMATION
SOFTWARE ASSISTANCE
ABB
COMMISSIONING IN THE FOOD INDUSTRY
When 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 difference between a crumbling
foundation and your dream home. To make
the process smoother, architects employ
specialist software that allows them to draw
the designs and integrate the electrical and
plumbing elements 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
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virtually, before building it in the physical
world. This includes simulating an exact
replica of the line with its current automation
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.
For the ongoing support and maintenance
of equipment, managers can also integrate
other simulation software like digital
twinning applications. A digital twin works
by simulating an exact replica of an asset,
subsystem or system and combines digital
aspects of the equipment such as the design
model with real-time aspects of how it
operates and is maintained, to offer insights
into the condition of equipment and the
likelihood of any part failures.
While virtual commissioning creates a safe
space for engineers to test and make sure
the right mix of components are being used
in their application, digital twinning offers
managers further verification of the overall
3-D design. By using simulation software like
ABB’s in the planning stages of this process,
plant managers can calculate figures such
as the optimum use of supply resources
to meet consumption schedules, to make
improvements in the whole supply chain.
The steps required to extend or adjust your
factory are very similar to that of adding to
your home. Disruptive delays or problems
not identified in the initial stages can be
costly, but with virtual commissioning, food
and beverage manufacturers can review the
final model before deployment to address
any issues and avoid any unexpected costs.
www.abb.com