Automation Software Developed for Conveyor Control System Saves $112M

Phil Black - PII Editor 25/10/2016

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UK based Clarian Automation has played a pivotal role in automating the packaging and distribution system for a well-known international snack food brand in Saudi Arabia

As part of a team of 22 people from different OEM’s all round the world comprising of 8 people from the snack food company, the project took almost 2 months to complete, including 4 weeks for installation and 10 days for commissioning.

Renowned for their extensive experience in programming a wide-range of PLC”s, Clarian Automation’s primary function was to write the automation software for the conveyor system which carries products and cases from the packing station to the palletising area. This included the graphics and operations on the Human Machine Interface (HMI). This involved constant monitoring of how many cases continued along the line, thereby guaranteeing the correct number as well as managing site expectations, i.e. conveyer system stage sequences were continually being re-configured.

Upon installing new software, Clarian Automation has successfully developed a conveyor control system to save $112M over 10 years and ensured an accurate count of the number of packaged products into bags and boxes. An updated conveyor system now places sealed bags in boxes, which are quickly transported upwards in a lift overhead and smoothly taken out of the factory for palletising.

To ensure the conveyor system adhered to the site’s safety categories, Clarian Automation’s knowledge in this area meant the system was not only safe, but very cost effective. In-depth technical operating manuals were written in advance by Clarian Automation explaining how the whole system worked. Furthermore, operators were also comprehensibly trained on how to effectively run the production line.

Ian Stones, Managing Director of Clarian Automation Ltd commented, “To be involved in this project has been a challenge at times from the point of view of successfully managing site expectations and developing accurate software for successful automation of the conveyor system. However, by identifying the major issues that could potentially hinder the system working to its full potential in terms of working to strict deadlines and ensuring that any problems are identified and resolved during testing, we have been able to develop a very satisfying solution to definitely speed up the packaging process.”

Additionally, Clarian Automation are giving one lucky customer the chance to win £300 worth of Amazon vouchers in their free prize draw until 30th November 2016.