The Challenge
The site was experiencing a number of operational and visibility challenges that were impacting efficiency and reliability.
Utility usage—particularly water—was not being effectively monitored, resulting in losses going unnoticed until billing cycles. At the same time, legacy PLC and HMI systems were becoming increasingly unreliable, with hardware faults and limited availability of spare parts posing a risk to ongoing operations.
The Solution
To address these challenges, a staged upgrade and integration project was delivered across three key areas:
1. PLC & HMI Upgrade
Legacy control systems were replaced with a modern Siemens platform, incorporating industrial Ethernet and a SIL2-rated PLC. This improved system reliability, reduced maintenance risk, and provided a scalable foundation for future upgrades.
2. SCADA Batch Recall & Analysis
A new SCADA solution was implemented using Ignition Perspective, integrated with a historian and SQL database. Batch records are now automatically captured and can be recalled using SKU, unique ID, or date/time filters. Users can compare batches in both tabular and graphical formats, with key metrics including ingredient volumes, timestamps, cooking duration, and temperature—enabling improved traceability and process insight.
3. Utility Monitoring & Reporting
The existing SCADA system was extended to monitor utilities such as water, gas, and incoming power. A custom “teach” function was developed to learn normal operating behaviour and identify anomalies, allowing for proactive reporting and improved resource management.
The Outcome
The upgraded system delivered significant improvements across operations:
- Data-driven insights to support better operational and energy management decisions
- Increased reliability through modernised control hardware
- Real-time visibility of utility consumption, enabling early detection of losses
- Enhanced batch traceability and the ability to quickly analyse and compare production runs