The cutting-edge technology of Wonderware®'s Factory Suite Software System was integrated
with Tri-Clover's complete line of process automation equipment by New England-based
oliver m. dean, inc. a Tri-Clover Team 2000 Distributor. At work since August 1997, the
system has already delivered greater efficiency and production for the Chelten House
Products, the 35-year old-plus Bridgeport, NJ.-based manufacturer of natural and organic
foods.
According to Chelten House President Steve Dabrow, "About five years ago, we saw that
the natural and organic foods industry was growing. So we got into the game by buying a
small company making organic salad dressings. Soon to follow were pasta sauces, salsa and
condiments under their own brand and for private label. Now, with Chelten House
growth at 25% a year and with natural-foods growth at 21% a year, Chelten House has sought
to upgrade its processes.
The new process operates with greater efficiency and repeatability than its predecessor,
with 30% fewer people. Employees once engaged in managing the process have been
transferred to other production-building positions. What's more, the company turns out a
more consistent product, with better yields, and with a technology that enables them to
keep up with their competition.
The Right "Recipe" for Automation
With the help of Oliver M. Dean Inc., Chelten House has significantly increased their
capacity with its automated production. Oliver M. Dean's process control engineer, Keith
Magill, sought to fully automate the process system into a seamless blend of
custom-software control, proven hardware technology, and a user-friendly operator
interface. As part of the upgrade, Chelten House decided to halt operation during July,
1997, while transforming the plant into an automated facility. Retaining just the kettles
from the plant built in the 1980's, the company and distributor completed the
automated-plant upgrade on schedule without a disruption in product shipments.
Tri-Clover pumps and valves shape the back-bone of the automated system, while the
Wonderware® Factory Suite provides the brains. An Allen-Bradley 540 Process Logic
Controller translates the Wonderware® commands which traffics product flow through the
process system.
Key ingredients for Chelten House include corn syrup, water, vinegar, oil, a slurry of
tomato paste and diced tomatoes. Seven cooking kettles formulate product along with a
pre-mix and a saute kettle.
Wonderware® tracks cooking through RTD sensors. |
The processing system turns on agitators when needed, prompts evaporators, and sets
heaters or cooling coils. At the end of the process, a Tri-Clover T Series
positive-displacement pump sends the product to the 500-gallon surge tanks. These larger
vessels store product before it is fed to their filler line.
Dabrow credits the T Series pumps for delivering an unusual combination: power with
particulate integrity. "This is very important for maintaining what we call piece
identity. We want the diced tomatoes and onions to come out the same way they came into
the process. The pumps are not beating up the product, simply pushing it along."
Another advantage is the flexibility of the hardware and software. Wonderware®'s capacity
for thousands of recipes coincides with Chelten House's strong R & D capabilities. The
combination helps Chelten develop new recipes for private label customers. "We come
out with very high-quality products; points out Dabrow. "So, now with our lower-cost
operation, we can give those customers the best of both worlds."
The role for Wonderware® extends well beyond the kitchen. The system is also on top of
production scheduling, inventory tracking and production modeling. For on-line
supervision, the software produces a graphic picture of the active process, including
batch status and process-equipment availability. Data become readily accessible so Chelten
House management can better analyze, troubleshoot and maintain optimal production.
According to Dabrow, the plant typically produces 50 batches per shift. Between runs, the
system sends down a rinse of hot water. At night, the system activates Tri-Clover
centrifugal pumps to begin nearly three hours of CIP.
As part of the service for the project, Oliver M. Dean Inc. was on hand for employee
training. "Prior to the month shut-down, we did an informational seminar to let
the crew know what was coming," relates Tony Fiore, Oliver M. Dean's project manager.
"After everything was up, they were pretty fluent in system operation within four
days." A representative from Oliver M. Dean Inc. stayed on site for two weeks
following installation to handle any necessary redesign adjustments.
Pleased with the contributions of its automated process, Chelten House officials are
already looking at ways to extend the system. Designs are in the works for an expansion
that will feed reports directly into the accounting system for automatic inventory
reconciliation.
"It's a great tool", Dabrow said,"one that helps the Company manage its
growth while managing to grow itself." |
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