GEA AVAPAC Case Studies
Case #1
In 2016, commissioned 3 GEA Avapac 25kg packing lines at Fonterra’s new Lichfield dryer. The new dryer processes 30 tonnes per hour of whole milk powder, this is packed into 25kg bags by three automated packing machines which run at 12 tonnes per hour each.
For this job the Rockwell ControlLogix PLC code was developed and installed for transfer of Production Order data from Fonterra’s MOM system to the automation layer. The PO data, including bag coding information was then sent out to the JMP palletising system the GEA packers and the RGL .Comm4 bag coders. All bags are tracked from the filling to the palletising system. Along the way the bags are automatically sealed, weighed and rejected if out of weight range. Bags run through a metal detector and are automatically stopped if contaminated. Good bags carry on past a RGL .Comm4 coder which is sent the coding data for each bag by the packer PLC.
PLC code was engineered for the creation of pallet records based on the bags stacked on the pallets and the sending of the pallet records to Fonterra’s MOM system for transfer to SAP.
The packing line commissioning involved mechanical adjustments and electrical work to complete installation. Pre-product testing of the packing line was carried out with changes to the Rockwell ControlLogix PLCs, PanelViews and FTView SE wireless tablets as required. The packer was then run on product, and fine-tuned to achieve best possible production rates and weight accuracy.
Case #2
In 2016, commissioned a GEA Avapac 25kg packing line for Biolac in Germany. This machine automatically packs 25kg bags of lactose powder at 8 tonnes per hour.
The commissioning involved mechanical adjustments and electrical work to complete installation, while working with local installers. Pre-product testing of the packing line was carried out with changes to the Siemens PLC and HMI software as required. The packer was then run on multiple lactose products, and fine-tuned to achieve best possible production rates and weight accuracy. Acceptance from the site was quickly achieved.
Case #3
In 2016, commissioned a GEA Avapac 25kg packing line for Hilmar in the United States. The Hilmar Cheese Company had built its first milk powder dryer in the town of Turlock, California. GEA Avapac supplied a 25 kg automated bag destacker and packing machine which packs 25kg bags of powder at 10 Tonnes per hour.
The commissioning involved mechanical adjustments and electrical work to complete installation. Pre-product testing of the packing line was carried out with changes to the Rockwell ControlLogix PLC and PanelView as required. The packer was then run on product, and fine-tuned to achieve best possible production rates and weight accuracy.
Case #4
In 2015, commissioned 2 GEA Avapac 25kg packing lines at Fonterra’s new Pahiatua dryer.
The new dryer processes 15 tonnes per hour of whole milk powder, this is packed into 25kg bags by two automated packing machines which run at 10 tonnes per hour each.
For this job the Rockwell ControlLogix PLC code was developed and installed for transfer of Production Order data from Fonterra’s MOM system to the automation layer. The PO data, including bag coding information was then sent out to the JMP palletising system the packers and the RGL .Comm4 bag coders. All bags are tracked from the filling heads out to the palletising system. Along the way the bags are automatically sealed, weighed and rejected if out of weight range. Bags run through a metal detector and are automatically stopped if contaminated. Good bags carry on past a RGL .Comm4 coder which is sent the coding data for each bag by the packer PLC.
PLC code for the creation of pallet records based on the bags stacked on the pallets and the sending of the pallet records to Fonterra’s MOM system for transfer to SAP.
The packing line commissioning involved mechanical adjustments and electrical work to complete installation. Pre-product testing of the packing line was carried out with changes to the Rockwell ControlLogix PLCs, PanelViews and FTView SE wireless tablets as required. The packer was then run on product, and fine-tuned to achieve best possible production rates and weight accuracy.
