Retrofit for bakery equipment
Retrofit projects often challenge both the operators and the engineers. Since the maintenance and modification windows are usually minimal, proper preparation for commissioning is essential. ICS has gained a lot of experience in various retrofit projects and, thanks to its team size, has the necessary resources to handle even larger retrofit projects. Whether Siemens S5, S7 or Rockwell, we have the necessary know-how to support you accordingly and guarantee a quick and careful retrofit phase with a successful return to production. Thanks to our 24/7 support, you will also receive all-round assistance after the conversion phase in order to operate the systems with maximum efficiency. Our activities include:
- on-site function analysis
- selection of successor components
- dimensioning for the replacement of drive and gearbox
- development of a safety concept together with the customer
- organization of modification and commissioning of control cabinets, sensors and control system
- connection to higher-level systems
- software and hardware engineering
- control cabinet construction
- time optimized mechanical and electrical conversion
- commissioning and handover to production after a few days
- 24/7 support thanks to remote access
Project description
The controls and electromechanical equipment of a bakery line, consisting of a pre-proofer, proofer and oven, at Jowa are obsolete and are to be replaced. The obsolete components not only represent a risk to production, they are also becoming more expensive and more difficult to procure every year. This problem also forms the basis for the decision in this retrofit project and, thanks to many years of cooperation, once again ends up as an extremely successful project. Together with the operators on site, functions are recorded, wishes and new requirements are specified and finally implemented in the new software. The existing hardware is evaluated and replaced where necessary. Finally, a lean commissioning, a start of production on schedule and a targeted operator training follow. Thanks to remote access, the customer now knows he is in good hands and is supported around the clock by experts from ICS.
Requirements
- restore the production safety
- takeover of the existing functionality
- takeover of the setting values
- transfer of recipes and products
- optimization of individual process steps
- connection to third-party systems
- integration of additional intelligence
- comply with current safety guidelines
- reuse of the power unit
- short time window for upgrading
- successful and short commissioning
Scope of supply
- recording of customer requirements
- recording of the existing functions
- recording of the existing hardware
- optimized control concept
- installation of modern safety equipment
- replacement of the electrical schematics
- reconstruction of the control cabinets
- replacement of obsolete sensor and drive technology
- replacement of the operator stations
- software engineering
- pre-acceptance at ICS
- conversion and commissioning
- production support
- 7/24 remote support
Hardware & control
- installation of new control components in existing cabinets
- 3 Siemens PLCs
- 4 HMIs TP1900 Comfort (via Ethernet)
- 1 Ethernet switch per plant section
- decentral I/O modules ET200SP
- new servo drives and various evaluation devices (Profibus)
- parameterization of decentralized devices via the operator panels
- replacement of separate hardware controllers by software controllers
- separated safety circuits
- additional process monitoring
- recording of process parameters
- automatic recipe transfer to other plant sections possible
- operator guidance in case of problems
- import / export data interface for recipes, temperatures, etc.
- electrical schematic created on CAD
- remote support via VPN
We would be pleased to demonstrate our expertise and present our worldwide references to you.
We are at your disposal at any time for a presentation of our skills and show you development possibilities for your business by means of some reference projects. We are convinced that, thanks to our many years of experience in various industries, we combine the necessary skills to accompany you profitably.
