Automated Bottling Plant and System

Parijat Solutions

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Packaging, Filling, Bottling Plant, Logistics Automation

Parijat Packaging, filling, bottling, Logistics Automation is modular, integrated system software for any manufacturing plant performing end-to-end automation for all the aspects of the order processing, scheduling, manufacturing control, downtime analysis, MES/ERP, six Sigma, regulatory aspects at a single point.

automated bottling plant

Fig: An automated packaging, filling, bottling plant

PCI design/builds end-to-end turn-key automation control systems from field devices to mobile devices to the top end of enterprise applications, including order fulfillment, Inbound order processing, inventory management, and outbound distribution activities using iBeacon, RF, SKU, barcode, and auto-ID technology. Logistics systems prioritize, direct, and confirm activities based upon the real-time conditions, constraints of space, equipment & inventory. A single application with a single copy of data with no islands & no dependency on any other 3rd party software vendors are provided. PCI also provides sectional services & solutions as a blank-fill.

PCI adopts a wide range of PLCs like Rockwell/Allen Bradley, Siemens, ABB, GE-IP, Schneider, Automation Direct, Opto22, Mitsubishi, Omron, etc. PCI uses Microsoft HMI/SCADA or 3rd party (to Microsoft) products Like Rockwell – FT/RSView; Schneider – Wonderware, Archestra, Indusoft, Clearscada, Citect; Siemens – WinCC; GE-IP – iFix, Cimplicity; Iconics, Inductive Automation, etc. The client has the choice to pick what precise combination to use. Best features & economies are achievable from Microsoft & Rockwell combination. Solutions are completely agnostic to the conveyor systems hardware & all other related peripheral equipment. Systems may be virtualized or run on virtual OS or cloud servers.

Traditional solutions: Typically, ERP, production management, local HMI, multi-layered systems are used & different products from different vendors, running on Microsoft Windows are employed. This results in a heterogeneous solution with multiple copies of data & multiple dependencies on multiple non-Microsoft vendors. PCI solution integrates all of the above layers into a single Parijat Packaging, filling, Execution/Management System. However, if there are adequate technical reasons in the project in question, then the solution may also be broken down into desired islands.

bottling automation flow chart

Fig: Parijat’s bottling automation vs Traditional model flow chart

Vertical Industry Applications:

  • Food & beverage
    ▪ Beer
    ▪ Soft Drinks
    ▪ Water
    ▪ Milk
    ▪ Non-Alcoholic Beverages
    ▪ Wine, Sprinkling wines, Spirits
    ▪ Food packaging
    ▪ General manufacturing
    ▪ Pharma
    ▪ E-commerce
    ▪ Direct to Consumer (D2C), eCommerce
    ▪ Petrochem

Applications for Packaging Management:

Features:

  • Support unlimited number of conveyors, Fillers, Cappers, Labelers, Cartoners, Case-packing, per facility – unlimited facilities & multi PLC systems per facility.
  • Handling of downtime reasons, Starving, Blocking, faulted & normal running scenarios, for maximized OEE.
  • Handling of complex CIP-associated features.
  • Integrated user, network, maintenance, documentation, asset management system is available.
  • Built-in simulation and override capability that may be invoked anytime for testing, training, troubleshooting, or bypassing failed equipment/hardware, etc.
  • Use commodity Ipads, Androids, or Windows Surface mobile devices for scanning, HMI, or user interface, throughout the enterprise. Native mobile apps, not just virtual desktops. Use Wi-fi, cell network, or broadband of the client’s choice.
  • Production, downtime, statistical complex analytics reports, and history can be accessed via email or web.
  • Decision support via advanced data analytics, artificial intelligence.
  • Alarm management & notifications by various means.
  • Documentation may consist of complete sketches of P&IDs, etc. Details of system electrical drawings, user manuals, and wiring for each section of the system.
  • Automatic recording of all available production data and losses
  • The customizable trend with the selectable timeframe
  • Greater planning reliability
  • Greater efficiency, lower TCO
  • Display of machine states across all lines
  • Identification of root causes of faults on the lead machine and assigned stations
  • Shorter Lead & downtimes
  • Maximum transparency across the entire system
  • Valuable metrics and analyses for optimization of the line
  • Synchronization of production processes with business processes
  • Tapping into efficiency reserves in the production line
  • Order planning with materials management
  • Cross-line acquisition of production data
  • Order planning for efficient production
  • Quality control for laboratory and production
  • IT package for the entire manufacturing process
  • Any vendor’s VFDs, MCCs, motors, conveyors, diverters, scanners, RFID, belt conveyors, encoders, photo-eyes, PLCs, robots, printers, vision system, weigh scales (including check-weighers, etc.) using any Fieldbus like ASI-bus, Profibus, Devicenet, ControlNet, Canbus, Ethercat, EthernetIP, ModbusTCP, etc. in any combination.
  • Directly feed orders into the system database or manual entry. Retrieve data directly from or to various ERP packages like SAP, Navision, Oracle, etc., if need be. If these packages are not in use, the PCI system will perform its functions.
  • The latest version of MS SQL Server used. No multiple copies of any piece of data.
  • Support unlimited number of conveyors, fillers, cappers, labelers, cartoners, case-packing, per facility – unlimited facilities & multi PLC systems per facility.
  • Handling of downtime reasons, Starving, Blocking, faulted & normal running scenarios, for maximized OEE.
  • Handling of complex CIP-associated features.
  • Integrated user, network, maintenance, documentation, asset management system is available.
  • Built-in simulation and override capability that may be invoked anytime for testing, training, troubleshooting, or bypassing failed equipment/hardware, etc.
  • Use commodity Ipad’s, Andriod’s, or Windows surface mobile devices for scanning, HMI, or user interface, throughout the enterprise. Native mobile apps, not just virtual desktops. Use Wi-fi, cell network, or broadband of the client’s choice.
  • Production, downtime, statistical complex analytics reports, and history can be accessed via email or web.
  • Decision support via advanced data analytics, artificial intelligence.
  • Alarm management & notifications by various means.
  • Documentation may consist of complete sketches of P&IDs, etc. Details of system electrical drawings, user manuals, and wiring for each section of the system.

sitepilot - bottling plant automation steps

Fig: Bottling plant automation steps

What Problems Does It Solve?

Know exactly what’s happening – and how it can be done even better: records and displays all production data. Users can harness, mine data and information from across the organization about the system (via any desired means) to achieve major improvements in the operation, including:

  • Unmanned operations – using video cameras to detect & report jams & other abnormalities.
  • Increased operator effectiveness for manned operations
  • Optimized material flow
  • Relieve traditional ERP, WMS (if being used) from real-time decision making
  • Reduced downtime due to advanced diagnostics & override capabilities
  • Painless handling of jams & spills – easy realignment & reconciliation
  • Energy efficiency – equipment sleeps if idling for user-configurable time delays
  • Standardized, simplified workflow processes – dynamically reallocate resources to suit your daily changing requirements
  • Continuously updated lean 6 sigma packaging operation
  • Optimized preventive maintenance, powerful system & hardware diagnostics
  • Configurable PLC I/O system, enabling quick retrofit, complementation, or upgrade of existing system w/o affecting existing wiring & equipment
  • Root cause analyses identifying faults that lead to performance losses on the lead machine and give specific advice on how line efficiency can be improved, preventing losses in production just as reliably as efficiency gaps.

Other available Activities and features:

Multi facility central SCADA system & business intelligence applications for reporting, analytics, or decision support
• Archive all the history data for any length of time from the system
• Multi-lingual, any MS Windows language support
• Redundant or clustered servers, communication paths amongst resources.
• Support video analytics via cameras & lasers for abnormalities detection & reconciliation
• Support RFID, iBeacon, Eddystone, IoT, Big Data, etc. for smart data lifecycle, localization & identification.
• Automatic vital, critical data backup at multiple locations.
• All the Products used are commodities, off the shelf. No 3rd party proprietary software. Source codes & technology transfer services available.
• Automated planning and expanding packaging efficiency could maximize resource utilization.

logistics bottling solutions

Fig: Logistics bottling solutions

All PCI employees are H2S and Land Safety Trained & have completed the IDAC HSE Rig pass course which includes SafeGulf and SafeLand USA.

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