In the dynamic landscape of food and beverage (F&B) manufacturing, the pursuit of new and improved production systems is an opportunity for firms to gain a competitive edge and promote sustainability. Integral to this pursuit is the adoption of innovative technology, such as human-machine interface (HMI). HMI serves as a bridge between human operators and automated systems, facilitating streamlined communication, monitoring, and control processes within F&B facilities.

A well-designed HMI is key to the successful implementation of production systems. It serves as the cornerstone for ensuring operational efficiency and maintaining safety standards. Importantly, a poorly designed HMI can lead to costly plant inefficiencies or, in extreme cases, catastrophic safety incidents. To allow user acceptance, an HMI must be intuitive, easy to navigate and designed to around the operator’s needs.  However, finding a communication, monitoring, and control platform that is brand-agnostic and that can improve operational efficiency and ensure consistent quality can be a challenging task.

Innovating frozen food manufacturing processes

A frozen food manufacturer recently adopted new technology into their operational processes, with an objective to enhance accessibility and aid inventory management, packaging production, and printing. The manufacturer required a solution that could seamlessly integrate with their existing systems. 

In response, they decided to build a new, state-of-the-art factory spanning 24,000 square metres whilst also digitising their existing operational technology and practices to unify the entire operation. Through consultation, the manufacturer implemented Emerson’s Movicon.NExT™ (Movicon) automation software to change how existing staff interact with the process. Automating several administrative tasks between machines and business systems eliminates the chances of human error and inconsistencies.

The new overarching system provided better insights and process workflows that meant staff could focus on key activities, resulting in handling larger production capacities. The secondary result allowed operators and executives with complete visibility of the production process, Overall Equipment Effectiveness (OEE), and critical operational data to make decisions for continuous improvement.

The adoption of Movicon brought several benefits with its real-time monitoring capabilities, which enabled unprecedented visibility across the entire production. Movicon interconnects with the ERP systems and all the automation equipment over the factory data communication network through a diverse range of native protocols. It captures and displays critical data points from raw material intake to packaging and distribution, allowing for informed decision-making and proactive issue resolution.

As a result of adopting Movicon.NExT software, the manufacturer was able to streamline their processes, reduce waste, and optimise costs in ways that were previously deemed impossible. Ultimately, they achieved impressive results

Movicon.NExT – Scale from Small IIoT to Full Plant Control and Monitoring

Movicon.NExT™ HMI/SCADA is a highly modular, secure, and interoperable platform that supports business scale from Small IIoT to Full Plan plant-level analytics in a single engineering environment.

With crisp graphical HMIs and immersive SCADA environments, Movicon simplifies deployment using simple drag-and-drop principles and supports a wide array of native communications. Movicon is compatible with ARM, LinuxOS and Windows systems to suit a broad range of industries.

Movicon collects process information from the programmable logic controllers (PLCs) and other automation equipment to store key data sets in SQL and Oracle databases for ERP integration and historisation. It also communicates with inkjet and labelling equipment to dynamically update information during production.

Emerson's Movicon.NExT uses the latest .NET architecture, offering an innovative solution with built-in libraries using SVG and WPF formats, enabling high-performance HMI graphics. Movicon.NEXT’s intuitive displays enhance operator efficiency by providing real-time information in a visually accessible format, facilitating faster response times and improved problem resolution.

Movicon supports high-resolution displays with HTML5 and augmented reality (AR), which is computer-generated content via a wearable device. So, just like wearing light safety glasses, Android smart glasses or Microsoft HoloLens have object recognition that lets operators instantly know the status of a machine, valve or pipe and recommend actions as they walk around the plant. 

Advised tools within Movicon.NExT facilitate alarm configuration, data analysis and report generation. The software allows quick and easy access to trends, charts, tables, and data analysis with just a click of a button from any location within the plant. Movicon features a complete historical data analysis, eliminating the need for additional tools and simplifying data extraction. Furthermore, its integrated report designer and sophisticated analysis solutions, delivered locally or on the web, ensure a streamlined operational experience. 

The addition of the Pro.Lean module simplifies OEE integration, enabling manufacturers to identify areas of wastage and implement targeted improvements that minimise losses and optimise resources. Key performance data is collected and analysed to measure OEE and downtimes, providing valuable insights to reduce equipment failures. The bolt-on pack also provides predefined OEE templates and reports that lower integration costs and speed up deployment.

Furthermore, the addition of Pro.Energy module provides real-time reporting on energy usage and consumption. This energy management system has analytical tools, data displays, trending, and dashboards tailored to WAGES supply and consumption. For example, a plant can have water and gas meters, 15 energy meters, four HVAC units, and three lighting units added to it, with the option for expansion in the future. Users can create energy performance indicators with a simple wizard, metrics that help analyse waste and reduce it. These indicators are exhibited on easy-to-use dashboards that can show data for a particular time and delve into a single piece of equipment for a thorough investigation.

The benefits of using Movicon solutions are not limited to a single department, but they extend to various facets of the organisation. Production managers have gained unparalleled control, quality assurance managers have witnessed enhanced traceability and compliance, and supply chain managers have experienced a new level of transparency throughout the production lifecycle. This newfound visibility has empowered decision-makers to respond quickly to production challenges, minimising downtime and optimising overall efficiency.

Movicon.NExT is designed to help manufacturers stay agile in a dynamic market where products evolve rapidly. With this platform, businesses can maximise their plant efficiency and productivity. IPD will partner with you in your project development and execution to provide pre and post sales support, along with helpful resources and instructor lead training. Contact IPD to register for a free 2-hour runtime here.