Building a Scalable Automation Foundation for a New Manufacturing Facility

CHALLENGE:

The new facility required a complete automation and manufacturing technology environment capable of supporting unloading, processing, blending, and packaging operations.

The project needed to integrate:

• Process control
• Batch management
• SCADA and visualization
• Manufacturing Execution System (MES)
• OEE and quality data
• Product traceability
• Production and work-order workflows

The goal extended beyond bringing the new facility online. The customer wanted an automation approach that could support future expansion while remaining flexible enough to accommodate new formulas, processes, products, and production requirements.

SOLUTION:

Actemium designed and implemented an integrated automation solution utilizing Rockwell Automation’s PlantPAx platform and associated technologies, including ControlLogix 5580 P controllers, FactoryTalk View, FactoryTalk Batch, and PhaseManager.

Four ControlLogix controllers managed the facility’s unloading, processing, blending, and packaging operations.

PlantPAx provided Rockwell Automation’s established process control standards, including PLC logic structures, HMI layouts, and faceplates. Actemium utilized and extended these standards to meet the customer’s specific operational requirements, incorporating performance functions, permissive and interlock visibility, security, and application-specific functionality.

FactoryTalk View provided a consistent, high-performance HMI environment throughout the facility. Hierarchical screen layouts gave operators visibility from area-level overviews down to individual device and phase controls, while situational awareness principles helped draw attention to conditions requiring action.

FactoryTalk Batch was tightly integrated with PhaseManager using a modular phase approach. This simplified troubleshooting and allowed recipe sequences to be changed without requiring modifications to PLC code. The solution also included historical batch reporting and automatic batch queuing based on required finished-goods pallet quantities.

The Rockwell Automation control environment was integrated with the facility’s MES to support OEE, quality, product traceability, and manufacturing workflows. Production and work-order information flowed between MES and the control layer, while key performance information was returned for OEE and quality tracking.

FROM DEVELOPMENT TO ADOPTION:

Actemium used an agile development methodology throughout the project, allowing customer stakeholders to see and interact with the developing system before formal acceptance testing.

Simulated PLC logic and the actual FactoryTalk View HMI application were used during regular sprint reviews, giving stakeholders an opportunity to provide feedback and identify enhancements throughout development.

The completed system progressed through simulated pre-FAT, Factory Acceptance Testing, I/O checkout, dry checkout, and commissioning.

Operator, maintenance, and engineering-level training helped prepare plant personnel to support the new environment. Training materials were also converted into focused online job aids for future reference, and 24/7 post-commissioning support provided continued access to support resources and project subject matter experts.

RESULTS:

The completed facility gave the customer:

• Increased manufacturing capacity
• Consistent implementation of Rockwell Automation technologies across major process areas
• Scalable control and SCADA architecture designed for future expansion
• Flexible batch management for changing formulas, products, and processes
• Intuitive PlantPAx-based operator interface with real-time production information
• MES integration supporting OEE, quality, traceability, and manufacturing workflows
• Architecture designed to accommodate planned additional packaging capacity

Rather than designing an automation system solely around the facility’s immediate requirements, Actemium established an environment capable of evolving with the customer’s manufacturing needs.

DESIGNING FOR WHAT COMES NEXT

A greenfield facility provides an opportunity to think beyond startup and design an automation environment for what comes next.

Establishing consistent standards, modular controls, flexible batch management, and integrated manufacturing data from the beginning can make it easier to introduce new products, add capacity, and adapt processes as production needs change.

For manufacturers planning new facilities, the lesson is to design for long-term flexibility, not just day-one production. The right automation foundation can simplify future expansion, improve supportability, and help organizations get more value from their technology investments over time.