The Challenge
An OEM machine builder had mechanical machines that were used to load, fill, and seal ice cream cups for a client. The mechanical cams that ran the machine, consisted of too many components, making it hard to service. The cams also limited the ability to change the line with ease. The machine did not run with a PLC or HMI, so it lacked in automation technology. The OEM knew that for their clients to keep up with their competitors, the machine would have to be fully automated, making it faster, more efficient, and producing more ice cream cups per minute.
An original equipment manufacturer(OEM) machine builder and MartinCSI create more flexibility with less components for the ice cream industry
The Solution
The OEM developed a completely automated system to replace the old mechanical machine. The cams on the old machine were converted into electric servos. With servo technology, a program controls all the motions of the machine instead of the mechanical cam, making the machine faster, and more adjustable. The program also provides the ability to troubleshoot remotely, so changes can be made within a matter of minutes. MartinCSI assisted with choosing the right servo equipment to fit the OEM’s needs. The OEM’s service staff were knowledgeable with Rockwell equipment, so MartinCSI integrated Rockwell Kinetix® servo drives, a ControlLogix PLC, and a PanelView Plus HMI to complete its automation overhaul.
The Results
- One automated machine replaced (2) mechanical machines for their client.
- Client was able to reduce their operator costs by half.
- The automated machine produced almost 40,000 more ice cream cups per day.
- Machine maintenance was significantly decreased.
- Ability to remote access to assist with troubleshooting.