ADM Milling in Port Colborne operated a 24 Metric Tons per hour Mix plant using an obsolete 5000 I/O AB PLC 3 communicating to a DOS based 5000 tag FactoryLink system. The system was approximately 10+ years old and did not run efficiently and was using obsolete automation components. ADM had a real concern about the support and reliability of the automation system and tasked Flomation to overhaul the system and replace it with a modern system that would enhance the process reliability with advanced report generation and scheduling.

Flomation’s solution consisted of:

* Replacing the 5000 I/O AB PLC 3 with an AB PC based PLC called SoftLogix;
* Replace the DOS based FactoryLink SCADA system with AB’s RSView. This included adding new report generation features and scheduling functions. All new schedules are downloaded to the new SCADA system with completion and batch reports being directed back to the office environment;
* Automated two bag dump stations with the addition of two PC based operator interfaces that are clients (linked) to the new RSView SCADA system;
* Replace 29 TTL based Scales with new scales controlled by a SLC 5/04. Provide new panels for these scales to be distributed on the five floors of the Mix plant;
* Commission the project within a two week period.

Result

ADM Milling now has a modern control system that runs faster and more efficiently then the older system. They can now batch 10% more product per day; and have features built in that allow additional automation to the rest of their process. The system allows detailed QC and batch data and the ability to link to the office environment for scheduling and production data exchange.