Complete control

A highlight of the new SIG Combibloc aseptic beverage packaging plant in Linnich, Germany, is its completely integrated process automation. While ER-WE-PA Davis Standard was tasked with the supply of the extrusion coating plant, Siemens was commissioned to do the conception, planning and execution of the process automation. This also included the technical co-ordination of all further directly commissioned suppliers of plant components, such as Linde cooling technology, Derichs granulate supply, and Venti Oelde for ventilation and recycling systems.

SIG Combibloc decided on a strategy of factory-wide consistently integrated automation to minimize the total cost of ownership and life cycle costs, and to maximize availability and flexibility of the plant. This may sound like a long term strategy with later returns, but it returns value right from the start as, in addition to the obvious advantages of integrated factory automation, for example, minimized costs for spare parts storage and service, there is also a decisive further aspect.

The integrated automation of a new factory improves planning security in relation to costs and deadlines, and the quality of processes and products. The commissioning risks can be reduced to the minimum possible with current technology by means of factory-wide homogenous automation; and the desired level of production quality can be achieved more quickly with technologically demanding processes.

To implement this logical and coherent strategy requires not only a suitable automation system, but also partners who implement it consistently and efficiently.

The Siemens PCS7 process control system guarantees integration from the MES level to the control level to the field level. It administrates all of the plant's signals, variables, user programs and project files, ensures transparent communication between all devices, stations and levels of production, and provides by means of a Continuous Flow Chart, standardized graphically oriented programming suitable for all automation levels. For example, open interfaces to visualization systems enable convenient realization of customer-specific interfaces for operator control, monitoring and recipe management, as well as simple connection to quality management systems.

The Siemens Application Centre for Production Machines in Cologne was commissioned to create a PCS7 specification to be followed by all machine suppliers involved in the SIG Combibloc project. For this purpose, Siemens formed a team of specialists in the fields of winding technology, goods channels and extruder temperature regulation, important for coating and converting.

As Siemens became involved in the planning at a very early stage, and had already created the specifications for the supply of energy, for the hall infrastructure, fire detection technology, telephone systems and line lighting, it was not just a question of being entrusted with the planning of the process control, but rather with the entire project and the on-site factors. SIG Combibloc therefore involved its automation partner in technical meetings with potential suppliers of winders, ventilation technology, and granulate supply. This formed the basis of a co-ordinated and effective communication, and reaped the benefits of efficiently agreed, clear and binding interfaces and methodologies for the integration of all plant components.

Once all the suppliers had been selected, the Cologne application engineers kept in close contact with them. All questions of fine detail were clarified in rotational meetings and the conformity of the running engineering to the agreed PCS7 specification was ensured. This enabled regular updating of the centralized PCS7 multi project as, in addition to the configuration information for all plant modules, all of the factory's signals, variables, system programs and user programs are also administered.

In addition to managing the co-ordination of all automation works and the integration of the plant software from the suppliers, the Cologne engineers were also involved in the completion of the coating plant on a practical level. They were able to bring previous experience of several coating plant modernizations at SIG Combibloc and, like the actual main contractor and machine supplier, ER-WE-PA Davis Standard, they assumed full responsibility for process and product quality.

In the case of typical automation or drives tasks, it was often possible to draw on the Siemens Application Centre's proven cross-sector standard solutions, which were then adapted for the new coating plant. Rational engineering was ensured right from the start, so there was also sufficient development capacity available at short notice to assume the automation of plants or the adaptation thereof for the PCS7 specification for two suppliers of important ancillary aggregates.

The SiPaperQCS coating plant quality control system integrated into PCS7, also made an important contribution. Siemens Brussels developed it in co-operation with Protagon Process Technologies, a manufacturer of the measurement engineering used in the new coating plant. The Brussels application engineers realized the section profile and longitudinal profile control, and Protagon assumed the element of measurement engineering.

As soon as the individual sections had been brought into operation by the component suppliers and the Siemens engineers, Protagon technicians checked the parameters relevant to quality. The process engineers from ER-WE-PA Davis Standard then analyzed these results.

This made it possible to undertake the necessary settings and changes to the new plant in both a targeted and efficient way.

At the same time, the Brussels Siemens engineers brought the lateral nozzle control into operation - a critical and often protracted step in the commissioning of a coating plant. Due to the very good interplay of the system components and the control software (developed in-house) used, the required quality standards for the nozzle control were achieved quickly and without complications.

The new Linnich plant began production on time, and the required product and process quality standards were achieved from the start.

This unconventional form of co-operation between purchaser, suppliers and automation partner worked so well that it can serve as a model for future turnkey projects. It has shown how the advantages of integrated process automation can be increased by including technological responsibility in the role of the automation partner.

The customer profits from the technical and technological integration of the process control of its production plant, and a level of process and product quality that can be reliably controlled. It also benefits from the high level of planning security during the plant's construction, as the automation partner takes responsibility for the technical and technological co-ordination.

As a provider of complete electro-technical fittings for factories, Siemens assumes partial responsibility for the planning and realization of new production sites at an early stage of the project. If the know-how of the suppliers involved is merged with the process technology competence of the Siemens Application Centres, it is possible to achieve a high level of quality of economical production quickly and efficiently.