OSBL Detailed Design

Performed instrumentation and automation detailed design for OSBL facilities of an animal feed manufacturing plant, covering utilities and support systems outside the core process area. Deliverables included:

  • Control narratives / functional descriptions for OSBL systems

  • Instrumentation index, datasheets, and specification sheets

  • PLC/SCADA integration requirements and I/O mapping

  • Loop diagrams, termination drawings, and cable schedules

  • Control panel design inputs, installation details, and commissioning readiness documents

  • Network and communication interface definition for OSBL equipment and instrumentation

HMI RECOVERY

Challenge: The existing HMI suffered a display hardware failure, and the obsolete unit had to be replaced with newer hardware. However, the backup HMI application (running as a Windows 7 executable) could not run properly on the new system due to operating system compatibility differences, risking extended downtime.

Action: Assessed the executable’s dependency on legacy file paths and rebuilt the required directory structure on the replacement hardware. Mapped the new system’s folders to mirror the original Windows 7 file paths so the application could locate all required resources and configurations.

Result: Successfully restored and re-commissioned the custom HMI on the new hardware without requiring a full software rebuild, enabling continued operations and minimizing unplanned downtime.

Plantwide Program Backup and Documentation

  • Legacy automation hardware significantly elevates the risk of unexpected downtime. Over 60 years of machine acquisitions from various OEMs, the client has accumulated 94 PLC and HMI systems across multiple versions and vendors—ranging from Beckhoff and Siemens to Allen-Bradley, B&R, Mitsubishi, Panasonic, LG, Yaskawa, Omron, and Pro-face.

  • Immediate Stabilization Actions

    Backup & Documentation

    • Extract and archive all PLC programs, HMI projects, SCADA configurations.

    • Create standard directory structure

    • Ensure version control and restricted access.

    Temporary Spares

    • Identify currently functioning systems with common modules that can be interchanged as emergency spares.

    • Purchase refurbished/used critical cards for short-term continuity.

    • Phase 1: Audit & Backup – 3–6 months – No production impact

    • Phase 2: Obsolescence Pilot – 6–9 months – Weekend shutdowns

    • Phase 3: Network Upgrade – Parallel – Minimal disruption

    • Phase 4: Line-by-Line Migration – 2–3 years – Controlled downtime

    • Phase 5: SCADA Unification – 3–5 years – Parallel implementation

    • Backup & Documentation

      • Extract and archive all PLC programs, HMI projects, SCADA configurations.

      • Create standard directory structure

      • Ensure version control and restricted access.

    • Knowledge Transfer

      • Disaster recovery plan for each machine to avoid prolonged downtime during hardware failures

ASEPTIC FILLER

Challenge:
The aseptic filling machine exhibited intermittent seal deformation and leakage, resulting in compromised package integrity and an increased risk of microbial contamination during transportation. Replacement of critical components—including the heating element, sealing head, and temperature sensor—did not resolve the sealing defects. Additionally, the Siemens Comfort HMI had no available development backup, and access rights to critical process parameters were locked, preventing operational adjustments and troubleshooting.

Action:
Conducted a comprehensive analysis of the complete filling and sealing sequence, validating all step logic, interlocks, and process parameters directly through the PLC due to restricted HMI access. Retrieved and verified sealing parameters via PLC monitoring and diagnostics. After confirming parameter inconsistencies and access limitations, fully redeveloped and reprogrammed the Siemens Comfort HMI from scratch to restore proper parameter visibility and control. Configured secure but accessible operator-level permissions to allow controlled adjustment of sealing pressure, temperature feedback loop settings, and dwell time in accordance with the bag manufacturer’s sealing specifications. Subsequently calibrated and fine-tuned all sealing-related parameters to ensure process stability and repeatability.

Result:
Achieved consistent, uniform, and fully cured seals, eliminating occurrences of warped and undersealed packages. Restored full operational control of critical process parameters through the newly developed HMI interface. Reduced material waste and product losses due to seal rejection, and improved overall equipment reliability by minimizing unplanned downtime associated with sealing failures.