ADM Milling UK - Smooth upgrade of production-critical 1980s control panel
ADM Milling is a market leader for flour and bakery ingredients with a strong reputation for product quality, technical support and customer service. At their Corby mill, OAL has seamlessly upgraded and modernised production-critical control panels, achieving zero unplanned plant downtime - a notable achievement given the complexities involved.
ADM Milling is a market leader for flour and bakery ingredients with a strong reputation for product quality, technical support and customer service. At their Corby mill, OAL has seamlessly upgraded and modernised production-critical control panels, achieving zero unplanned plant downtime - a notable achievement given the complexities involved.
Upgrading ageing control panels presents significant challenges, particularly for businesses like ADM that depend heavily on continuous production and cannot risk sales losses due to downtime. In this critical situation, ADM trusted OAL based on several key strengths: OAL's industry reputation for being “easy to work with, their proven ability to meet stringent deadlines, and their commitment to prioritising customer needs in all proposed solutions.
The purpose of this project was to replace the existing obsolete MCP12 control panel.
The panels control three flour packing lines.
The new control panel offers less downtime and easier maintenance moving forward due to up-to-date components and accurate documentation. Furthrermore the new panel meets the latest electrical standards and incoprates extra functions
“OAL showed excellent health and safety whilst on-site. They were a respectful team and a diligent workforce with high standards. Nothing was too much trouble for the team and there was no noise on the project!”
OAL engineers complete the installation of the new control panel.
Challenge
The control panel dated from the 1980’s, so although there was a nearly complete set of original drawings, all the modifications over the years were not necessarily fully documented.
Additionally, the fact that the existing field devices and cabling were to be reused, meant that a lot of survey work was required to ensure there were no unknowns when the old panel was disconnected and the new one installed.
The panel needed to be swapped out during a 14-day shutdown, during which no packing could take place, so it was essential to the business that it was completed on time.
The “old” control panel.
Solution
OAL executed the project using our proven methodology, “The OAL Way”. The key activities completed are highlighted below:
Extensive survey work to ensure there were no unexpected issues when disconnecting the existing old panel. As the old saying goes, “An hour in planning (specification) saves 10 hours of doing!”
Designed and build of the new control panel at our factory in Peterborough.
Software modifications the new PLC and I/O sensors.
Factory acceptance test (FAT) of all equipment at OAL.
Disassembly of the new control panel into sections. Reassembly in situ on site due to access restrictions; it needed to be on the 3rd floor.
The following tasks were completed in the 14-day planned downtime window whilst the clocks were ticking:
Identify and disconnect cables from the old panel.
Disassemble and remove the old panel.
Position the new control panel and reconnect cables
Perform I/O testing of all field devices and recomission each packing line.
The plant was ready for start-up on Monday as planned. OAL provided 24/7 cover for support issues following go-live which has subsequently rolled into an annual support contract.
The new upgraded control panels in situ.
Results
Since the successful completion of the project, ADM has had no electrical component failures. The project has secured future reliability and adherence to DSEAR regulations.
The integration of new, current-specification equipment is expected to significantly reduce downtime and simplify maintenance due to the availability of updated and precise documentation.
Upgrading the control panel construction to meet current standards has facilitated the easy modification of control sequences and enabled the incorporation of several additional functions, as requested.
OAL can upgrade your systems too - speak to our team today for advice and guidance.
At a glance
Customer since: 2004
Challenge
Packing lines reliant on a critical control panel from the 1980s
No original electrical drawings
Lots of survey work required
Strict lead time to begin and complete work
Solution
Extensive survey work carried out enabling an accurate work timeframe
The new current spec allows less downtime and easier maintenance
Up-to-date system documentation
Addition of several extra functions
Results
Zero electrical component failures
Up-To-Date system for reliability and longevity
Documentation now up to date for easier future maintenance
Edwards the Welsh Butcher, UK - Eliminate errors with OAL's AI-Driven Label and Date Code Verification System
As a fast-growing leader in the high-quality convenience meats industry, Edwards needed to ensure the correct application of labels and date codes on its expanding range of award-winning products. OAL automated their manual processes with a state-of-the-art, AI-driven label and date code verification system that has been critical in Edwards growth plans.
As a fast-growing leader in the high-quality convenience meats industry, Edwards needed to ensure the correct application of labels and date codes on its expanding range of award-winning products. OAL automated their manual processes with a state-of-the-art, AI-driven label and date code verification system that has been critical in Edwards growth plans.
Challenge
Edwards, The Welsh Butcher faced the daunting task of maintaining label and date code accuracy amid rapid business growth.
Mistakes could lead to expensive recalls, tarnished brand reputation, and regulatory snags. A rapid expansion from 20 to 50 SKUs alongside similar branded artwork was significantly increasing the risk of error.
Why OAL?
Edwards chose to partner with OAL not only for our cutting-edge solutions but also for our ease of collaboration. Our reputation for being easy to work with made OAL a perfect fit for this critical project.
Solution
OAL provided our OAL Connected system for label and date code verification, a hardware and software solution that automates the set-up of printers to stop date coding errors. It uses cameras powered by AI to verify that the packaging is correct. Key features include:
Digitalised master product database. No more paperwork.
Real-Time AI 100% Date Code Verification: Advanced artificial intelligence inspects and verifies every pack date code, eliminating missing and wrong date codes on the pack.
2D Barcodes for Version Control: OAL assisted Edwards in adding 2D barcodes to their packaging artwork, thereby enabling better version control and traceability.
Seamless Integration: Our system is smoothly integrated with Edwards current manufacturing setup, ensuring minimal disruption.
Scalability: Designed with expansion in mind, the system can easily scale to meet increasing production volumes.
User-Friendly Interface: The system features a straightforward dashboard, requiring minimal training for monitoring and control.
APRIL Eye inspects and verifies every pack date code, eliminating missing and wrong date codes on the pack.
Artwork and technical support
Worried about artwork changes? OAL provided consultancy and advice to assist in the integration of 2D barcodes onto the packaging.
2D codes provide full artwork version control. By standardising 2D code placement, cameras are fixed on the line, eliminating operator interventions.
Key results
After implementing OAL’s AI-based label verification system, Edwards experienced:
Zero Errors: The system eliminated previous issues related to incorrect labelling and date coding.
Operational Efficiency: Automation of the verification process, formerly manual, allowed staff to reallocate their time to other key tasks.
Streamlined Growth: The system’s scalability has been crucial in facilitating Edwards growth initiatives.
Enhanced Compliance: Regulatory compliance is now more straightforward, alleviating administrative burdens significantly.
Conclusion
OAL’s AI-driven label and date code verification system has been a cornerstone in the Edwards growth strategy. By ensuring unparalleled accuracy in labelling and date coding, we’ve enabled them to concentrate on what they do best: crafting quality convenience meat products.
For more information on how OAL's AI solutions can help your business, please contact us.
You can automate and digitalise your operations - speak to our team today for advice and guidance.
At a glance
Customer since: 2023
Challenge
Retailer Code of Practice Compliance
Maintaining Label and Date Code Accuracy
Managing complexity as the business grew from 20 to 50 SKUs
Increased Risk of Errors
Solution
Digitalised Product Database
Real-Time AI Date Code Verification
2D Barcodes for Version Control
Seamless Integration
Scalability
User-Friendly Interface
Results
Zero Errors
Operational Efficiency
Streamlined Growth
Enhanced Comliance
Worldwide Fruit, UK - Stopping human error with automated product label verification
Worldwide Fruit is a growing £200+ million turnover fruit marketing and distribution business. Quality is critical to their customers, and they wanted a solution that could scale across their complex operations handling thousands of SKUs from over 1,000 global growers. OAL has helped Worldwide Fruit automate to ensure all its products have the right date code, right packaging and country of origin.
Worldwide Fruit is a growing £200+ million turnover fruit marketing and distribution business. Quality is critical to their customers, and they wanted a solution that could scale across their complex operations handling thousands of SKUs from over 1,000 global growers. OAL has helped Worldwide Fruit automate to ensure all its products have the right date code, right packaging and country of origin.
UPDATE: Worldwide Fruit is on a SMART Industry journey supported by OAL. The first phase deployed label and date code verification to ensure the right-first-time packaging and date coding in 2020, including the use of AI vision checks with APRIL Eye.
In the second phase in 2023, OAL has helped Worldwide Fruit seamlessly integrate their ERP (Prophet), Label and Date Code Verification (OAL), and OEE (Redzone) systems.
Challenge
The right apple must be in the right packaging with the right date code and country of origin.
Ensuring the highest standards of quality control and food safety are mission-critical priorities for Worldwide Fruit. Previously manual human checks of product labels, date code and country of origin were undertaken, but these methods are susceptible to human error, especially in a high-complexity business.
Complexity to Worldwide Fruit is driven by the different product, grower, and packaging combinations. For one category like apples, there are many varieties of apples from different countries with different packaging and promotion requirements from each retailer.
For a production run, Worldwide Fruit must ensure the right product (apple), is in the right packaging with the right date code and country of origin. Any mistake in the process could result in a product recall and a fine from retailers. To address these challenges Worldwide Fruit turned to automation.
Solution
Phase 1: Label and date code verification - 2020
After a review of suppliers, Worldwide Fruit chose to work with OAL because of recommendations and previous experience implementing the OAL system. Furthermore, they wanted to work with a business that could integrate with their existing ERP system, which OAL could demonstrate.
The priority was implementing an “online” label and verification system across its 16 packaging lines to accelerate its digital transformation. Online meaning, every product is verified as opposed to “offline” where a sample is verified.
“The team at OAL are easy to work with, working together we have implemented a robust automated label and date code verification system. By introducing cutting edge artificial intelligence technology we’ve futureproofed our packaging lines, enabling further automation. Crucially we’ve been able to customise the system to meet our unique requirements. The 24/7 support is quick, friendly, and efficient!”
First, a master product database was installed on a site-based SQL server. This is a database managed by the technical team that stores all product information. OAL’s ex-industry trainers assisted WWF in populating the database.
The OAL system was installed and commissioned comprising:
OAL Line Terminals on every line for operators to start and finish jobs and conduct quality checks related to the job.
Cameras to scan and verify packaging to ensure the right packaging is applied to the product.
Each online printer was connected to the OAL system. The OAL system controls the printer and tells it the date code to print based on the date code rules in the master product database.
The offline print room printers were also under the control of the OAL system to ensure offline printed labels were also correct.
Finally, the site chose to add an extra layer of assurance with APRIL Eye date code verification. APRIL Eye gives the OAL system the functionality to read back and verify printed date codes in an image. This ensures the right date code is applied, it’s legible and in the right location.
At Worldwide Fruit, as part of start-up, interval and end-of-run checks the operator takes a picture of a finished pack with the OAL line terminal hand scanner. The system checks it’s correct and legible against the current job.
Finally, every check, scan and data point is recorded providing a complete digital audit trail to ensure BRC and retailer code of practice compliance.
OAL provide a 24/7 support contract to minimise downtime and ensure the system is functioning to specification.
Phase 2: ERP and Redzone Integration - 2023
Worldwide Fruit had a long-term vision to automate and digitalise its packhouse to ensure the right data first time. OAL utilised the Ignition SCADA/MES Platform to integrate the different business systems driven by works orders generated in Prophet.
The user experience is:
Job scheduled in Prophet
Job appears for selection on the OAL Line Terminal as a works order
Job selection by operator on the OAL Line Terminal sets up cameras, printers and starts a job in Redzone.
“Working with OAL on this project has been great for managing complexity and automating several ERP tasks with the Ignition MES. OAL has made it easy to ensure right-first-time data by integrating Prophet with Redzone and Autocoding applications. We are looking forward to uncovering more opportunities together in the future.”
Key results
Worldwide Fruit has scaled and improved its quality control processes, resulting in happier customers and reduced operational risk. Automation has helped find and prevent “hard to spot errors” whilst reducing the time it takes to complete quality control checks. They have also removed substantial paperwork from the business helping meet and surpass sustainability goals.
The 2023 system integration project has created a single source of truth for Worldwide Fruit helping them make critical business decision based on accurate, real-time data. This integration has resulted in Worldwide Fruit’s SMART Industry Ready Index rank being better than ever and closer to their SMART Industry roadmap.
You can automate and digitalise your operations - speak to our team today for advice and guidance.
At a glance
Customer since: 2020
Challenge
Complex operations with thousands of SKUs
Improve quality control and labelling
Future ERP integration capability
Solution
OAL Connected with Autocoding, Paperless and APRIL Eye functionality.
24/7 support with annual audits to ensure code of practice compliance
Integration with Prophet ERP and Redzone OEE using Ignition SCADA/MES
Results
Improved quality control through an automated system
Deployed AI-based verification to enable further automation
Improved sustainability by removing paperwork
Right first-time data from a single source
Heinz Secure Infant Formula Packaging Integrity with OAL System
Heinz secures infant formula packaging integrity with OAL automation system scanning spinning cans at 97ppm.
100% read rates on spinning cans at a rate of 97 per minute to secure packaging integrity of baby formula for Heinz.
Customer
At the HJ Heinz factory in Cumbria, UK, baby milk powder is manufactured and packaged ready for distribution overseas. Due to the sensitive nature of the products, accurate barcode reading is essential to ensure the correct products are identified and shipped to the correct customer.
Challenge
The site was using a label verification system from another supplier where one element could only read ladder barcodes. Although a separate system was created to read the picket fence barcodes, the readers could not cope with the 97 cans per minute high-speed production. Heinz were keen to upgrade to a more reliable system which could achieve 100% read rates, eliminating any risk of packaging errors.
“Heinz chose the OAL Autocoding system because they were the only suppliers we reviewed to offer 100% read rates on products. The integrated quality checks on the Autocoding system and ability to offer 24-hour support have added significant value to the business.”
Solution
OAL installed their Autocoding system using six Cognex DataMan 302X readers, enabling at least two of the readers to read the code on the can as it rotated through 360 degrees. Importantly the system was able to handle the convex structure and reflective surface of the large cans. If incorrect barcodes or ‘no reads’ are detected, alarm beacons and display screens alert the operators who will stop the line and clear the defective product to ensure no incorrect product continues into the packaging area.
Read rates are reported as part of the standard OAL Autocoding system, allowing for easy monitoring of production performance. The system also links to the site’s Domino inkjet printers and Markem case printers to ensure the correct dates are printed on each pack, ready for shipment.
Results
Autocoding has eliminated any risk of packaging errors; 100% read rates prevent incorrect tins being packed and print control has ensured the correct dates are applied. False line stoppages due to ‘no reads’ have been removed improving production performance.