Mondelez International

1
Mondelez International (Formerly Cadbury India Ltd.)
Bournvita plant is automated to achieve high quality product with optimum batch-time.
PROJECT AT A GLANCE
Project type
Food Processing
Location
India (Rewari-Haryana)
Application
Bournvita – Malted Food Drink
System Components
• UAG
• M340 PLC
• X-80 Remote I/O






Vijeo Citect SCADA
Vijeo Historian
SUPERBatch Batch Management
Magelis HMI
Altivar 32/ 71 VFDs
MCC
Customer Benefits
•
•
•
•
•
•
Flexible Manufacturing
Advanced Batch Process Management
based on ISA S88 Batch Standard
High and consistent product quality
Easy diagnostics
Energy Management
Batch and Management Information
Reports
Cadbury India Ltd. is a part of Mondelez International.
Cadbury India operates in five categories – Chocolate
confectionery, Beverages, Biscuits, Gum and Candy. In
the Chocolate Confectionery business, Cadbury has
maintained its undisputed leadership over the years.
Some of the key brands are Cadbury Dairy Milk,
Bournvita, 5 Star, Perk, Bournvita, Celebrations, Gems,
Halls, Éclairs, Bubbaloo, Tang and Oreo. It today has six
company-owned manufacturing facilities at Thane,
Induri (Pune) and Malanpur (Gwalior), Bangalore and
Baddi (Himachal Pradesh) Hyderabad with the
corporate office is in Mumbai. “Bournvita” – the Malted
Food Drink is their main product in the Milk Food drinks
segment.
2
The Challenge
The liquid ingredients – Malt, Liquid Glucose, Cocoa Liquor, Caramelized Sugar Syrup etc. are charged in the
in wet mix tank. Dry ingredients – Cocoa Powder, Crystal Sugar, Skimmed Milk Powder, Vitamin Mix,
Mineral Mix, Whey Powder etc. are charged in the hopper. Both the liquid and dry charging process are
working in parallel. Both the wet mix tank and hopper materials are charged in paste mixer and mixed.
Paste mixer outlet called “magma” is transferred to magma heating tanks. The magma is separated in two
parts. One part of the magma product is transferred to Chocotech system and other is transferred for the
oven system. The output of Chocotech system is sent to Band Dryer. Band dryer is a long tunnel with four
temperature zones under vacuum. The Chocotech product is distributed on ten conveyor belts which pass
through the four zones. Dried cake coming out of the band dryer is crushed and the crushed product falls in
a series of hoppers. The other part is dried in ovens and then crushed into powder. The Band Dryer and
oven products are then mixed in certain proportion to get the final Bournvita product. Finally the product is
sent to packing section for packing in different sizes of packages.
3
The challenges involved in the process control were:
1. Accurate charging of liquid raw materials
2. Accurate charging of solid raw materials
3. Accurate Mixing time in mixers
4. Precise Temperature Control of liquid ingredients
5. Integration with “Chocotech” system used for cooking of Magma for Band Dryer
6. Temperature and Vacuum Control in Band Dryer
7. Conveyor speed and material flow control in Band Dryer
8. Integration with Parker Swivel system used for uniform cake width on the belts
9. Integration with CIP system
10. Recipe based flexible manufacturing
11. Management Information Reports and ready for integration with SAP in future.
The Solution:
Batch/Historian
Server
SYSTEM CONFIGURATION
Engineering +
Operating
Station
Engineering
Station
SUPERBatch Modules
1. SUPERBatch Manager
2. Plant Editor
3. Recipe Engine
SPARE
BMXAMI0810
BMXAMO802
BMXAMI0810
BMXAMI0810
BMXDDO3202K
BMXDDI6402K
BMXDDO6402K
BMXDDI6402K
BMXDDI6402K
Process UPS MCC
BMXNOE0100
BMXCPS2000
Main Plant PAC 8.5 M
LOCATION: Process UPS
MCC Panel
BMXP3420302
Ethernet TCP/IP 100 Mbps
CANOpen
Remote I/O- 2 5.5 M
LOCATION: Remote I/O2 Panel
MCC Process Utility RIO
LOCATION: MCC Process
Utility Panel
SPARE
BMXAMO802
BMXAMO802
BMXAMI0810
BMXAMI0810
BMXDDO3202K
BMXDDI6402K
BMXDDO6402K
BMXDDI6402K
BMXDDI6402K
BMXCPS2000
C
A
N
O
p
e
n
BMXP3420302
SPARE
BMXAMO802
BMXAMO802
BMXAMI0810
BMXAMI0810
BMXDDO3202K
BMXDDI6402K
Ethernet TCP/IP 100 Mbps
BMXDDO6402K
BMXDDI6402K
BMXDDI6402K
BMXPRA0100
BMXCPS2000
SPARE
SPARE
HMI EL5.5M
BMXAMO802
BMXAMI0810
BMXAMI0810
BMXAMI0810
BMXAMI0810
BMXDDO3202K
BMXDDO3202K
BMXDDI6402K
BMXPRA0100
Remote I/O- 1 0.0 M
LOCATION: Remote I/O1 Panel
BMXDDI6402K
SPARE
BMXCPS2000
SPARE
BMXAMO802
BMXAMI0810
BMXAMI0810
BMXAMI0810
BMXAMI0810
BMXDDO3202K
BMXDDO3202K
BMXDDI6402K
BMXPRA0100
BMXDDI6402K
BMXCPS2000
HMI EL0.0M
MCC BV Process RIO
LOCATION: MCC BV Panel
OFFERED IO's
DI
DO
AI
Main Plant PAC
192
96
24
AO
8
MCC BV Process RIO
192
96
16
16
MCC Process Utility RIO
192
96
16
16
LEGENDS :
Remote I/O- 1 0.0M
128
64
32
8
ETHERNET TCP/IP 100 MBPS
Remote I/O- 2 5.5M
128
64
32
8
CANOpen
Process Utility MCC
4
The system consists of 3 no. M340 Controllers - Main PAC, BV Process, Utility and 4 nos. Remote I/O
stations - RIO1, RIO2, RIO3, PMCC RIO. There are two MCC panels – Process MCC and Utility MCC consisting
of conventional motor starters and Altivar 32/ 71 VFD based starters. Conventional motor starters are
connected with the PLC on remote I/O and VFDs are connected on Canopen bus. The PACs and remote I/O
communication is Ethernet TCP/IP. One Engineering cum Operating Station and one Operating Station has
been provided in the main control room. Two 10.4” Magelis HMI have been provided in the field for local
operation. A Batch/ Historian Server has been provided for ISA S88 based Batch Management System SUPERBatch and Vijeo Historian. Flexible recipe based operation is achieved through SUPERBatch, a Batch
Management software based on ISA S88 Batch Standard developed by Supertech. SUPERBatch is tightly
integrated with PlantStruxure components – UAG, Unity Pro, Vijeo Citect SCADA and Vijeo Historian. It uses
the MS SQL Server data base integral with the Vijeo Historian for batch data as well. Various Batch reports
and Historian based Management information reports are generated by the system.
For precise temperature and vacuum control standard PID control blocks from UAG library have been used.
Special program was developed for complex control involved in Band Dryer according to the logic provided
by the German OEM.
Following are the solutions provided for the key challenges: =
1. Accurate weighing of raw materials are achieved through load cells based weighing system which
was developed by using material charging functional block, designed by Supertech. During auto
charging through SUPERBatch every raw material (liquid and solid) is added accurately, following
screen shows the comparison between set quantity and actual charged quantity.
5
2. Solid raw materials are conveyed to Dry Batch hopper one by one as per the instructions provided in
HMI, after every Dry material is charged acknowledgement is done through HMI as shown.
6
3. Chocotech system (make: Allen Bradley) was integrated with Schneider-Electric control system. The
SCADA screen is developed so as to provide supervision for chocotech system, controlling the main
feed pump.
7
4. Formation of cake with uniform width is critical parameter needed for appropriate product
formation, for these two parameters were considered – Belt speed and swivel stroke.
a. Belt speed: belt speed of band dryer is automatically calculated based on residence time
provided on SCADA which decides period for which the material will be exposed to different
temperature zones.
b. Swivel stroke and speed: CANopen based communication is done between Parker Drive and
Schneider control system, which enables the input options either through SCADA or through
HMI. Furthermore resulting in control of stroke and speed of swivel.
8
5. Modbus based communication CIP (clean in place) cleaning system is integrated with Schneider
system which provides selection of appropriate equipment. Moreover it also indicates the CIP
cycle status.
9
SUPERBatch – ISA S88 Based Batch Management System
Advanced Batch Management is achieved by using “SUPERBatch” which is a Batch Management software
developed based on ISA S88 Batch Standard and fully integrated with “PlantStruxure PES” architecture. It
consists of six modules viz. Plant Editor, Recipe Engine, Batch Scheduler, Batch Execution, Online Batch
viewer, Reports Viewer.
SUPERBatch has enhanced the value of the Control System to the customer in following ways:
Product Consistency with best use of Recipes Management comprising of SOP and formulations
Automatic generation of Batch Reports, raw material consumption, comparison with Golden Batch, Aborted
batches etc.
Batch Based Data Availability for analysis that may result in KPI improvements such as optimum utilization
of resources and achieving level of maximum production using improved Batch cycle Time etc.
Provision is provided for back-to-back auto downloading of batches which saves time, provides accuracy
and avoids unwanted adulteration/excess use of raw materials, which may occur during manual operations.
And Many more…
Vijeo Historian Based KPI Reports
Process and Energy data from VJC and Batch
data from SUPERBatch are recorded in MS
SQL Server integral with the Vijeo Historian.
Based on customer requirements, about 15
KPI reports were developed using Report
Development Tool of VJH. Some examples
are – Oven Cycle Time, Pasteurizer/
Sucrofilm/ Holding Tank Temperature, Dried
Material Weighing, Vertical Silo Weight, No.
of PSM Batches, Energy Consumption, etc.
These reports can be viewed from any
machine on Mondelez network through
Internet Explorer.
This system was designed and supplied by Supertech - Alliance Partner of Schneider Electric :
Supertech Instrumentation Services (I) Pvt. Ltd.
12, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE – 400601 (Maharashtra) India
Phone: +91-22-41550100 e-mail: automation@supertech.co.in URL: www.supertech.co.in