Turn-Key Solutions for the

Milling Industry

Wednesday, March 6 at 10 a.m. CT

Matt Gugle, Project Manager

Mark Hommertzheim, Senior Systems Engineer

Andy Forrester, Director Technical Sales

Project ManagementThings to consider in order to choose the right team

Skillset

• Process knowledge

– Bulk Solids definition

• Industry knowledge

• Communication

Time and Resources

• Capacity

– Is the project a good fit?

• Backing

– How will the company stand behind their work?

– Do they have the knowledge required, or access to the people who do?

– How accessible are they?

Listed Deliverables

• Scope definition

• Timeline/ schedule

• Project budget

• Start up and commissioning

Proven Track Record

• References

– How many and what have they said?

• Examples of past projects

Conclusion

• Think of what you want

• Paint the picture of who you need

• Ask the right questions

• Know what you are getting

Kice AutomationMark Hommertzheim

Automation and Electrical Engineering

Who We Are!

• An established department of electrical engineers and automation specialist

• A Premiere Systems Integrator in Bio Fuel, Grains and Flour Milling business.

• A turnkey solution provider with expertise in power distribution, control system design & engineering, control network specialist with in house UL® fabrication shop.

• We provide seamless PLC programming with user friendly HMI interfaces. Conduct Start-up and 24/7 support.

• We offer our clients total solutions for their factory automation needs to improve productivity, quality, reliability, and maintenance.

Industry Overview

The goals for any commercial or industrial process are simple:

• Provide a safe work environment

• Minimize overall costs and enhance productivity

• Reduce energy consumption

• Optimize plant operation

• Reduce downtime

• Decrease direct labor

• Be cost competitive

Industry Trends for Control Systems

• Tighter integration between plant floor and business systems

• Mobile devices / Smart phone usage / Plant WiFi

• Alarm management to optimize operation

• Tracking and traceability throughout the process

• Ethernet enabled devices on plant floor

• Integration of power consumption data into HMI

• Enhance network security

• Ethernet enabled Motor Control Center (MCC)

• Migration to newer and updated control system

Today’s market demands innovative strategies and technologies

• If you answer Yes to any of the following:

• Is your control system 20+ Years old?

• Are spare parts obsolete or difficult to find?

• Do you rely on one person or vendor for support?

• Making changes to your system are costly or not possible?

• Do you have unexpected and not easily resolved downtime?

• Are you missing critical production data?

When to Upgrade your Control System

• What can you gain – Benefits?

• Reduced downtime

• Increased safety

• Increased access to process or production data

• Ease of making changes to your system – flexibility

• Reduced reliance on one person or vendor for support

When to Upgrade your Control System

Options for upgrading?

• Full upgrade vs. Partial upgrade

• Upgrade in phases– Reduces Downtime

– Reduces Risk

• Upgrade the PLC Processor

• Replace the I/O Modules

• Update PC Windows operating systems– Consider Virtual Machines

• Replace legacy/unsupported networks

When to Upgrade your Control System

Perform a System Audit

Use a System Integrator to audit your control system

Perform some of the audit in-house

Gather reliable information

– Electrical schematic drawings

– PLC / HMI Programs

– Network drawings

Identify items that are near or at end-of-life

Identify legacy communication networks

Steps to Upgrade your Control System

I/O

Consumed

by each

motor or

device

Type of

signal from

device

Skip Motor

Data if not

replacing

MCC

Motor or

Device

Description

Skip Motor

Data if not

replacing

MCC

Motor Data

Create a Motor & Device ListSteps to Upgrade your Control System

Create a System Flow Diagram (P&ID)

- Depict System Flow

- Identify Motors

- Identify Devices

Steps to Upgrade your Control System

Motors

Devices

Future of Control Systems

• Secure Wireless networks supporting highly automated process, seamlessly interlinked with enterprise software working through clouds.

• Plant operators will track production lines, perform maintenance operation, and monitor process issues from their tablets.

• New smart sensors will be wirelessly connected and provide real-time data and notify you when it is time to be serviced – all to your phone.

• Managers will receive critical production data and be notified of issues in real-time.

New Grain Milling OfferingsAndy Forrester

Summary

• Select an appropriate, reliable & accountable partner

– (as early as possible)

• Process & Industry knowledge to provide tailored custom solutions

– Now enhanced in Milling through formal partnership with Sangati Berga

• Integrate latest technology for maximum efficiency and ROI

• Meet latest code and regulation requirements for maximum safety &

reliability

Questions?