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Food & BeverageBakoma InTouch HMI, Wonderware System Platform

“Wonderware ArchestrA

technology allowed us to

build modern and far-

reaching SCADA system

giving Bakoma

employees full access to

process data and allowed

them to stay in line with

every production detail

to ensure quality of

production work orders.”

Artur Zielinski, System Developer, Atempol

SCADA system built within Wonderware ArchestrAtechnology provides robustness and ease-of-maintenance in yogurts productionby Astor Sp. z o.o.

VALUE DRIVERS

Goals

• Modernization of old ControlSystem and SCADA system;

• Integration and standardizationof operators HMI applications;

• Functional extension of oldSCADA system capabilities;

• Provide ease-of-maintenanceand remote developmentavailability.

Challenges

• Plenty of existing visualizationapplications and distributed, butnot integrated SCADA stations,

• Implementation and set-upprocess executed on runningproduction line,

• Lack of remote maintenanceaccess to plant applications,

• Lack of users managementfunctionality.

KEY METRICS

Wonderware Solutions

• InTouch HMI;

• Wonderware System Platform.

Results

• Wonderware System Platformbased SCADA system gave usersbroad-perspective softwaresolution ensuring ease-of-maintenance and extensioncapability;

• Users have access to accuratepieces of information about theprocess in real-time;

• System redundancy providessystem robustness;

• System administrators areprovided with modern usersmanagement based on ArchestrAtechnology security system;

• Software DevelopmentEngineers have remote access torunning application and are ableto support solution in real-time.

Company Overview Bakoma Sp. z o.o. – Szymanów, Poland Bakoma Sp. z o.o. is the biggest Polishmilk haberdashery manufacturer. Thecompany was established in 1989 and,from 1997. it was quoted on stockexchange. Production of wide line ofyogurts, cheeses and milk-desserts isperformed in modern production plantnear Sochaczew (Poland). To mantainthe highest quality of its products,Bakoma implemented a control systemfor the analysis of the critical points(HACCP), so that everything producedby Bakoma follows the Internationalstandards ISO 9001. These efforts wereappreciated and well estimated by themarket and consumers all over theworld: Bakoma dairies are being sold notonly in Poland but also in USA, England,Ireland, Portugal, Slovakia, Hungary,Romania, Lithuania, Estonia and Russia.

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Bakoma has a strong market position in Poland andas well as other markets, such as: USA, UK, Ireland,Portugal, Slovakia by increasing export volume. The

quality of the products is ensured by being compliantwith the international ISO 9001 standard. Moreover thecompany has set-up and maintained the HACCP system.In 2007, the board of directors decided to make aninvestment in the implementation of a new controlsystem and Wonderware-based SCADA (SupervisoryControl and Data Aquisition) solution. It was a crucialstep to be up-to-date with technology and increaseproduction robustness and quality.

Key factors which have inclined Bakoma to use theWonderware solution are as follows:• Scalability of the Wonderware ArchestrA technology;• Ability to integrate old operator interfaces to 1comprehensive InTouch HMI application;• Ease-of-maintenance by remote access to WonderwareDevelopment Studio.

Implementation process

According to Bakoma production lines, high-availabilityrequirements Wonderware ArchestrA-based system wasimplemented in 3 steps to minimize production downtimes. In the 1st step, there was an exchange in control systemmodules and Ethernet network. During the 2nd phase ofthe project engineers started tests of the SCADA system,it was running parallel with existing SCADA application toensure functional compliance. In the last phase, remotecontrol system peripheries were connected to newcontrollers and production was successfully started.

Wonderware SCADA system isbased on two redundantWonderware System Platform and5 operator stations running withInTouch HMI. Real-timeconnectivity to PLC controllers isprovided by Wonderware DeviceIntegrations servers.

A big role in SCADA solution isplayed by Wonderware Historianserver collecting all productionalarms, activities and historicaldata values. Engineers are allowedto remotely-access application byWonderware Development Studiofunctionality.

Key MetricsBenefits from the investment made are visible at firstglance. Far-reaching software solution based onWonderware ArchestrA technology ensures easydevelopment of further functions.Wonderware Historian functionality improvesinformation flow and gives employees right context-based data in the right time.Built-in Wonderware System Platform redundancy enablesBakoma to handle unforeseen application failures and avoidproduction profits loss. It is worthy to say that the logicstructure of the application created within WonderwareDevelopment Studio hosts over 5000 application objectsand almost 200 visualization windows. Moreover, the systemis able to handle this amount of data effectively and evenallows for extended functionality in real-time.With Wonderware SCADA solutions Bakoma’s productionexcellence became a real “low-hanging fruit”.

This document was realized thanks to the support of: Atempol Sp. z o.o.

Food & Beverage InTouch HMI, Wonderware System Platform

System structure

Application diagram

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