Ali Ali, the national accounts manager for Siemens, led the project together with David James and a local distributor. The line control was re-configured, then updated with Siemens drives, motors and related hardware automation. David James supplied the wiring diagrams for the retrofit to Programmable Logic Controllers (PLCs) on the original equipment. Furthermore, Variable Speed Drive (VFD) technology was needed to properly synchronize the line elements. SE Packaging also provided and engineered level sensors to help the line vibrators adapt to the increased weight and height, a problem the end-customer had encountered and one that literally made the chips fall off the conveyor. These sensors interface to analog inputs on a Siemens SINAMICS G120 VFD. Having the G120 drive system used on this job led to an overall production process improvement in excess of 10 percent, a substantial increase in line efficiency, compared to the original equipment from another controls supplier. Likewise, a significant energy savings of approximately 20 percent was achieved, according to David James. This savings resulted from the fact that the system was able to power down when the pans were empty, compared to a simple fast-slow setting on the previous line controls.  

“While the original controls on the line were from another manufacturer, SE Packaging and Siemens won the project thanks to their cost-effective solution that provided a 20 percent reduction in maintenance cost, zero downtime in the first year of operation and much higher reliability,” according to James. He notes the Siemens strategy involved technically empowering and partnering with the snack food plant to create a G120 application-specific drive solution, which is optimized for the operation. Siemens technical support also conducted G120 drive and software training at the snack food plant to ensure all operators and maintenance personnel were familiar with the new drive systems. Over-current relays, for example, protect the single-phase motor output, while the VFDs onboard enable the motor current to remain within the torque limits set, during vector control. The result is a more stable “ride” for the chips, James mused.  

“This is the first installation for Siemens at the plant of this well-known snack food producer, though it certainly won’t be the last,” said James. Ali Ali added, “I’m happy to report that everything is operating successfully. The company is very pleased with the results as well as the training we’ve provided.” Ali concluded by saying he feels confident this relationship will continue into the future, with additional retrofits and new line projects possible. 

Other Siemens products incorporated on this project were the Simatic PLC and various food-grade components.

James concludes, “Because we were able to be essentially a one-stop shop for the customer, providing the solution, engineering, product, installation and training, all at a nice price, we won the day. We expect this success will lead to more business in food and beverage, together with Siemens and their network of distributors.”