Client Goal

The new 2,400 can per minute two piece aluminum can line was commissioned on schedule in Kiev.
 
The system utilized a world class control and information system architecture with several key elements that contributed to Canpak’s goal:

• Line Control using a modular design with distributed power and control components to provide lowest cost of ownership
• Line Awareness to annunciate line conditions and production information to provide operation staff with what they needed to operate the line at design capacity
• Data Management to provide historical and real-time web based access to critical operational information

Project Overview

Line Control

The line control system was built using the industry’s
latest PLC and on-machine variable frequency drive (VFD)
technologies. The PLC and distributed input/output (I/
O) architecture provided the client with a modular and
highly scalable architecture. The distributed PLC and I/O
structure also lowered the cost of installation and allowed
the system to be commissioned in a fraction of the time
required by traditional centralized control designs. The
on-machine variable frequency drive design provided
a smaller overall control system footprint. All control
panels (motor control and I/O) were smaller because the
space utilized for mounting the VFDs would have been
unutilized otherwise. The distributed VFD design also
puts the power components and I/O geographically as
close as possible to the portion of the process that is
being controled making the system much easier to maintain
and troubleshoot.

Line Awareness

Having the right information in the right place is the key
to getting the most out of production and maintenance
support resources. The line awareness system delivered
this through several large multi-line LED and industrial
graphic displays. The displays provded:

• Real-time OEM equipment and conveyance states
• Real-time OEM equipment and conveyance faults
• Real-time system diagnostic displays including area
  alarms, detailed rack I/O views, and localized calibration functionality for conveyor tracking
• Real-time production goal monitoring
• Dual language support on all displays for English and
  Russian
• The right line awareness system turns data chaos into
  clear actioinable information.

Scope of Supply

Roeslein and Tegron provided full turn-key project delivery services for this client including:

• Project Management
• Electrical Controls and Power Distribution Design
• CAD Documentation
• PLC Software Design, Development, & Testing
• HMI Design, Development, & Testing
• Electrical Construction Management
• Start-up and Commissioning
• System Training

The Outcome

The can line was commissioned and brought to design
speed ahead of expectation. The line operates at above
85% effi ciency. Utilizing the tools provided by the system
the overall effi ciency of the line continues to improve.
Roeslein and Tegron delivered a world class design and
implementation that continues to pay dividends for our
client.