Enhancing High-Speed Bakery Performance with Inductive Automation Ignition

Process and Data Automation (PDA) recently collaborated on a project that revolutionized the operations of a renowned manufacturer of individual packaged pies and baked goods. The company’s rapid expansion necessitated a comprehensive data collection system to monitor and optimize their manufacturing processes across seven high speed lines.

The manufacturing facility featured a mix of older and newer processing lines, each differing in technological capabilities. The company sought a flexible solution that could seamlessly integrate with their diverse equipment to standardize supervisory control across all lines and streamline data visualization. Enter PDA, a turnkey systems integrator known for their expertise in high-speed manufacturing environments.

Led by Shaun McCausland, our team devised a system based on Rockwell Automation controllers and Inductive Automation’s Ignition suite. We utilized a Rockwell CompactLogix controller at each line and that enabled centralized control and real-time data collection for critical production metrics.  We also provided a new communications infrastructure which included managed Ethernet switches and line-specific VLAN segmentation for enhanced network efficiency.

We used Ignition’s versatile platform for supervisory control, data collection and reporting, thus the client gained enterprise-wide visibility. The seamless integration of Ignition with existing equipment such as proprietary packaging machines and standalone line VFDs provided rich information about the systems’ performance and empowered operators to make data-driven decisions in real-time.

The successful implementation of this project not only met the client’s immediate control and data management needs but also laid a foundation for future scalability. The client can now replicate the system across future lines or plants thanks to a modular design that allows for expansion without extensive re-engineering efforts.  The licensing scheme for Ignition will allow for in-plant expansion without incurring additional licensing fees.

The collaboration between PDA and the client proved to be a game-changer for their manufacturing operations. With improved data visibility, standardized control systems, and enhanced operational efficiency, the client is well-positioned to achieve sustained growth and operational excellence in the competitive bakery industry.