Case Study

Ignition Software Integration for Mixer Control System Upgrade

Problem faced:

An international industrial conveyor belt manufacturer faced challenges with outdated Automation Direct control system components, hindering efficient data collection, control, and monitoring of their mixer operations. Lacking a robust data management system, the manufacturer struggled to record historical data, manage recipes, and respond to alarms, leading to operational inefficiencies, troubleshooting difficulties, and potential production downtime. A scalable, centralized solution for data collection, monitoring, and control was essential to uphold high production standards and ensure system resilience.

AFI Systems solution:

AFI Systems offered a comprehensive solution using Ignition software to modernize the control system. Alongside upgraded hardware, Ignition provided a unified platform for data collection, alarming, historian capabilities, and recipe management—empowering the company with enhanced control and operational insight.

Project Scope by Phase:

Phase 1: Hardware Delivery

AFI Systems supplied all components, including a 1769-L36ERM CompactLogix PLC, required I/O modules, 25B-DxxxN104 series PowerFlex 525 VFDs, and an Advantech FPM-221W 21.5” industrial touch monitor. These components were selected to integrate seamlessly with Ignition software, creating a foundation for data-rich HMIs and enabling connectivity essential for Ignition's historian, alarming, and data visualization features.

Phase 2: System Programming with Ignition Integration

In this phase, AFI Systems programmed the new control components and configured Ignition software. Tailoring PLC and HMI functionality, AFI maximized Ignition’s real-time data collection, alarm management, historical data storage, and recipe control capabilities. The Ignition package included the Vision Module Unlimited, SQL Bridge Module, Tag Historian Module, and Alarm Notification Module. This integration allowed for detailed operational data capture, efficient recipe management, and real-time alarms for enhanced monitoring and rapid response.

Ignition panel screen shots:

Phase 3: Installation and Full Ignition Deployment

During the final phase, AFI Systems installed and integrated the new components onsite, configuring Ignition's historian and alarming functions. The Ignition software enabled access to and analysis of critical historical data, recipe storage and retrieval, and system performance monitoring through an intuitive interface. The designed alarming system promptly alerted operators to issues, ensuring operational continuity and minimizing downtime.

Results:

The integration of Ignition software transformed the customer's operations, providing a centralized, scalable platform that modernized their control infrastructure and enhanced data visibility, alarm response, and recipe management. Ignition's historian allowed for detailed data tracking and analysis, enabling the facility to optimize production processes and resolve issues efficiently. With AFI's Ignition integration, the customer now benefits from an advanced, user-friendly solution that promotes operational efficiency and improved process management.

This project highlighted AFI Systems' expertise in implementing comprehensive data, alarm, and control solutions with Ignition, delivering a resilient and insightful control system for the customer's mixer operations.

Engineering services - standard AFI practices

Whether you call or send an email to us, you will get through to someone who can put you in touch with one of our engineers to begin reviewing your needs.

• AFI Systems engineers with thoroughly review your needs, and work within your existing operating parameters or come up with a completely new system or machine.
• AFI Systems can easily procure or fabricate all the needed system or machine components
• You will receive a detailed quotation and a thorough explanation for our proposed solution, so you can quickly evaluate your return on investment.

We believe in being accessible. Our account managers / customer service team promptly answers incoming calls, and provides quick responses to incoming emails. Many of our customers have 24/7 schedules and we always try to service their needs accordingly.

Contact us today to see how AFI Systems can service your food or beverage manufacturing equipment!