The Task
IES was engaged to provide the process, mechanical and electrical design, control, automation, installation, commissioning and validation support on a new film coating solution delivery and spray system.
The aim of the project is to replace the existing spray assembly and solution delivery system to improve coater reliability, provide better content uniformity and sanitary connections to remove the potential for contamination within the spray assembly.
IES Responsibilities
- To design the process and mechanics of the new process to spray arm assembly, specification, and procurement of components.
- The electrical design to integrate the new solution delivery system (provided by others)
- To control system design and specify the requirements of the new functionality.
- To update the existing control system to replicate the control of the previous system using the new components combined with new functionality.
- To identify any remediation work required to ensure compliance with the Machinery Directive.
The Challenge
It was an ambitious schedule, with limited downtime to return the system to operate to meet the demanding production schedule.
To reverse engineer the existing system (which was obsolete and unsupported) to ensure consistent integration of new control elements, ensure existing functions remain unaffected.
To achieve process performance requirements within expected tolerances.
The Result
IES identified the risks associated with the project, established a robust mitigation plan and continuous assessment ensured a successful delivery. The resourcing of the project was key to meet the schedule and technical challenges.
Contingency plans were drawn up to ensure the project met the customer’s expectations. Because the control system was an obsolete and unsupported version, a significant effort was required by the team familiarising themselves with the system. This work was done offline and in advance to ensure minimal impact during the shutdown period.
Extra, subject matter experts, supplemented the project team to provide the necessary backup and support to reduce and remove any risk to project outcome.
Did You Know?
Possibly the very earliest complex HMI (Human Machine Interface) was the Jacquard Loom. Invented by Joseph Jacquard and first demonstrated in 1801, this was an attachment for powered fabric looms which used a chain of punch cards to instruct the loom on how to make intricate textiles. The system was then used for early computers.
Xenophon the Greek soldier and historian writes about alarm systems: “The Persian army is then subject to great inconveniences, for their horses are tied and generally shackled to prevent them from running away, and if an alarm happens, a Persian has the housing to fix, his horse to bridle, and his corset to put on before he can mount.”
In a recent competition for work safety slogans, one of the losers was: “In case of fire, leave the building before putting it on Facebook.”