Cost Saving Control from Bottling to Building

APPLICATION OVERVIEW

INTERBUS systems enabled a large bottling company to implement a facility-wide control system for storage, logistics, and administration, and enabled them to increase production capacity—filling up to 170,000 bottles every day. In addition to storage capacity expansion, the plan included the simultaneous implementation of an improved forwarding logistical system. Capacity of the forklift-accessible storage center is approximately 25,000 fully loaded pallets. INTERBUS was chosen to network the new facility, including both the conveyor system and a sophisticated building automation system.

CONTROL SYSTEM

Conveying System
Two PLCs with INTERBUS interfaces are used for the conveyor system bridging the production section with the new storage center. Three automated chain conveyors transport loaded pallets to the forklift unloading stations. Approximately 600 digital and analog I/O for the conveyor system are connected to decentralized INTERBUS smart terminal stations. This configuration eliminates the need for intermediate terminals, with sensor and actuator lines connected directly to the modules. Also, MMIs are wired directly to flat remote terminals. Barcode scanners track product movement controlled by the INTERBUS-based system, ensuring accurate routing.

Storage Facility
INTERBUS also forms the basis of a sophisticated lighting and HVAC control system. Light sensors in the facility’s aisles detect forklifts transporting pallets from the unloading stations to any of the seven storage areas. Only active areas are illuminated according to forklift movement; timers automatically switch the lights off after a period of forklift inactivity. In the subsequent “trans-shipment” area, brightness meters measure illumination intensity and set the lighting values according to available daylight. Video cameras monitor the truck loading area—only when truck loading completes does the bay’s door open to allow the truck to exit. Controlling the bay doors enables tight, efficient regulation of the HVAC system via temperature and humidity sensors also tied into the system via INTERBUS.

Administration Building
A third PLC controls processes in the administration building, accepting feedback through the INTERBUS network from light switches in the offices, anemometers, and light sensors used for shutter control. Devices are connected to individual distribution boards using smart terminal components.

Interfacility Connections
Separate PLCs of the entire building complex are networked by INTERBUS to exchange building lighting and climate status information. INTERBUS slave cards connect to the master PLC by a single bus terminal block each, enabling data exchange between the PLCs in blocks of up to eight input and eight output words.

RESULTS/BENEFITSSUMMARY

This world-class customer experienced “significant cost savings” thanks to many advantages offered by INTERBUS. Configuring system connections was done using familiar, previously developed tools, eliminating the need for expensive, time consuming programming of communications protocols. INTERBUS is an open system which automatically senses replaced or added system devices from multiple suppliers.

The additional costs to implement such advanced facility sensing and automation are expected to be recouped in about two years, thanks to a saving of approximately 300,000 kWh of electricity per year.

INTERBUS offered the added, substantial benefit of reducing the amount of cabling in this installation by 35%, compared to conventional systems. The drastic reduction in the amount of cables containing PVC, along with the use of metal conduits and cable raceways, reduced the installed fire load by more than 50%—from 70,000 kWh for conventional cabling, to approximately 35,000 kWh with the reduced cabling requirements of INTERBUS.

Administration building houses the central control computer feeding the PLCs throughout the building and the warehouse.

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