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II World Wide Pasta Congress

Venezuela October 2000

PAGE
1


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


the partner for the

Flour Mill and Pasta Plants

SIEMENS



II World Wide Pasta Congress

Venezuela October 2000

PAGE
2


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

PRESENTATION PROGRAM



Introduction


Concept


Requirements


Solution


Communications


Information management


Advantages


Conclusions

II World Wide Pasta Congress

Venezuela October 2000

PAGE
3


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


INTRODUCTION (1)



The automation of pasta plants had in these last years an
important evolution.


The programmable controllers are able to integrate all the
process control functions into a PLC and now into PC
integrating through Profibus, peripherals as inputs/outputs,
drives, intelligent devices and operator panels


The actual scenario is characterized by a Totally Integrated
Automation Concept using a common hardware/software
platform standard networking to satisfy the customers
demand.

II World Wide Pasta Congress

Venezuela October 2000

PAGE
4


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


INTRODUCTION (2)



The Totally Integrated Automation Concept consists in
integrating under a single automation system, three important
areas which till now were automated separately as:




Semolina silos

(
upstream
)






Pasta production

(
mainstream
)






Packaging and warehousing

(
downstream
)



Totally Integrated Automation (T.I.A.) is performing process
control, recipes handling, lots scheduling, products tracing,
traceability, warehousing and web connectivity.

II World Wide Pasta Congress

Venezuela October 2000

PAGE
5


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

Raw Material

Wheat Receiving

Milling

Semolina Silos

Mixing Silos

Press

Extrusion

Drying

Cooling

Packaging

Palletizing

Warehousing

Utilities

Upstream

Downstream

Mainstream

PLANT FLOW SCHEMATIC DIAGRAM

II World Wide Pasta Congress

Venezuela October 2000

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6


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

Wheat Receiving

Milling

Semolina

Silos

Press Extrus.

Drying Cool.

Packaging

Palletizing

Utilities


PLANTWIDE ISSUES

Distributed I/O

Controller

HMI

Drives / Field devices

Communication

Configuring/Programming

PCS

Data management

II World Wide Pasta Congress

Venezuela October 2000

PAGE
7


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


Handling,Packaging

Palletizing,Warehousing

Field Automation

P
rocess
C
ontrol
S
ystem

M
anufacturing
E
xecution
S
ystem

E
nterprise
R
esource
P
laning

Semolina Silos

Extrusion,Drying,
Cooling,Utilities

ARCHITECTURE STRUCTURE

II World Wide Pasta Congress

Venezuela October 2000

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8


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


THE CONCEPT



T.I.A. means design the plant automation introducing a new
concept that has to consider the factory in its entirety.


Production flexibility, costs control and total quality approach
are successful key points for small and large companies.


The target is to change a production process from a critical
factor to a qualifying factor.


To perform a complete control of all the different production
phases starting from raw materials receiving and forwarding to
the finished products.


TIA is given an important contribution in terms of costs
reduction, for revamping and new pasta plants

II World Wide Pasta Congress

Venezuela October 2000

PAGE
9


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

PASTA PLANT WIDE ARCHITECTURE

Ethernet TCP/IP, 100 MBit

Engineering

stations

Short pasta line

ERP

Industial Ethernet

TCP/IP, 100 MBit

Water

treatment

Waste water

treatment

Compessed

air

Cooling

Silos floor

Fieldbus system


PROFIBUS

AS
-
Interface

MES

Boiler

Ground floor

Press Bridge

Press Foot

Cutter

Pre dryer

Dryer

Cooling/

Storage

Grinding

Last floor

silos

Press bridge

Flour silos

Long pasta line

Press Bridge

Press Foot

Spreader

Pre dryer

Dryer

Cooling

Storage

Packaging


Palletizing


Wincc
Client

Grain

Receiving

Milling

Sieving

Wheighing

Sistem

Flour silos

Flour Silos

Wincc
Server

Milling Plant

Wincc
Client

Wincc
Client

Wincc
Client

Packaging

Handling

Palletizing

Warehousing

Wincc
Server

Wincc
Server

Wincc
Server

II World Wide Pasta Congress

Venezuela October 2000

PAGE
10


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


PLANT REQUIREMENTS



Real time monitoring of process variables through supervisory
system, and relevant corrective actions in order to guarantee
high quality.


Client/server technology to address information of concurrent
process to Control Room and plant Information Room in order
to maximize the sinergy.


Communication and interoperability of production areas
(orizontal way) and other plant departments (vertical way)


Production data provided simply and clearly to the decision
level

II World Wide Pasta Congress

Venezuela October 2000

PAGE
11


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


AUTOMATION SOLUTION



SIMATIC S7 controllers with distributed ET200M, drives
technology and field instruments linked through Profibus.


SIMATIC OP panel for distributed visualization and monitoring


Drives Technology


WINCC supervisory system based on client/server
architecture with Industrial Ethernet networking


SIMATIC Industrial Software integrated through all Project
Phases

II World Wide Pasta Congress

Venezuela October 2000

PAGE
12


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

SIMATIC Controllers

More than just PLC's



S7 300 , S7 400 , S7 400H


I/O ET200M , ET200S


Operator Panels OP27 , OP37


Profibus and Ethernet Cards


II World Wide Pasta Congress

Venezuela October 2000

PAGE
13


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

DRIVES TECHNOLOGY

II World Wide Pasta Congress

Venezuela October 2000

PAGE
14


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

The Multi Client server architecture


A Multi Client provides a common view of

the process data of distributed servers in one picture

all the measured value archives, e.g. in one curve window

all the message archives

the pictures/picture windows of different servers




WINCC SUPERVISORY SYSTEM

II World Wide Pasta Congress

Venezuela October 2000

PAGE
15


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

WinCC Goes Web

Operation and monitoring of the
plant via the Worldwide Web


WinCC WEB TECHNOLOGY

VENEZUELA H.Q.

USA Plant

INTERNET

MEXICO Plant

II World Wide Pasta Congress

Venezuela October 2000

PAGE
16


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

ENGINEERING STARTS WITH TOP
-
DOWN DESIGN OF YOUR SYSTEM

Plant / System

Unit Operation

Equipment Group

Device / Loop


-

Overall plant architectural structure

-

Control strategy

-

Operator visualization

-

Local operator panels

-

Peer communication

-

Field devices, including transmitter parameteriz.

-

3rd Party PROFIBUS devices


THE
SIMATIC

MANAGER IS THE SINGLE TOOL


TO COORDINATE THE COMPLETE
TIA

SYSTEM CONFIGURATION

II World Wide Pasta Congress

Venezuela October 2000

PAGE
17


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

S7 400

AUTOMATION SYSTEM TOPOLOGY FOR LONG PASTA LINE


WIN CC

INDUSTRIAL ETHERNET

PRESS

DRYER/PREDRYER


COOLING/STORAGE


SPREADER

DOSING SYSTEM

MIXER

EXTRUSION SCREW

UP TO 4

PRESS BRIDGE


PRESS FOOT

REMOTE I/0

ET200

REMOTE I/0

ET200

REMOTE I/0

ET200

PROFIBUS
-
DP

REMOTE I/0

ET200

FAN

CHAINE MOTOR

REMOTE I/0

ET200

OP

OP

II World Wide Pasta Congress

Venezuela October 2000

PAGE
18


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


Distributed I/O systems save up to 20% of the wiring costs:



A family of distributed I/O systems provides the right


I/O for the right application and reduces wiring costs


distributed motor starters and drives used in the pasta


lines allow distributed wiring of the power bus

20%

Cost for wiring

REDUCED INVESTMENTS IN THE PASTA PLANT

DISTRIBUTED I/O SAVE WIRING COSTS

II World Wide Pasta Congress

Venezuela October 2000

PAGE
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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


Each supervisory station can handle supervision functions of
the entire plant in addition to graphic pages, recipes handling,
data archiving real time/historical trending, alarming.




Comunication and interoperability are key factors for data flow
from orizontal way to vertical way.



To achieve production flexibility , for successful growth, of
small, medium and large companies


COMMUNICATIONS (1)

II World Wide Pasta Congress

Venezuela October 2000

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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


With T.I.A. concept and relevant networking /communications
we can assure data flow from process level to supervisory and
management level, from incoming raw materials to the
finished products.


It means :



-

Right info



-

To right people



-

At right time



-

At right place



In any kind of pasta plants




COMMUNICATIONS (2)

II World Wide Pasta Congress

Venezuela October 2000

PAGE
21


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

TYPICAL SYSTEM TOPOLOGY FOR PASTA PLANT

WINCC

Multi Client

ETHERNET

WINCC
SERVER

WINCC
SERVER

PROFIBUS DP

PROFIBUS DP

PROFIBUS DP

PROFIBUS DP

SHORT PASTA LINE

IND.ETHERNET

SHORT PASTA LINE

LONG PASTA LINE

LONG PASTA LINE

II World Wide Pasta Congress

Venezuela October 2000

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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


VERTICAL INTEGRATION


TCP/IP, @aGlance, ODBC, SQL, OPC,
Net DDE...


Web Browsers, intra / internet...


Gensym bridge...


SAP R/3 PP
-
PI…




HORIZONTAL INTEGRATION


Ethernet, PROFIBUS,, ASi
-
Bus


DATA MANAGEMENT STANDARD INTERFACING APPROACH

II World Wide Pasta Congress

Venezuela October 2000

PAGE
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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


INFORMATION MANAGEMENT



MES and ERP Connectivity in order to have plant information
and management decision support



Process optimization and data analysis



Web connectivity for remote information and production
control



Certified module for linking to SAP

II World Wide Pasta Congress

Venezuela October 2000

PAGE
24


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


MAIN FEATURES:


-

process data acquisition


-

data analysis


-

process optimization


-

certified module for linking to SAP




MAIN BENEFITS:


-

improved production quality


-

improved process diagnostic

Operation

Management

Draft

Model

Intelligent
Production


Systems

Profound Process
Knowledge

Integrated Software and
Services

Platform Independence

PCS

Process Control
Systems

Field Instrumentation &


Operating Control

ERP

Cross
-
Company

Resource Planning

Supply Chain
Management & Business
Systems


COMPLETE INFORMATION MANAGEMENT WITH INFOPLUS.21

II World Wide Pasta Congress

Venezuela October 2000

PAGE
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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


THE ADVANTAGES



It is able to satisfy adequately the requirements to operate and
manage integrally the plant.


It trasforms the process control into plant production control
with a single system solution.


It is garanted quality and HACCP certifications


It can begin from a minimum architecture of one to several
lines, of a small to a large plant.


It reduces costs and spreads the investments according to
plant growing, with an interesting pay back.

II World Wide Pasta Congress

Venezuela October 2000

PAGE
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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

INCREASING EFFICIENCY IN THE PASTA PLANT



E.U. ADVANTAGES
:


Central control room to control upstream,
mainstream and downstream areas data
production



Repetitive quality and relevant improvement



Fast trouble shouting (more lines availability)



Less Spare parts (maintenance costs
reduction)



Energy saving


The Totally Integrated Automation advantages are the followings:

II World Wide Pasta Congress

Venezuela October 2000

PAGE
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Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

COSTS REDUCTION IN THE PASTA PLANT

ENERGY SAVING

OUTPUT QUALITY

LESS HUMAN
RESOURCES

Due to optimization of motors control according to
production needs (less power consumption using drives
technology)

Repetitive quality and relevant improvment ,due to integrated

process control and less reject during shape change

Fast trouble shouting ,less spare parts,resources optimization
due to T.I.A. concept,central control room, diagnostic systems,
intelligent allarms

II World Wide Pasta Congress

Venezuela October 2000

PAGE
28


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation


CONCLUSIONS



T.I.A. concept will give an important contribution in terms of
costs control and cost reduction.


T.I.A. concept will increase the possibility to build up new
plants in new geographical areas where there are new
markets with less specific experience


The experience tipically of the Mediterranean countries is now
available using T.I.A. concept in the ROW.


By using T.I.A. both the pasta lines manufacturer and pasta
producer can achieve important market advantages.

II World Wide Pasta Congress

Venezuela October 2000

PAGE
29


Totally Integrated Automation

SIEMENS



in the Pasta Plants

Competence in Pasta Plant Automation

SIEMENS



Thank for your attention

Contact


A&D Competence Center Food & Beverage
-

Mill &Pasta



Antonio Rossetti :phone +39 02 66762933


Massimiliano Andreoli :phone +39 02 66762889


fax +39 02 66762916

E
-
mail to


antonio.rossetti@siemens.it


massimiliano.andreoli@siemens.it