“In recent years, Amadori has always been asking for the most innovative solutions, aware that technological innovation allows us to remain competitive on the market. And this goal has led us to the deployment of Wonderware platforms.”

Carlo CaramanicoSoftware SupportCid Engineering

The Ideal Temperature

Goals• Optimizetemperaturemanagementduring

meatprocessingsteps• Ensuretraceability,withexacttemperaturedata

foreverystep:processing,stockingandpreservation

• Deployasystemthatimprovesplantefficiency

Challenges• Difficultyinsoftwaremigrationfromanoutdated

versiontoahighlyinnovativeandscalablesystem

• Createatemperaturecontrolsystemthatadjustsaccordingtotheexternalweatherconditions

Solutions and Products• WonderwareActiveFactory• WonderwareInTouchHMI• WonderwareHistorian

Results• Solutionenabledcompliancewith

governmentregulations• Optimizedproductioncycleand

energymanagement• Automationoftheproductioncyclehelped

eliminatemanualdataentryerrors• Thesolutionwasinitiallyonlyimplemented

inlimiteddepartments,buthasnowbeendeployedinallotherprocessareas

INDUSTRY:FOOD&BEVERAGE

Amadori Group, GESCO Consorzio Cooperativowww.amadori.it

Teramo, Italy–Amadoriisoneofthemarketleadersinthefoodprocessingindustry.FoundedinSanVittorediCesenafortyyearsago,theGroup–withaturnoverofover1billioneuroin2008–leadstheItalianmarketwith16industrialplants,33subsidiariesandit6,400employees.

Amadorihasbeensuccessfulbecauseofitsinnovationanddecisiontomanagetheentireproductioncycledirectly,allowingimmediatecontrolovereveryproductionstep.Thisincludesthechoiceofrawmaterials,farms,hatcheries,feedmills,processingplants,packaginganddistribution.

TraditionandinnovationaretheGroup’shallmarks:itiscomprisedofaprofessionalteamthatpresentsinnovativegastronomicsolutionsandworkstodeliverfreshandsafeproductstoconsumers.IntheprocessingplantinTeramo,wherebreadedproductsandthe“IlCampese”lineareproduced,fulltemperaturecontrolisessentialtoensurehighproductquality.

ThepopularityoftheAmadoriGrouphasgreatlyincreasedinthepastfewyears,thankstoadvertisementsfeaturingcompanytestimonialsandthe“guaranteedbyFrancescoAmadori”slogan.Byemphasizingthehighqualityofitspoultryproductsinvariousversions,thecompanyissendingoutastrongandimportantmessage.

The Ideal Temperature

Oneofthemostimportantchallengesfacingindustrialplantsisguaranteeingaconsistentlyhighlevelofquality.

Themostsensitivepartofproductionisthecorrectmanagementoftemperature,bothintheprocessingandinthestockingandpreservationsteps.Temperaturemustbekeptconstantinthecoldstoresusedinthepreservationofslaughteredmeatinordertopreventitfromquicklyspoiling.

Itisimportanttoavoidguessworkinthetemperaturesettingsduringtheprocessingstepsandeverydepartmentisconstantlymonitoredtopreventthemodificationoftemperaturemetrics.

Ahightemperature,forexample,couldfavormicroorganismgrowth,riskingproductquality.Ontheotherhand,ifthetemperatureistoolow,themeatwouldbedifficulttobone.

Thisisstrategictoglobaloperationsbecausedifficultiesintheseparationphasecanslowtheproductionprocessdown,affectingtheentiresupplychain.Moreover,ifconditionsarenotoptimized,partofthemeatcouldremainonthebone,causingconsiderablewastethataffectsoverallbusinessprofiability.

Growing Together

Becauseofthesedemands,Amadoriisfocusedondeployingsystemsthatareabletooptimizetemperaturemanagementduringtheprocessingandstockingsteps.

“ThatiswhyAmadorihasbeeninvestinginhighperformancecontrolsolutionsthatareabletosupportthecompany’sbusinessandexpansion.Atendofthepastdecade,wegotintouchwithAmadorifortheupgradeoftheirexistingWonderwareInTouchHMI,”saidCarloCaramanicowithCidEngineering

Thismutualcollaborationconsolidatedduringtheyears,andCidEngineeringhasbeensupportingallofAmadori’supgradesanddeploymentofnewplatforms.

“Amadorihasalwaysbeenaskingforthemostinnovativesolutions,awarethattechnologicalinnovationallowsthemtoremaincompetitiveinthemarket.ThisvisionledtothedeploymentofWonderwareplatforms.Theselectionhasbeendeterminedbythefactthat,asqualifiedpartners,wearehighlyexperiencedintheseapplications,aswellasthefactthatWonderwarehasbeenintroducingnewandinnovativesolutionsthatarecapableofmeetingthecomplexdemandsoftheAmadoribusiness,”saidCaramanico.

Quality and Savings

Temperaturemanagementhasbeenaccuratelystudiedoverthepastyears,specificallyitseffectonsavingsandenergyefficiency.Theoldsystemwasbasedonsimplethermostats,whichwascharacterizedbyexcessivelyslowresponse.

WonderwareInTouchHMI(HumanMachineInterface),ontheotherhand,allowsforsmartoperation.Thesystemisabletomanagetheactivationoftheairconditioningsystemaccordingtoactualneedsanditalsoestablishesthepowerneededtoguaranteeidealconditions.

Asidefromtemperaturevalues,airqualityandhumiditymustalsobetakenintoaccount.Humidity,inparticular,mustbekeptwithinpre-setvaluesinordertopreserveahealthyenvironmentfortheoperatorsintheprocessingplant.TheWonderwareInTouchHMInodeshelpanalyzeenvironmentalconditions,helpinginthecontroloftheairconditioningsystem.

Itistheabilitytooperateeffectivelythatallowsthesystemtoturnonandoffaccordingtothedifferentworkingcycles,inboththeautomaticcalculations.Byevaluatingexternalconditions,thesystemdeterminesthetimenecessarytoreachtherighttemperatureaccordingtoactualneeds.Thispreventsearlycoolingofcertainenvironmentsandeliminatesthepostponementofprocessingbecauseoptimalconditionshavenotbeenmet.

The History of Temperature

Theoptimizationofenvironmentalmetricshasastrongimpactonproductqualityandtheworkingconditionsofoperators.Italsoplaysadecisiveroleinprecisefoodtraceability.Industryregulationsrequireatracebackofalltheoperationalconditionsfoodhasgoneunderandauthoritiesconsistentlycheckthisinformation.Inmanycases,largecustomersalsowanttoverifythecontractualcomplianceoftheproductionprocesses.

Inthepast,allthesevalueswereenteredmanuallybytheoperators.Butthiswayofworkingcausedconsiderableproblems,bothintheneedtoemployextraoperatorswhomanuallytranscribeinformation,aswellasthehighriskoferrorsthatcomeswithhumantranscription.TheWonderwareHistoriansoftwareisspecificallydesignedforthehistoricizationandarchivingofprocessdataandhelpssolvethisproblem.

ActiveFactorysoftwareaccessesallofthisinformationandtransformitintographicsandusefulinformationthatallowsoperatorstovisualizehistoricalevent-relatedtemperaturetrendsintuitively.

Thisfeaturehelpswithtraceabilityanditalsoallowstheoperatorstobeimmediatelyinformedaboutabnormaloperatingsituations.Inthisway,itispossibletorespondquicklytocasesofdeviationsfromsetvalues,manytimesbeforeproblemsoccur.

TheWonderwaresolutionwasalsohighlyscalable.Whileinitiallyonlyimplementedinlimiteddepartments,thesolutionhasnowbeendeployedinalltheotherprocessareas,ensuringtheoptimizationoftheproductioncycleandenergymanagementthroughouttheTeramoplant.

Recently,AmadorichosetoreplacetheoldS5PLCwithanewerSiemensS7PLC.ThishasbeensuccessfullyimplementedwithoutaffectingtheWonderwareautomationsolution.Oncethenewhardwarehadbeenconfigured,itwasthenimmediatelydeployed,withnonegativeimpactontheproductioncycle.

Thankstothemostinnovativeandadvancedtechnologies,itispossibletoensurethehighestefficiencylevelsthatalwaysensurehighqualityproducts.

Invensys,theInvensyslogo,ArchestrA,Avantis,Eurotherm,Foxboro,IMServ,InFusion,SimSci-Esscor,Triconex,andWonderwarearetrademarksofInvensysplc,itssubsidiariesoraffiliates.Allotherbrandsandproductnamesmaybethetrademarksorservicemarksoftheirrepresentativeowners.

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Rev.03/10