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MediaService Digital Industries Newsroom

Retrofit for a secure future - Mozzarella producer updates production with end-to-end Siemens control technology

A molding drum machine (“Rullo”) produces the ball-shaped portions of mozzarella.

As well as its famous Brimi mozzarella, the milk processor also produces a range of additional cream cheese products, fresh milk, cream, butter and drinking yoghurt. The manufacture of all these products is subject to strict regulations imposed by the Ministry of Health. All processes have to be seamlessly documented and traceable. One requirement is that any faulty batch has to be detected and reported to the market within just four hours. Quality is checked by over 70,000 microbiological and around 260,000 chemical analyses a year, and the results have to be stored for a minimum of two years. As this placed a heavy burden on the existing automation system, Brimi took the decision to modernize its process control technology using a Simatic PCS 7 V8.2 control system from Siemens.

From the central control room, production managers are able to keep an eye on all parts of the plant, with the familiar look and feel of the Simatic PCS 7 enabling convenient operation and monitoring.

Reliable automation using standard modules

Long-term Siemens partner Pavis Engineering GmbH based in Ravensburg was in charge of implementing the retrofit. The new solution encompasses one Engineering Station (ES), two redundantly configured Operator Stations (OS) and ten operator clients distributed around the plant. A Simatic S7-410 controller takes care of central automation. Integrated in the visualization system are three distributed Simatic S7-400 head controllers for the production plant, the cheese dairy and cheese vats, and a dozen controllers for smaller ancillary operations. The visualization system was created by replicating familiar user interfaces to provide a more user-friendly, convenient operator experience. Brimi uses the Advanced Process Library (APL) as its programming standard. The PCS 7 standard library supplies prepared building blocks for the implementation of individual automation tasks, simplifying the engineering process. Seamless traceability of the entire production is enabled by the Simatic PCS 7 Process Historian. This archiving and reporting system enables the long-term archiving of process data such as temperatures, alarms and charge data from the Simatic Batch software in real time, without adding to the engineering workload.

Forming part of the retrofit is a new reverse osmosis plant automated using Simatic PCS 7 which is now integrated into the overall process.

All-round satisfaction

“We took the right step with the right partner when we decided to retrofit our process control technology to Simatic PCS 7 Version 8.2,” concludes Brimi’s Project Manager Markus Stecher. “Our production is now firmly back on a standardized foundation. We’ve managed to overcome our innovation bottleneck and are now back in a position to optimize and expand our operations.”

Configuration scheme of Brimi’s new totally modernized milk and mozzarella production automation system using Simatic PCS 7.

MediaService application reports may be based on previously published Siemens technical articles.

Contact

Ursula Lang

Siemens AG

Gleiwitzer Str. 555
90475 Nuremberg
Germany

+49 (911) 895-7947