1

Mondelez International (Formerly Cadbury India Ltd.)

Bournvita plant is automated to achieve high quality product with optimum batch-time.

PROJECT AT A GLANCE

Project type Food Processing

Location India (Rewari-Haryana)

Application Bournvita – Malted Food Drink

System Components • UAG

• M340 PLC

• X-80 Remote I/O

Vijeo Citect SCADA

Vijeo Historian

SUPERBatch Batch Management

Magelis HMI

Altivar 32/ 71 VFDs

MCC

Customer Benefits • Flexible Manufacturing • Advanced Batch Process Management

based on ISA S88 Batch Standard • High and consistent product quality • Easy diagnostics • Energy Management • Batch and Management Information

Reports

Cadbury India Ltd. is a part of Mondelez International.

Cadbury India operates in five categories – Chocolate

confectionery, Beverages, Biscuits, Gum and Candy. In

the Chocolate Confectionery business, Cadbury has

maintained its undisputed leadership over the years.

Some of the key brands are Cadbury Dairy Milk,

Bournvita, 5 Star, Perk, Bournvita, Celebrations, Gems,

Halls, Éclairs, Bubbaloo, Tang and Oreo. It today has six

company-owned manufacturing facilities at Thane,

Induri (Pune) and Malanpur (Gwalior), Bangalore and

Baddi (Himachal Pradesh) Hyderabad with the

corporate office is in Mumbai. “Bournvita” – the Malted

Food Drink is their main product in the Milk Food drinks

segment.

2

The Challenge

The liquid ingredients – Malt, Liquid Glucose, Cocoa Liquor, Caramelized Sugar Syrup etc. are charged in the

in wet mix tank. Dry ingredients – Cocoa Powder, Crystal Sugar, Skimmed Milk Powder, Vitamin Mix,

Mineral Mix, Whey Powder etc. are charged in the hopper. Both the liquid and dry charging process are

working in parallel. Both the wet mix tank and hopper materials are charged in paste mixer and mixed.

Paste mixer outlet called “magma” is transferred to magma heating tanks. The magma is separated in two

parts. One part of the magma product is transferred to Chocotech system and other is transferred for the

oven system. The output of Chocotech system is sent to Band Dryer. Band dryer is a long tunnel with four

temperature zones under vacuum. The Chocotech product is distributed on ten conveyor belts which pass

through the four zones. Dried cake coming out of the band dryer is crushed and the crushed product falls in

a series of hoppers. The other part is dried in ovens and then crushed into powder. The Band Dryer and

oven products are then mixed in certain proportion to get the final Bournvita product. Finally the product is

sent to packing section for packing in different sizes of packages.

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The challenges involved in the process control were:

1. Accurate charging of liquid raw materials

2. Accurate charging of solid raw materials

3. Accurate Mixing time in mixers

4. Precise Temperature Control of liquid ingredients

5. Integration with “Chocotech” system used for cooking of Magma for Band Dryer

6. Temperature and Vacuum Control in Band Dryer

7. Conveyor speed and material flow control in Band Dryer

8. Integration with Parker Swivel system used for uniform cake width on the belts

9. Integration with CIP system

10. Recipe based flexible manufacturing

11. Management Information Reports and ready for integration with SAP in future.

The Solution:

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128 64 32 8

128 64 32 8Remote I/O- 2 5.5M

MCC Process Utility RIO

Remote I/O- 1 0.0M

Main Plant PAC

MCC BV Process RIO

OFFERED IO's

Ethernet TCP/IP 100 Mbps

Engineering

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HMI EL0.0M HMI EL5.5M

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LOCATION: Remote I/O-

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2 Panel

MCC BV Process RIO

LOCATION: MCC BV Panel

MCC Process Utility RIO

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Utility Panel

Process Utility MCC

CAN

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SYSTEM CONFIGURATIONBatch/Historian

Server

SUPERBatch Modules1. SUPERBatch Manager

2. Plant Editor3. Recipe Engine

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The system consists of 3 no. M340 Controllers - Main PAC, BV Process, Utility and 4 nos. Remote I/O

stations - RIO1, RIO2, RIO3, PMCC RIO. There are two MCC panels – Process MCC and Utility MCC consisting

of conventional motor starters and Altivar 32/ 71 VFD based starters. Conventional motor starters are

connected with the PLC on remote I/O and VFDs are connected on Canopen bus. The PACs and remote I/O

communication is Ethernet TCP/IP. One Engineering cum Operating Station and one Operating Station has

been provided in the main control room. Two 10.4” Magelis HMI have been provided in the field for local

operation. A Batch/ Historian Server has been provided for ISA S88 based Batch Management System -

SUPERBatch and Vijeo Historian. Flexible recipe based operation is achieved through SUPERBatch, a Batch

Management software based on ISA S88 Batch Standard developed by Supertech. SUPERBatch is tightly

integrated with PlantStruxure components – UAG, Unity Pro, Vijeo Citect SCADA and Vijeo Historian. It uses

the MS SQL Server data base integral with the Vijeo Historian for batch data as well. Various Batch reports

and Historian based Management information reports are generated by the system.

For precise temperature and vacuum control standard PID control blocks from UAG library have been used.

Special program was developed for complex control involved in Band Dryer according to the logic provided

by the German OEM.

Following are the solutions provided for the key challenges: =

1. Accurate weighing of raw materials are achieved through load cells based weighing system which

was developed by using material charging functional block, designed by Supertech. During auto

charging through SUPERBatch every raw material (liquid and solid) is added accurately, following

screen shows the comparison between set quantity and actual charged quantity.

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2. Solid raw materials are conveyed to Dry Batch hopper one by one as per the instructions provided in

HMI, after every Dry material is charged acknowledgement is done through HMI as shown.

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3. Chocotech system (make: Allen Bradley) was integrated with Schneider-Electric control system. The

SCADA screen is developed so as to provide supervision for chocotech system, controlling the main

feed pump.

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4. Formation of cake with uniform width is critical parameter needed for appropriate product

formation, for these two parameters were considered – Belt speed and swivel stroke.

a. Belt speed: belt speed of band dryer is automatically calculated based on residence time

provided on SCADA which decides period for which the material will be exposed to different

temperature zones.

b. Swivel stroke and speed: CANopen based communication is done between Parker Drive and

Schneider control system, which enables the input options either through SCADA or through

HMI. Furthermore resulting in control of stroke and speed of swivel.

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5. Modbus based communication CIP (clean in place) cleaning system is integrated with Schneider

system which provides selection of appropriate equipment. Moreover it also indicates the CIP

cycle status.

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SUPERBatch – ISA S88 Based Batch Management System Advanced Batch Management is achieved by using “SUPERBatch” which is a Batch Management software

developed based on ISA S88 Batch Standard and fully integrated with “PlantStruxure PES” architecture. It

consists of six modules viz. Plant Editor, Recipe Engine, Batch Scheduler, Batch Execution, Online Batch

viewer, Reports Viewer.

SUPERBatch has enhanced the value of the Control System to the customer in following ways:

Product Consistency with best use of Recipes Management comprising of SOP and formulations

Automatic generation of Batch Reports, raw material consumption, comparison with Golden Batch, Aborted

batches etc.

Batch Based Data Availability for analysis that may result in KPI improvements such as optimum utilization

of resources and achieving level of maximum production using improved Batch cycle Time etc.

Provision is provided for back-to-back auto downloading of batches which saves time, provides accuracy

and avoids unwanted adulteration/excess use of raw materials, which may occur during manual operations.

And Many more…

Vijeo Historian Based KPI Reports

Process and Energy data from VJC and Batch

data from SUPERBatch are recorded in MS

SQL Server integral with the Vijeo Historian.

Based on customer requirements, about 15

KPI reports were developed using Report

Development Tool of VJH. Some examples

are – Oven Cycle Time, Pasteurizer/

Sucrofilm/ Holding Tank Temperature, Dried

Material Weighing, Vertical Silo Weight, No.

of PSM Batches, Energy Consumption, etc.

These reports can be viewed from any

machine on Mondelez network through

Internet Explorer.

This system was designed and supplied by Supertech - Alliance Partner of Schneider Electric : Supertech Instrumentation Services (I) Pvt. Ltd. 12, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE – 400601 (Maharashtra) India Phone: +91-22-41550100 e-mail: automation@supertech.co.in URL: www.supertech.co.in

[Grain Processing]

1

Navasasyam Processing Equipments

4 TPH Pigeon Peas Processing Plant is automated to achieve high quality

product with minimum breakage and waste

PROJECT AT A GLANCE

Project Type

Grain Processing

Location Samay Agro, Latur, Maharashtra

Application 4 TPH Pigeon Peas Processing

System Components • Modicon M580 Processor • EcoStruxure Hybrid DCS • Specially Developed Templates

CUSTOMER BENEFITS • Higher Yield • Continuous and consistent

production • Efficient Control System Adds to

highest level of productivity • Reduced errors due reduced manual

intervention • Increased Safety and Reliability of

Operation • Optimum utilization of the mill

capacity, lower power consumption per ton of production

Navasasyam Processing Equipments is a team of experts in various field such as Process Design, Product Design & Development, Engineering and Project management. They are experts in planning and delivery of projects for the Grain & food industry. They apply the latest technology and knowledge within key areas such as food safety, hygiene, process equipment design and Selection, operational setup and controls, as well as efficiency in all processes including optimizing of energy consumption and minimizing waste i.e. by-products generation in process. This project was executed by Navasasyam for M/S Samay Agro Dal Processing Mill at Latur in Maharashtra.

Supertech provided user friendly graphics and operating faceplates in the DCS for the complex material handling operations. They provided excellent support during commissioning by adapting to the frequently changing process requirements. The project was completed within the desired project schedule” Janardan Pawar Director, Navasasyam

[Grain Processing]

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The Process

The process consists of pre-cleaning the raw material with drum sieves and pre-cleaner machines to

remove coarse foreign particles. Fine cleaning process removes fine dust, mud etc. Next the material

passes through grading section in which it is classified into Bold, Medium and Small. The classified

material undergoes hulling process in which peas are scratched to loosen the skin. Water and Oil is

added to the hulled peas and kept for resting in the resting bins for 8-16 hours. The bins are then passed

through heaters to achieve de-skinning. The process repeated till the complete skin is removed. The de-

skinned whole peas then undergo splitting process. The split peas i.e. the Dal passes through the colour

sorter. Colour sorter sorts the product into three types – Accept, Re-sort and Reject. The accepted

product is sent for polishing in buff polishers or polishing conveyors. The finished Dal product is sent for

bagging and packing.

Some of the pictures of the plant are as follows:

Dal Processing Plant Classifier

The Challenge

• To produce Quality product like- sharp edges, graded dal, reduction of powder

• Minimizing grain breakage and waste

• Reduce manual operation

• Low operator skill levels

• Complex Material Handling due to large no. of equipment

[Grain Processing]

3

The Solution

The Automation system consists of EcoStruxure Hybrid DCS with 1250 objects license and M 580 Level 3

processor with 1200 nos. X-80 I/O.

The process involves charging and discharging of material and conveying by means of a series of

conveyors and elevators, control of heating, water and oil addition etc. The plant consists of approx..

450 motors with conventional starters and a few of them with VFD. All motors are controlled through

DCS auto sequence. Customized Hybrid DCS templates were prepared for sequential operation, charging

and discharging. Auto start-up, fault, stop and emergency shutdown sequences were developed. The

auto sequences have a facility of PAUSE and RESUME. Operations are repeated multiple times

depending on the quality of raw material.

DCS operating screens of some of the important operations are as follows:

[Grain Processing]

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[Grain Processing]

5

[Grain Processing]

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The Benefits

• Unique innovative automated process reduces mechanical stresses and heat buildup in the grain,

thereby minimizing grain breakage and producing uniformly polished grain, with higher Yield

• Automation allows multiple operations to be carried out at different stages simultaneously and results in consistent quality and higher throughput.

• Efficient Control System Adds to highest level of productivity

• Reduced errors due reduced manual intervention

• Increased Safety and Reliability of Operation

• Optimum utilization of the mill capacity, lower power consumption per ton of production

This system was designed and supplied by Supertech – Master Alliance Partner of Schneider Electric: Supertech Instrumentation Services (I) Pvt. Ltd. 12, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE – 400601 (Maharashtra) India Phone: +91-22-41550100 e-mail: automation@supertech.co.in URL: www.supertech.co.in