Efficient Plant February 2018 - 40

feature | solution focus
weren't automated. Consequently,
operators needed to manually keep
processes moving forward.
An automated greenfield central-hub terminal, MFC reasoned,
would not only be key to developing
a larger customer base for the co-op's
patrons, it could help keep operating
costs low.

them, production moves more
quickly and efficiently compared
to older terminals. Case in point:
The terminal has a capacity of
2.75 million bushels, which could
more than double if warranted.
The receiving end has the capacity
to take in 1,000 bushels every two
minutes, and receives an average
of 300 trucks each day. The site
THE SOLUTION
also reports that remote monitorCo-op management found a location
ing reduces downtime and helps
in Syracuse, in southeastern Nebrassave maintenance costs.
ka, that met their requirements for
One of the biggest benefits,
rail-line access. Once the land was
though, may have come as a result
secured, the project moved forward.
of the project's development
"This was the first time MFC was
process and expedited commisdeploying a centralized DCS in a
sioning. MFC began building
terminal," said Daniel Alvarez, autothe terminal in December 2015.
mation software systems consultant
Wachter began performing the
Up and running since October 2016 with no major downtime events, the
at Wachter and a lead on the project.
upfront engineering and design
Midwest Farmers Cooperative's fully-automated central-hub terminal
in
Syracuse,
NE,
is
helping
efficiently
move
corn
and
other
grains
to
"We knew that the PlantPAx modern
in March 2016. The PlantPax
customers around the world.
DCS would be easy to design and
DCS was deployed by October of
deploy quickly, helping to get the
that year-and began validating
facility operating sooner."
processes less than two weeks later.
receiving, weighing, and loadout. Typically,
When designing the control system,
"Our operations, management, and
terminals would require multiple operators
Wachter leveraged the Rockwell Automaleadership teams have varying levels of
to manually manage the process.
tion Library of Process Objects. The preautomation experience, from little or none,
The new system also smoothly manages
built, pre-engineered, and tested process
to full-on, wholly automated facilities," said
enterprise-level monitoring, data storage,
objects allowed Wachter to quickly design
Eric Werth, manager for the MFC Syraand alarming. The system's connectivity to
and deploy the system.
cuse terminal. "With the PlantPAx system,
the enterprise-level monitoring also enables
The Rockwell Software Studio 5000 Logix
Wachter helped us go from design to operremote access. If an issue arises, Wachter
Emulate software application enabled the
ations at the same location, within a year,
can remotely access the control system for
Wachter team to validate, test, and optimize
letting our patrons reach a bigger customer
maintenance and troubleshooting, reducing
code without hardware. This reduced design
base faster than expected."
costs and time for both.
time by about 25%, and allowed the team to
Bottom line: The Midwest Farmers CoopTHE ROI
gather buy-in from MFC stakeholders and
erative plans to standardize on the PlantPAx
MFC's greenfield terminal has been opertrain operators.
system across its facilities as it builds future
ating with no major downtime events to
With an EtherNet/IP backbone, the
terminals and upgrades existing ones. EP
date. Its rail-line access allows the co-op
modern DCS integrates smoothly with the
to deliver corn and other grains to more
facility's new machines, including conveyors
Results mentioned in this article are specific
national and global markets, at higher profit
and dryer systems, to efficiently monitor
to the Midwest Farmers Cooperative's use of
margins.
and visualize the terminal from inbound to
Rockwell Automation products and services
The business is realizing a number of
outbound. This comprehensive view enables
in conjunction with other products. Specific
specific benefits from its first centralized
operators to control all areas of the site
results may vary for other users. For more
DCS and fully automated operation. Among
through only three workstations located at
information, visit rockwellautomation.com.

40

| EFFICIENTPLANTMAG.COM

FEBRUARY 2018


http://www.rockwellautomation.com http://www.EFFICIENTPLANTMAG.COM

Table of Contents for the Digital Edition of Efficient Plant February 2018

Maximize CMMS, EAM Use
Tribology Program Fills Skills Gap
Caring For Bearings In Extreme Environments
Press-Brake Safeguarding Matters
Oil Systems Need To Breathe
SAP: Kicking Bad Habits
Advice For Automated Substations
Good BOMs Boost Maintenance Efficiency
Smarten Up About Rotor Analysis
Heed These Signs of Inefficiency
Implementations
IIoT
Efficiency Insight
Editorial
On The Floor
Solution Focus
Products
Showcase
Efficient Plant February 2018 - Cover1
Efficient Plant February 2018 - Cover2
Efficient Plant February 2018 - 1
Efficient Plant February 2018 - 2
Efficient Plant February 2018 - 3
Efficient Plant February 2018 - 4
Efficient Plant February 2018 - 5
Efficient Plant February 2018 - Editorial
Efficient Plant February 2018 - 7
Efficient Plant February 2018 - Implementations
Efficient Plant February 2018 - 9
Efficient Plant February 2018 - Maximize CMMS, EAM Use
Efficient Plant February 2018 - 11
Efficient Plant February 2018 - 12
Efficient Plant February 2018 - 13
Efficient Plant February 2018 - Tribology Program Fills Skills Gap
Efficient Plant February 2018 - 15
Efficient Plant February 2018 - 16
Efficient Plant February 2018 - 19
Efficient Plant February 2018 - 20
Efficient Plant February 2018 - Caring For Bearings In Extreme Environments
Efficient Plant February 2018 - 22
Efficient Plant February 2018 - 17
Efficient Plant February 2018 - 18
Efficient Plant February 2018 - 19
Efficient Plant February 2018 - 20
Efficient Plant February 2018 - Caring For Bearings In Extreme Environments
Efficient Plant February 2018 - 22
Efficient Plant February 2018 - 23
Efficient Plant February 2018 - Press-Brake Safeguarding Matters
Efficient Plant February 2018 - 25
Efficient Plant February 2018 - 26
Efficient Plant February 2018 - 27
Efficient Plant February 2018 - Oil Systems Need To Breathe
Efficient Plant February 2018 - 29
Efficient Plant February 2018 - 30
Efficient Plant February 2018 - SAP: Kicking Bad Habits
Efficient Plant February 2018 - Advice For Automated Substations
Efficient Plant February 2018 - Good BOMs Boost Maintenance Efficiency
Efficient Plant February 2018 - Smarten Up About Rotor Analysis
Efficient Plant February 2018 - Heed These Signs of Inefficiency
Efficient Plant February 2018 - On The Floor
Efficient Plant February 2018 - 37
Efficient Plant February 2018 - IIoT
Efficient Plant February 2018 - Solution Focus
Efficient Plant February 2018 - 40
Efficient Plant February 2018 - Products
Efficient Plant February 2018 - 42
Efficient Plant February 2018 - 43
Efficient Plant February 2018 - 44
Efficient Plant February 2018 - Showcase
Efficient Plant February 2018 - 46
Efficient Plant February 2018 - 47
Efficient Plant February 2018 - Efficiency Insight
Efficient Plant February 2018 - Cover3
Efficient Plant February 2018 - Cover4
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-june-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanfeb2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjulyaug2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epfeb2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjan2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovdec2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptoct2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptember2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epaugust2018
https://www.nxtbook.com/atp/MaintenanceTechnology/0818schneider
https://www.nxtbook.com/atp/MaintenanceTechnology/epjuly2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtsept2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJune2015
https://www.nxtbook.com/atp/MaintenanceTechnology/M
https://www.nxtbook.com/atp/MaintenanceTechnology/0415endress
https://www.nxtbook.com/atp/MaintenanceTechnology/MTApril2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTMarch2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTFebruary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJanuary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTDecember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTNovember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTOctober2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTSeptember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2014
https://www.nxtbookmedia.com