Baking & Snack - August 2021 - 70

INGREDIENT HANDLING
A remote
supervisory control
application along
with the ingredient
batching system
allows various
departments
to monitor the
operation.
Sterling Systems & Controls
when something is nearing end of life. This allows customers
to schedule focused maintenance efforts around
planned downtime rather than repairing post-failure. "
24/7 cyber inspection
Jack Kilbride, vice president systems and automation engineering,
Zeppelin Systems USA, observed that modern
control systems provide visibility into the process by
comparing current and historical data regarding a bulk
ingredient handling operation.
" Bakers need to monitor the data regularly and check
for changes in pressures, temperatures, fill rates and
more, " he said. " When an anomaly is found, you can
investigate thoroughly the portion of the process where
the operation of the system has changed. "
Becoming familiar with all components is critical
when troubleshooting a pneumatic ingredient conveying
system, suggested Tom Leach, national sales manager,
pneumatic conveying systems, Camcorp, a member of the
Scheuch Group. These parts include the blower, piping,
filter receiver and the various valves such as airlocks, divert
valves, butterfly valves and slide gates, to name a few.
" It's important to have a good understanding of these
parts' function and design features, " he said. " And don't
forget the controls, the brain of the pneumatic system.
Understanding the normal operational state of the
equipment and the system will help when it comes to
discerning problematic issues. "
Kevin Pecha, sales manager, AZO Food, observed that
smart technology also enhances an ingredient system's
reliability.
" Good programming methodologies help to not only
promote consistent functionality of the equipment but
also monitor for signs of issues such as valves taking too
long to switch or motors pulling higher amperage ratings, "
he said. " Some changes to hardware may be needed
to take advantage of some control items. "
However, Mr. Stricker stressed, bakeries need to do
their detective work when a system's controls signal that
something has gone awry.
" Proper PLC and HMI programming will provide visual
alarms when things are not operating as intended. It
is difficult for a PLC to provide the exact cause, " he noted.
" It can only point you to the malfunction. Determining
the cause of the failure is really the territory of the data
management or IIOT portion of the controls. "
Still, digital technology and software today is a lot
more intelligent - some may argue intuitive - than just
a few years ago.
" Smart variable-frequency drives (VFDs), which
can control multiple motors, allow for the data capture
of motor amperage of each connected motor, " said Joe
Lewis, marketing, Sterling Systems & Controls. " This allows
the ingredient batching controls system to monitor
and sound alarm warnings if conditions fail. "
Most control components, he added, can be interconnected
with minimal wiring using Ethernet communications
to capture data and transmit it to PLCs.
Mr. Schwartz observed that programmable controls
also verify that a system is in good working order before
it's fired up. Prior to starting a conveying air blower, for
instance, there must be a clear path to the correct destination,
such as a bin or holding tank, which then must
be vented in some way.
" Instrumentation and signal devices, such as limit
and pressure switches, provide the 'permissives' that allow
the final desired action to start, " he said. " If a system
does not start, the permissives for a given operation
can be checked and then used to easily determine what
is preventing the system from starting. While the ladder
70 Baking & Snack August 2021 / www.bakingbusiness.com
Baking & Snack - August 2021

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