Mondelez International (Formerly Cadbury India Ltd.)

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John Horton
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1 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 (Delhi-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 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 and vacuum zones. 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 powder falls in a series of hoppers. The other part is dried in ovens and then crushed into powder. The Band Dryer and

3 BMXP BMXP BMXNOE 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. The challenges involved in the process control were: 1. Accurate charging of raw materials Liquid and solid 2. Accurate Mixing time in mixers 3. Precise Temperature Control of liquid ingredients 4. Temperature and Vacuum Control in Band Dryer 5. Conveyor speed and material flow control in Band Dryer 6. Recipe based flexible manufacturing 7. Management Information Reports and ready for integration with SAP in future. The Solution Engineering Station Engineering + Operating Station SYSTEM CONFIGURATION Batch/Historian Server SUPERBatch Modules 1. SUPERBatch Manager 2. Plant Editor 3. Recipe Engine Ethernet TCP/IP 100 Mbps Main Plant PAC 8.5 M LOCATION: Process UPS MCC Panel Process UPS MCC CANOpen HMI EL0.0M HMI EL5.5M Ethernet TCP/IP 100 Mbps Remote I/O M LOCATION: Remote I/O- 1 Panel OFFERED IO's Remote I/O M LOCATION: Remote I/O- 2 Panel MCC Process Utility RIO LOCATION: MCC Process Utility Panel C A N O p e n MCC BV Process RIO LOCATION: MCC BV Panel DI DO AI AO Main Plant PAC MCC BV Process RIO MCC Process Utility RIO Remote I/O M Remote I/O M Process Utility MCC LEGENDS : ETHERNET TCP/IP 100 MBPS CANOpen

4 4 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 VFDs. 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 filed 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. Accurate weighing of raw materials is achieved through load cell based weighing systems and specially developed material charging function block developed by Supertech. 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. 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 PES 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 which may result in KPI improvements such as optimum utilization of resources and achieving level of maximum production using improved Batch cycle Time etc. And Many more

5 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.

5 5 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 in 2014 : Supertech Instrumentation Services (I) Pvt. Ltd. 12, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE (Maharashtra) India Phone: automation@supertech.co.in URL:

Mondelez International (Formerly Cadbury India Ltd.)

Mondelez International (Formerly Cadbury India Ltd.) Bournvita plant is automated to achieve high quality product with optimum batch-time. 1 PROJECT AT A GLANCE Project type Food Processing Location India