Intake

When a driver has their truck in position they swipe the magnetic card at the unit situated next to the pit. Providing all details are correct AutoPilot4Feed starts the correct transfer route to the allocated bin and permits the driver to start tipping. All deliveries are automatically allocated a lot number which is traced right through to the finished product deliveries that leave site. Traffic lights indicate to the driver when he can move into position (amber) and tip (green).

Main Control Room

Four operator stations in the main control room allow two operators to control the two main blending lines and the 3 bio-secure pellet press lines. Two stations have multiple screens to allow the operator to view the whole process at a glance.

Orders required for production are imported automatically from the Perito business system. These are then scheduled on to the production plan using the Plan4Feed order scheduling system. This allows the planner to simply drag and drop orders on to the required production line. Each production line is represented by a colour coded graphical time line. This clearly and concisely shows the status of each production line and highlights any problems e.g. late delivery, cross contamination or die change. Some orders are automatically generated using the Kanban option. This creates new orders for high volume products based on current stocks and histrorical requirements.

The production is optimised by AutoPilot4Feed  to keep the press bins for the 10 lines topped up with feed. The operator, if required, has ultimate control by moving production requirements up and down the list. The weighing is optimised by balancing the large inclusions over two or more weighers if possible. If more than one bin on one weigher has the same ingredient  both feeders can be run at the same time. Accuracy is achieved by sophisticated in-flight calculations and automatic jogging features.

Formulations are automatically imported from the FORMAT International formulation system.

Ingredients are weighed in an order to help optimise the next stage of grinding. The most difficult to grind materials are split to be part weighed at the start and end of the batch.

Using  AutoPilot4Feed’s “Speed Batch” technology a new batch starts to grind while the previous one is still being transferred to the mixer. The grinder load is monitored to optimise the feeder speed and gate opening.  Sophisticated techniques are used to monitor for worn beaters and blocked screens. The last ten grind times are displayed on the graphics to clearly show grinder performance.

Batches can be crossed over from one blending line to another in case of mechanical breakdown. AutoPilot4Feed automatically controls this when enabled by the operator.

Hand additive ingredients are barcode scanned, checked and logged before tipping. The hand additives hopper door is not unlocked until the barcode is accepted ensuring mistakes are prevented. Some hand additives are made up in advance using DSL’s integrated off-line weighing system Masterweigh NT. Masterweigh NT generates barcode labels that can be scanned at the hand tip stations providing full traceability for every lot of every ingredient.

Pellet Press Control Room

Press runs are started very simply by clicking on the ’Go’ button on the screen. A form is displayed with destination bins, liquid levels and pressing parameters e.g. temperature.  Normally the operator clicks the start button unless they need to change a setting.  

Self-learning steam control ensures the required temperature is achieved rapidly. This is particularly important for the bio-secure lines that require a minimum of 86˚C.  Press run variables e.g. temperature, amps and throughput are logged every 30 seconds during a run for later analysis.

Some of the press lines are configured to allow new runs to follow-on after the previous run without a full cleanout. Providing the cross contamination criteria are satisfied, the fast change-over can be enabled by the operator. The new product is tracked through the production line and settings are changed e.g. fat levels as the new product progresses through the plant.

Packing

Finished product can be transferred to the packing lines using a simple "Start" button from the graphics. Stocks are deducted from the bin using a bag counter. Product information is automatically sent to the Domino in-line inkjet spray printer and the Domino label printer (including product declaration infomation imported from the FORMAT formualtion system).

Bulk Outloading

Trucks are assigned orders for collection using a remote station in the dispatch office. When a truck arrives at an outloading bay the operator or driver types in the registration number which displays a list of orders for collection. Each order is selected in turn. The filling of each compartment is automatically controlled. Accuracy is achieved using similar weighing techniques to the blending. The exact weight of each order is checked, logged and a ticket printed making it simple and fool proof.

A truck is shown above being outloaded with an LED display in the top right corner to display to the driver the current status of the operation.

Main Gate Weighbridge

Trucks departing from site have their final weight taken and a ticket printed. Finished product trucks are checked that they are within tolerance of the sum of the individual order weights. This helps prevent mistakes and fraud. Truck delivery data is exported for use by the office computer system.

Remote Support

Remote support allows remote users to ‘take over’ an AutoPilot4Feed  PC as if they were sitting in front of it. Using standard Microsoft Windows XP and internet technology the AutoPilot4Feed system at John Thompson and sons can be accessed securely by DSL and authorised engineers from anywhere in the world. A remote connection provides access that allows modifications and fault diagnosis to be performed quickly and efficiently. DSL have fully trained engineers available 24-hours a day 364 days a year in order to minimise any downtime.

Comments

“DSL exceeded our expectations in the level of integration provided, allowed us to analyse plant bottlenecks and make further changes to greatly improve the plant performance.
The guys at DSL are very experienced and combined with a high level of practical knowledge gained in other mills, they are able to quickly resolve issues.”
Aidan Mitchell; Operations Director