| Plant Monitoring System |
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| Client: Bucknell Bakery, Atlanta, GA |
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| System Summary: 15 SLC 500 1000+ I/O |
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| Description: The Pro-MACS system monitors the Ingredient System, Mixing equipment, 2 Pie Lines, Spiral Cooler, 2 Spiral freezers, Conveyor Equipment, Packaging equipment. |
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| Results: The efficiency is monitored and reported constantly by line and shift and the downtime is kept to a minimum due to the automated diagnostics and voice annunciated failures. |
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| Complete Plant Controls System |
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| Client: Bucknell Bakery, Atlanta, GA |
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| System Summary: 15 SLC 500 1000+ I/O |
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| Description: Control systems for the Ingredient System, Mixing equipment, 2 Pie Lines, Spiral Cooler, 2 Spiral freezers, Conveyor Equipment, Packaging equipment. |
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| Results: A completely integrated system. |
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| Plant Refrigeration System |
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| Client: Country Home Bakery, Atlanta, GA |
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| System Summary: 1 - PLC5-30, 1500+ I/O |
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| Description: Automated Plant Refrigeration System consisting of 10 refrigeration compressors, ammonia vessels and 17 evaporators and a Glycol system. The system controls the freezer warehouse, cooling rooms and 3 spiral freezers. |
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| Results: Totally automated the defrost cycles and coordinated them between the different pieces of equipment. Increased the overall efficiency of the refrigeration plant system. |
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| Plant Monitoring System |
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| Client: Country Home Bakery, Atlanta, GA |
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| System Summary: 6 PLC 5, 12 SLC 500 1200+ I/O |
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| Description: The Pro-MACS system monitors most of the plant consisting of the 3 Bulk Ingredient Systems, Cream Yeast System, a Bread Line, a Roll Line, 2 Cookie Lines, a Biscuit line, 12 Mixers, Line Conveyors, Packing equipment, Refrigeration System, and 3 Spiral Freezers. |
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| Results: The savings in downtime on the ingredient system alone due to the automated diagnostics and voice annunciation of failures reduced the downtime by over 5%, thus saving the plant in excess of $200,000 in the first year. |
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| Plant Monitoring System |
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| Client: Merita Bakery, Jacksonville, FL |
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| System Summary: 88 PLCs approximately 4500 I/O |
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| Description: The Pro-MACS system monitored the entire plant consisting of the Bulk Ingredient System, Liquid Brew and Cream Yeast System, a Bread Line, Roll Line, Hearth Bake Line, the Refrigeration Equipment, Plant Air Makeup Equipment. It controlled the Plant and Office Air Conditioning and Heating, and All Plant, Office and Parking Lot Lighting. |
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| Results: Not only is the downtime kept at a minimum due to the automated diagnostics but the plant realized an $1100 per month savings in lighting electrical usage in the first month. |
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| Plant Monitoring System |
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| Client: Penny Curtis Bakery, Syracuse, NY |
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| System Summary: 5 PLC 5s 300 I/O |
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| Description: The Pro-MACS system monitored most of the plant consisting of the Bulk Ingredient System, Cream Yeast System, a Bread Line, and Roll Line. |
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| Results: The savings in downtime due to the automated diagnostics and voice annunciation of failures reduced the downtime, thus saving the plant in excess of $170,000 in the first year. |
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| Pro-MACS Diagnostic System |
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| Client: Entemann's Bakery, Bay Shore, NY |
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| System Summary: Pro-MACS diagnostic and reporting system monitoring 4 spiral coolers and associated packing lines. |
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| Description: There was noted downtime losses on these particular lines and the causes were in dispute. A Pro-MACS system was installed to monitor the downtime and determine the exact causes. |
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| Results: After the first week it was determined that Operator E. Stops were the cause of over 90% of the downtime. It was also determined that over 90% of these E. Stops were Unjustified and amounting to approximately 32 hours per week per line. By identifying and analyzing the causes the plant management has been steadily reducing this downtime each month. The first month more than 10 hours per line were saved. |
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| Automated Pie Line Refurbishment |
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| Client: Entemann's Bakery, Bay Shore, NY |
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| System Summary: 1 - PLC5-20, 1 - SLC500 1 - PanelView 1000, 100+ I/O |
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| Description: Automated Pie Line from oven to cooler. The system controls had to be completely replace after a major fire. All the control wiring diagrams and documentation were lost. BIT provided engineering, design, installation for the new system controls for this (custom) equipment after it was rebuilt. Equipment setup and Product selection is configurable through the PanelView. |
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| Results: The project engineering BIT provided helped the plant get the line running ahead of schedule and under budget. |
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| Bulk Handling System |
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| Client: Country Home Bakery, Atlanta, GA |
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| System Summary: 1 - PLC5-40, 1 - PLC5-30, 1 - PLC5-20, 4 - SLC500s, 12 - PanelView 1200s, 1500+ I/O |
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| Description: Automated Bulk handling system including 3 types of flour with CO2 cooling, liquid sugar, oil, cream yeast and water. The system controls the drawing of all the ingredients and the complete cream yeast system, the batching of the ingredients to 12 mixers. The batching and mixing system is operated by a PRIMS system. |
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| Results: Increased yields by 5%, 20% reduction in batch cycle times, and 100% conformance to batch specifications. |
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| Plant Batching System |
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| Client: Bucknell Bakery, Atlanta, GA |
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| System Summary: 6 PLCs 300+ I/O |
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| Description: Bulk System: Flour, HFCS, Corn Syrup, Water, CO2, 2 Horizontal Mixers; Fruit Cook System: 3 Cooking Blenders, 3 Cook Kettles, 2 Liquefiers, 1 Refrigerated screw feeder; Custard Cook System: 1 Continuous Mixer, 3 Surface/Scrape heat exchangers |
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| Results: A completely integrated system that increased yields by 5%, 10% reduction in batch cycle times, and 100% conformance to batch specifications, and reduction in operator errors. |
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| Plant Monitoring System |
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| Client: Holsum Bakery, Phoenix, AZ |
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| System Summary: 3 PLC 5, 16 SLC 500, 1500 I/O |
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| Description: The Pro-MACS system monitored the entire plant consisting of the Bulk Ingredient System, Liquid Brew and Cream Yeast System, a Bread Line, Roll Line and a Pan Storage and Retrieval system. |
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| Results: The savings in downtime due to the automated diagnostics reduced the downtime. |
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| Plant Batching System |
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| Client: Holsum Bakery, Phoenix, AZ |
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| System Summary: 1 PLC 5/80, 1 PLC 5/40, 3 SLC 500 400 I/O |
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| Description: Bulk Flour, HFCS, Corn Syrup, Water, Cream Yeast, Minor Ingredient system, 2 Horizontal Mixers, 1 Continuous Mixer, Brew System, Nutrient System. |
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| Results: Increased yields by 5%, 20% reduction in batch cycle times, and 100% conformance to batch specifications, and reduction in operator errors. |
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| Chocolate Coating Batching and Process System |
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| Client: Hershey Plant, Robinson, IL |
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| System Summary: 1 - PLC5-30, 80+ I/O |
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| Description: Bulk system, HFCS, Water, Minor Ingredient system, Milling System, 1 Horizontal Mixers. |
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| Results: 100% conformance to batch specifications and reduction of operator errors. |
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| Plant Batching System |
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| Client: PJ Foods, Gilbert, AZ |
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| System Summary: 2 SLC 500, 50 I/O |
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| Description: Bulk Flour, Water, Yeast, Salt, Oil, Sugar, Refrigeration, 1 Horizontal Mixer |
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| Results: Increased yields by 5%, 10% reduction in batch cycle times, and 100% conformance to batch specifications and reduction in operator errors. |
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| Plant Batching System |
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| Client: Vieira's Bakery, Newark, NJ |
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| System Summary: 2 - SLC500s, 3 - PanelView 1000, 100+ I/O |
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| Description: Bulk Flour, Water, Oil, 6 Vertical Mixers |
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| Results: Increased yields by 5%, 10% reduction in batch cycle times, and 100% conformance to batch specifications and reduction in operator errors. |
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| Plant Monitoring and Systems Integration System |
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| Client: Carlisle Foods, Carlisle, PA |
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| System Summary: 28 SCL500, 500+ I/O |
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| Description: This new donut plant consisted of 4 production lines. The project entailed writing integration specifications for the machine vendors and reviewing the designs and programs of their electrical controls. The various control system PLC required additional interface programming. |
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| Results: Through the efforts of BIT the plant started up on time and within budget. |
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| Automated Bread Line |
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| Client: IJ White Customer, PA |
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| System Summary: 2 - Square-D PLC, 2 - computer interfaces 400+ I/O |
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| Description: Automated Bread Line from makeup equipment, spiral proofers to oven and spiral coolers, including pan and basket loading systems. The system controls the product setup of various equipment and process variables. Product menu selection and scheduling is configurable through the computer terminals. |
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| Results: Through the efforts of BIT the plant started up on time and within budget. |
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| Automated Pastry Line |
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| Client: Entemann's Bakery, Miami, FL |
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| System Summary: 2 - PLC5-25s, 2 - PanelViews 1400, 900+ I/O |
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| Description: Automated Pastry Line from mixing, sheeting makeup equipment, spiral proofers to oven. The system controls the product path and setup of various equipment and process variables. Product menu selection and scheduling is configurable through the PanelViews. |
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| Results: This system reduced change over time by automatically starting and converging the new product runs into the various conveyor paths and production equipment. The increase in production was 200% from a standard production line automation configuration. |
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| Large Multi Product Donut Line |
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| Client: Entemann's Bakery, Bay Shore, NY |
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| System Summary: 1 - PLC5-30, 4 - SLC500s 1 - PanelView 1000, 400+ I/O |
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| Description: The first automated Pastry and Donut integrated Line to produce 3 types of donuts and a pastry simultaneously from fryer to packaging. The system controls the product path and setup of various equipment. Product menu selection and scheduling is configurable through a Pro-MACS terminal. Failure notification via voice over a PA speaker reduced downtime to a bear minimum. |
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| Results: This system reduced change over time by automatically starting and converging the new product runs into the various conveyor paths and production equipment This line produced twice the volume of previous designed lines. |
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| Automated Panless Pastry Line |
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| Client: Entemann's Bakery, Bay Shore, NY |
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| System Summary: 2 - PLC5-30, 3 - SLC500s 1 - PanelView 1000, 400+ I/O |
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| Description: The 1st Panless Automated Pastry Line from sheeting makeup equipment, spiral proofers to oven. The system controls the product path and setup of various equipment and process variables. Product menu selection and scheduling is configurable through a Pro-MACS terminal. Failure notification via voice over a PA speaker reduced downtime to a bear minimum. |
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| Results: This Pan-less system eliminated the need for pans, therefore it did not require depanners, and pan washers - also the personnel required handle the pans. This line produced 75% more volume of previous designed lines. |
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