Honeywell New Zealand

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					             Honeywell
             New Zealand
             Tom Lewis

             Plant Automation Solutions




Honeywell New Zealand
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                                   Honeywell New Zealand Solutions
     Meadow Lea Foods - Food Solutions

         Company:              Meadow Lea Foods
         Location:             Auckland, New Zealand


         Process:              Manufacturing Margarine, Cooking Oils
                               and processing Dairy Products

         Needs:                Improve Quality & Reduce „Human-Error‟
                               Expand Recipe Selection
                               Automate Reports and provide complete
                               component tracing to meet legislation


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                                                   Honeywell New Zealand Solutions
     Meadow Lea Foods - Process

        Process:               Batch


        Phase 1:               Weigh & Blend
        Phase 2:               Transfer    (holding tanks)
        Phase 3:               Column      (recipe management)
        Phase 4:               Discharge


        Detailed Batch History reports are created during each
        Phase.
        The final product quality and audit report is created at
        the Discharge phase.
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                                                    Honeywell New Zealand Solutions
     Meadow Lea Foods - Automation




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                               Honeywell New Zealand Solutions
     Meadow Lea - Flow Diagram

                                                      Weighing           Lab Recipe
        Product
        Orders                         Scheduling      & Blend            Download



                                                      Transfer to
                Recipe Calculation to Total Volume     Holding
                         (usually 10 tonne batches)

                                                       Column             Auxiliary
                                                      “Cooking”          Processes


      Shipping &                        Storage
                                                      Discharge
      Distribution                    or Packaging

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                                                         Honeywell New Zealand Solutions
     Meadow Lea Foods - Control Solution




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                               Honeywell New Zealand Solutions
     Meadow Lea Foods - Blend Phase Detail




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                               Honeywell New Zealand Solutions
     Meadow Lea Foods - Summary

           •    The Control System solution has been in operation
                for 7 years and keeps on expanding
           •    With the Batch solution, the consistency of recipe
                production, operator effectiveness, and quality
                reporting has improved by 100%
           •    The Batch User Interface means minimum training
                for Operators when introducing new recipes
           •    Batch History has provided essential data for Quality
                reporting, and meeting the strict demands of Food &
                Beverage Regulations in New Zealand
           •    The remote access function improved site support
                and reduced maintenance costs
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                                                 Honeywell New Zealand Solutions
     Cavalier Bremworth - Carpet Solutions

         Company:              Cavalier Bremworth
         Location:             Auckland, New Zealand


         Process:              Manufacturing of high quality woolen
                               carpet, mainly "Tufted" (stitched on a
                               synthetic backing)


         Needs:                Improve Quality, Reduce Waste
                               Improve Efficiency
                               Identify Operating and Machine Problems
                               (collection of statistical data for analysis)
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                                                      Honeywell New Zealand Solutions
     Cavalier Bremworth - Process

         Process:              Continuous - Semi-Batch


         Phase 1:              Winding


         Phase 2:              Beaming


         Phase 3:              Tufting


         Each phase is executed as a batch, and is tagged with
         an ID number, so quality tracking is possible.
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                                                 Honeywell New Zealand Solutions
     Cavalier Bremworth - Winding




The wool arrives at the                   Wool
factory in large bales

The wool is unloaded and
pre-treated
                                                 Winders
64 Winders spin the wool
at 200kg / hour
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                               Honeywell New Zealand Solutions
     Cavalier Bremworth - Beaming
From the winders, the
wool is fed into the
beaming machines.

                                1x Beam, holds about
                                500kg of wound wool.




                 200
             Winder
           “Cones”




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                               Honeywell New Zealand Solutions
     Cavalier Bremworth - Tufting
From the beams, the wool
is fed into the tufting
machines, producing the
finished carpet.

                               Tufting Machine




8 Beams

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                                            Honeywell New Zealand Solutions
     Cavalier Bremworth - Control Solution




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                                Honeywell New Zealand Solutions
     Cavalier Bremworth - Batch Control

           •    Batches are specified from the Planning Department, and
                downloaded to the PlantScape system.
           •    Operators login before operating machines. The Batch ID
                is checked, and the operator productivity and machine
                efficiency is tracked.
           •    Each machine has a selection of “downtime” codes for
                tracking machine performance. Statistical data is
                reviewed to determine problem machines, and focus on
                reducing bottlenecks.
           •    Each machine has its own "Batch Control" program that
                is designed to guide the operator when starting/stopping
                batches.
           •    Each “Batch Control” program has logic steps and plant
                feedback to minimize error and maximize productivity.
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                                                    Honeywell New Zealand Solutions
     Cavalier Bremworth - Carpet Solutions




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                                Honeywell New Zealand Solutions
     Cavalier Bremworth - Carpet Solutions




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                                Honeywell New Zealand Solutions
     Cavalier Bremworth - Summary

           •    The Control System solution has been in operation
                for nearly 6 years and keeps on expanding
           •    Cavalier Bremworth achieved excellent results:
                   – Reducing the number of operators and
                     maintenance staff by 50%
                   – Increasing productivity by over 150% (by
                     identifying machine downtime trends, focusing
                     on Operator training, and providing operators
                     with productivity information).
                   – This is a unique system, tailored for this
                     application. But the principles can be applied to
                     any industry.
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                                                    Honeywell New Zealand Solutions