Integration of a New Production Line

Context

The client wanted to integrate multiple, diverse pieces of equipment into their Granby facility to commission on a new R&D production line. These are new products intended to enter the Canadian market, based on a concept already established in the United States.

Mandate

A first pre-engineering phase aimed to define the scope and deliverables for both the electrical contractor and PCI’s technical team in electrical engineering, machine safety and PLC / HMI integration. During the engineering and integration phase, PCI was responsible for commissioning the packaging equipment for the new production line. PCI also handled the electrical installation and coordinated the IT integration of the new line with MES and SAP systems.

All work had to be completed within a 16-week schedule, targeting full commissioning the line ahead of the official production launch for a strategically targeted client identified early in the project.

Task performed

o Continuous coordination with the client and supervision of the electrical contractor and the industrial IT contractor to ensure the quality of the work.
o Completion of risk assessments for 5 machines and 4 conveyors.
o Development of functional descriptions and safety‑function diagrams.
o Upgrading and compliance of multiple pieces of equipment.
o Preparation of safety validation protocols and reports for the production line.
o Design of the control architecture, network, and electrical schematics.
o Electrical plans for various sub‑equipment.
o Support for the mechanical design of guards for two machines.
o Programming and integration for equipment modernization or the addition of new machines and sub‑equipment.
o Integration of interlocks, alarms, injection‑rate control, and “cut‑off” optimization.
o Development of HMI screens according to client standards (quality sampling, washing, interlocks/alarms, production, and fruit injection).

Tools and methods used

o SICK Scanner: SOPAS ET
o Electrical: SeeElectrical
o Allen‑Bradley PLC: Studio 5000
o Allen‑Bradley HMI: FactoryTalk Studio ME
o Markem Coder: Colos
o Videojet Printer: Clarity

You can access the project sheet in PDF format by clicking here.