UHT Integration & Aseptic Tanks

Context

The client aimed to double the processing capacity of certain ultra-high temperature (UHT) dairy products. To achieve this goal, the project was structured into three phases: increasing heating and cooling capacities (Phase 1), installing new UHT equipment (Phase 2), and expanding storage capacities (Phase 3). The work was carried out in parallel with outgoing production operation, with the dismantling of the old UHT system scheduled once the new one was commissioned.

Mandate

PCI was responsible for electrical integration engineering (power and control), PLC programming (Siemens Step 7) and SCADA (WinCC). The scope of work covered the entire project cycle: preliminary engineering, deign, manufacturing, installation supervision, commissioning and post-production support.

Task performed

o Development of the high-level control diagram for the three project phases (preliminary engineering)
o Support to the client during technical meeting with suppliers
o Drafting of electrical installation specifications
o Design and manufacturing of seven power and control panels
o Modification of more than ten existing panels
o Update of the plant’s network architecture
o Integration of machine safety system from new equipment into existing circuits
o Writing of programming guides and documentation for new sequences
o Programming of PLC’s (Siemens Step 7) and SCADA system (WinCC)
o On-site supervision of electrical work

o Execution of tests, simulation and equipment commissioning

Solutions provided by PCI

o Use of As-i actuators and instrumentation to minimize panel footprint
o Design of a legal enclosure supporting both UHT systems operating in parallel
o Precise product inlet control using cascading PID loops
o On-time equipment delivery despite supply chain disruptions
o Support for integrating Rockwelll technology into object-oriented WinCC

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