machine where it is then inspected and shipped.
“With more than 11 machines required for
our production process, we couldn’t just turn
each OEM loose without clear specifications and
an overall integrated design architecture,” said
Williams. “If we had, we would have had to learn
several types of PLCs and HMIs, and stock sev-
eral varieties of the same part for repairs.”
In addition to standardized specifications,
King’s Hawaiian wanted a plant that its own
staff could easily maintain and troubleshoot. “I’m
a big supporter of ensuring a plant can support
itself as much as possible,” Williams said.
In less than a year, the company had to specify and procure equipment from more than seven
suppliers, integrate it and test its reliability to
meet production volumes of 8,000 pounds of
bread per hour.
Williams worked with his team and Bachelor
Controls Inc. (BCI), a Rockwell Automation
Solution Partner, to create an architecture that
would enable King’s Hawaiian to meet its short-term goals of getting the equipment up and
running to open the plant on time, while laying
the groundwork for information gathering and
sharing throughout the enterprise.
“BCI put a lot of emphasis on front-end design
and forced me to be a better customer,” Williams
said. “They made us work hard to answer
important questions up front so they could pro-
vide a return that was closer to what we actually
wanted versus what we started with.”
As the integrator on the project, BCI gathered
the controller and human-machine interface
(HMI) requirements from each OEM and wrote
an overall specification standardized on the
Rockwell Automation Integrated Architecture™
system. BCI then worked with Rockwell
Automation to validate the system’s design.
“We wanted to establish a common configuration for the OEMs so that everything would connect easily and communicate well,” said Rusty
Bailey, Memphis office branch manager, BCI.
“We also understood the bigger picture: King’s
Hawaiian needed to be able to monitor its pro-
cess across the enterprise and make intelligent
decisions to increase production efficiency.”
BCI directed all the OEMs to use the Allen-
Bradley® ControlLogix® programmable auto-
mation controller (PAC) featuring an integrated
platform for scalable motion and machine con-
trol in a single programming environment. This
integration provides King’s Hawaiian with fewer
spare parts to maintain, while the control plat-
form’s openness helps ensure easy integration
with third-party components.
The specifications also required a standardized approach to the visualization and
information software used on each machine.
Factory Talk® View Site Edition software is
used on each machine to simplify applica-
tion development and training — a crucial
time-saving element on a fast-turnaround
project. BCI specified the Site Edition version
of the software to make it easier for the King’s
Hawaiian team to manage upgrades on its
own long-term. Each version of the visualiza-
tion software is then running on Allen-Bradley
Industrial Environment Computers with a sep-
arate touch screen and solid-state hard drive
to protect the system and reduce the number
of failures in the future.
For the packaging machines, BCI specified