Daim commissioned adi Group to provide a number of potential upgrade solutions, including a complete electrical, control and software re-write as an option, which would see the entire legacy control system including all control panels replaced and the entire process operational interface streamlined.

A crucial requirement for the company was to remodel the automation process in to the International S88 Batch Standard. This provides a common method of defining the process plant in automation terms to give greater consistency across the plant processes. The S88 standard also provides a a suitable platform for the new wireless based track and trace system, which tracks raw ingredients through to finished product. Considerable manual effort will be reduced and the automated batch reporting will further improve efficiency and provide reliable product traceability.

The complete solution provided by adi Group and eventually chosen by Mondelez was based on a direct exchange of the old control panels for  new, thus enabling existing field cabling to be re-utilised as necessary without time consuming re-laying of cables and  avoiding unnecessary downtime. The new technology architecture meant that many cables could be rendered obsolete and therefore considerable termination time was saved during the shutdown which all helped to ensure the ambitious shutdown window was maintained.

High demand for the product meant that the planned stoppage time could not be exceeded without directly affecting deliveries to Daim’s customers. In addition to the careful design and planning undertaken to help streamline the installation effort during the shutdown, adi’s solution underwent extensive  testing to make certain that it was fit for purpose and could be commissioned with a high degree of confidence that when the time came to start up, the plant operated as seamlessly as possible.
Furthermore, to maximise production efficiency post start up, it was imperative that Daim’s staff were also trained prior to installation. Line operators were given the chance to work with the new system and hone their skills in a simulated environment, ready for when the system went live.
The replacement of the entire control system was completed within the four week shutdown window and early production results are showing an overall increase in production efficiency at the Daim production process.

Further to this, adi Group now offers on-going support to Mondelez through a servicing and maintenance contract, which includes remote technical support if and when necessary.