Complete control

The system also has advantages when a new product is launched or a recipe changed. Previously, this would have meant a period of shutdown while new operator stations were installed; now, the mobile ones can simply be wheeled to different areas to keep an eye on the important process steps. ’Because of the wireless network, we do not need to systematically invest in new control stations, even if the production of new products requires a change to the plant equipment or layout,’ said Novartis automation expert Patrick Borschert.

The new systems have also helped Novartis to diversify production at Huningue. As well as the single-chain Xolair molecule, it is now able to produce more complex, multi-chain molecules, such as monoclonal antibodies and immunosuppressives.

Keeping operators in touch with the process is vital, wherever their workstations are, and the key to this is workable human-machine interfaces (HMIs); these are standard in larger facilities, but still not widespread in smaller operations. This was recently a problem for Nicholl Food Packaging, which makes foil containers and disposable packaging for the catering industry. Based in Cannock, Staffordshire, the company found that the HMIs on its electrically controlled presses were failing, probably because of the machinery’s vibration.

’We spent a long time trying to rectify the problem but were eventually left with no alternative but to look for replacements,’ said engineering manager Joe Taylor. However, the PLC system to which the HMIs were interfaced did not need to be replaced, so the new HMIs had to be fully compatible to allow Nicholl’s operators to continue monitoring the processes and keep them running.

“Some managers are unaware how simple it is to incorporate HMIs into the plant’s automation”

To provide the solution, Taylor turned to Schneider Electric and its Magelis HMI range, which has an open connectivity function that allows it to work with legacy control systems. ’HMIs are fast becoming an essential part of plant management,’ commented Schneider Electric’s Dave Collier.
’They are now commonplace in most large production lines, but new compact terminals are making them ideal for smaller applications too. However, some managers, despite being keen to utilise the benefits of this technology, are unaware of how simple it is to incorporate the system into the plant’s existing automation,’ he added.

For Nicholl, the key ability of the Schneider HMIs was to mimic the way that its previous systems had worked. ’Our previous HMIs had physical function buttons, whereas the Schneider Electric products have touch screens,’ explained Taylor. ’However, we were able to configure the screen to match exactly the layout that our operatives were familiar with, which meant that we did not have the time or inconvenience of retraining to the new models. That made it a very smooth transition for us.’