Project Overview

The project consisted of installing a new 1200 bottle per minute line from the de-palletizer to the final casers. Dahlen Systems, Inc. primary role included the design and purchase of the electrical and controls systems, the creation of a process narrative, programming the control system, plant checkout, start-up and operator training.

Dahlen Systems, Inc. also provided overall construction management for the project. The construction management included doing a feasibility study, preparing documents in order for the customer to obtain funding, machinery procurement, etc.

The plant needed the ability to vary the speed of the bottling line based on the filler speed. Each piece of equipment controlled by our system had an automatic mode and a manual mode for maintenance and testing. All of the systems function in full automatic with minimal operator intervention.

Project Costs

Project Total: $4.4MM
Control/Electrical Engineering and Materials: $660K

Controls

Allen-Bradley ControlLogix™ 5500 processor

	3 Racks of IO on ControlNet
	200 discrete points

Allen-Bradley 160 and PowerFlex VFDs on DeviceNet

	3 DeviceNet Networks
	160 Motors
	155 VFDs

Discrete IO on DeviceNet using InterlinkBT

	3 DeviceNet Networks
	30 InterlinkBT Drops

Allen-Bradley PanelView 1000e

	1000 Tags
	5 Main Screens showing a graphical representation of the process
	ControlNet link to controller