Rockwell Automation recently supplied South African Breweries’ (SAB) first fully automated and networked EtherNet/IP-based control system for its new maltings plant in Alrode, Gauteng. The new control system will integrate traditionally disparate malt production processes into a single networked EtherNet/IP-based solution to provide plant-wide visibility and actionable data from the malting plant’s production floor to SAB’s top floor. The new maltings plant will account for more than half of the breweries’ South African and Namibian malt production when fully commissioned early in 2016.

In a move to support the local economy, the new maltings plant, situated next to the company’s existing brewery in Alrode, will increase local malt production from 60 to 90%, reducing the financial impact of imported malt. The plant will greatly enhance the production capabilities of its predecessor by increasing malt production from 42 000 to 150 000 tons per annum.

SAB contacted Rockwell Automation to design a fully automated and networked EtherNet/IP solution for the maltings plant, a first for SAB. The solution Rockwell Automation implemented in the maltings plant connects all data from the plant floor to the rest of the SAB enterprise, transforming the plant into a Connected Enterprise.“By converging operations technology and information technology, we enable SAB secure access to operational, business and transactional data to improve the malting plant’s supply chain, economic and sustainable performance,” explains Adrian van Wyk, Business Manager for Power and Components, Rockwell Automation, Sub-Saharan Africa.

All devices and processes within the plant are integrated in a single secure network with dual-port EtherNet/IP-based hardware connected in a Device Level Ring configuration. “This provides a strong future-proof technical solution with high-performance delivery and Network resilience at Device Layer,” comments van Wyk.

 Controlled by Allen-Bradley ControlLogix Controllers and Allen-Bradley Stratix Industrial EtherNet/IP Switches, the Motor Control Centers comprise more than 500 E300 Intelligent Electronic Overload Control Relays, 70 PowerFlex 750 AC Drives and 50 SMC Flex Smart Motor Control Softstarters for motor starting, stopping, control and protection with greater production efficiency delivery.

To address the plant’s energy metering, energy consumption, load shedding and harmonics analysis, Rockwell Automation supplied a range of its Allen-Bradley PowerMonitor metering solutions. Technical partner, MSE, provided all packaged Motor Control Centers distributed throughout the plant to reduce cabling costs.

“The new automated system gives SAB personnel plant-wide control, from plant floor to executive level, via a single, secure integrated EtherNet/IP network,” adds van Wyk. “By enabling secure access to actionable run-time production data, machine diagnostics and automatic fault-finding, SAB gains full visibility of the maltings plant, ultimately facilitating a faster time to market, lower total cost of ownership, improved asset utilisation and enterprise risk management for the maltings plant.”

In order to keep the plant running 24/7, 365, all Motor Control Centre Device Level Hardware are equipped with the Rockwell Automation Automatic Device Configuration (ADC) for automatic self-healing and configuring of replaced componentry. ADC, paired with the Rockwell Automation Device Level Ring network that ensures uninterrupted real-time device communication, provides SAB with greater network resilience and reduces unplanned downtime.

“There is no part of the new plant that isn’t connected; everything is networked on EtherNet/IP,” comments van Wyk. “We’ve used the very latest Control and Motor Control technologies that are not only future-proof, but provide backward capability to ensure SAB’s operations are more productive, sustainable and respond competitively to dynamic market demands on a global level”.

Integration partner, Advansys, is responsible for the integration of all processes and control systems for the plant. Currently running at 70% capacity, SAB Maltings Alrode is set to be fully commissioned early 2016.