Improving formulation accuracy and product grading in food processing
A potato processing manufacturer required an automation solution to support the production of specialty potato products. The project focused on the Wet Preparation stage, where precise formulation is essential, as well as supporting systems responsible for bulk potato handling and grading operations. With a re‑design of the automation layer, Contec delivered ensured not only reliable process control and operational transparency but also consistent product quality.
Delivered Solutions:
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Automation of Wet Preparation processes
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Precise control of water and ingredient dosing and mixing
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Alignment with site-specific electrical standards
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Automation of tote systems for bulk potato handling
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Integrated grading systems for quality, size, and shape sorting
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Standardized control using Rockwell PlantPAx 5
The challenge
Ensuring accuracy and consistency across multiple processing stages
The Wet Preparation phase requires accurate mixing of water and raw ingredients to achieve consistent product formulation across multiple variants.
At the same time, the facility required automation of additional production stages, including bulk potato handling and grading operations. The grading process plays a critical role in sorting potatoes based on size, shape, and defect detection while maintaining high production throughput.
The challenge was to control these interconnected processes within a unified automation system, ensuring accuracy, reliability, and clear operational visibility.
Our approach
Implementing a standardized manufacturing control architecture
Contec implemented the solution using Rockwell PlantPAx, ensuring a standardized and scalable control environment.
Control logic was developed in Studio 5000 for multiple ControlLogix PLCs, enabling coordinated operation of Wet Preparation and supporting systems. The solution ensures precise dosing and stable mixing conditions throughout the process.
Operator interfaces were developed in FactoryTalk View SE, providing real-time visibility into system status, process parameters, and operational events.
The system also integrates tote handling for bulk storage and transport, along with automated grading processes to ensure consistent product sorting.
By consolidating all processes within a single architecture, the solution improves maintainability, operational efficiency, and readiness for future expansion.
