Modernizing sauce production with flexible batch control and recipe management
A seafood processing facility in Kungshamn, Sweden, required a modernization of its sauce production installation. The existing automation platform relied on obsolete hardware and software, limiting flexibility and making it difficult to introduce new recipes or improve production control.
Contec implemented a new control solution based on an ISA-88 batch architecture, enabling flexible recipe management, improved operator guidance, and full integration between production and higher-level systems. The new platform supports more efficient batch execution while improving traceability and control.
Key Project Details:
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ISA-88 compliant batch control system for sauce production
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Migration from Mitsubishi PLC and InTouch HMI to Siemens S7-1500
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Batch execution and visualization using Ignition and Sepasoft Batch
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Integration of recipe, order, and BOM management via CPMS
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Operator guidance during manual dosing to reduce errors and scrap
The challenge
Replacing legacy systems while enabling flexible batch production
The existing sauce production system relied on outdated automation hardware and software, making maintenance increasingly difficult and limiting the ability to introduce new recipes or production variants.
The facility needed a modern platform capable of supporting flexible batch production, including easier introduction of new recipes and production variants.
At the same time, production processes required tighter integration with order management, recipe handling, and BOM validation. Operators also needed clearer guidance during manual dosing to reduce errors and improve consistency.
Our approach
Implementing ISA-88 batch control with system integration
As system integrator and automation expert, Contec implemented a new system based on Siemens S7-1500 PLC technology, programmed in TIA Portal and designed according to the ISA-88 batch standard.
The project began with a feasibility and site study to assess the existing installation and define the requirements for the new system. The legacy control logic from the Mitsubishi PLC and InTouch HMI was reverse engineered to understand the current production functionality.
A high-level electrical design was developed to support the migration from legacy hardware to a Siemens automation platform using Profinet communication.
Batch control logic was implemented using the ISA-88 structure, including phases, equipment modules, and recipe handling. This structure allows flexible configuration of production sequences and simplifies the addition of new recipes.
The HMI layer was implemented using Ignition Perspective, providing modern visualization of batch processes and operator interaction.
Vertical integration with our CPMS system enables production order execution, recipe management, BOM validation, and operator guidance for manual dosing steps. This integration ensures accurate production tracking and improves process traceability.
The project also included PLC and HMI development, system testing, on-site commissioning, and training for the plant’s engineering and operations teams.
