Scalable production and integrated control for high-capacity snack manufacturing
A major snack production facility expanded its operations with the installation of a new, high-capacity production line. The sixth line at the site was designed to increase throughput, enable flexible product manufacturing, and support modern packaging and traceability requirements.
Contec delivered an end-to-end automation and digital manufacturing solution, integrating process control, packaging systems, and production data into a unified environment. Built on a modern Rockwell PlantPAx architecture, the solution enables synchronized operations, real-time monitoring, and scalable production growth.
Implementation Overview:
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Installation and automation of a new snack production and packing line
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Integration of processing and packaging systems within PlantPAx 5
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Standardized HMI visualization for full line control
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Improved traceability of components and system structure
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PackML-based integration of packaging equipment
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Industrial IT infrastructure supporting production data management and traceability
The challenge
Expanding production capacity while maintaining standardized automation
The facility needed to increase production capacity while introducing new product variants and maintaining consistent automation standards.
The main challenge was integrating multiple OEM machines, processing systems, and packaging equipment into a unified control architecture without compromising reliability or performance.
At the same time, the solution had to support production monitoring, historical data storage, and alignment with global standards, including sustainability requirements for packaging.
Our approach
Implementing a unified automation and industrial IT architecture
Contec implemented a centralized control platform based on Rockwell ControlLogix PLCs, developed in Studio 5000 following PlantPAx®5 standards, ensuring coordinated operation across processing and packaging systems.
Electrical engineering, including power and network design, was developed in EPLAN P8, enabling seamless integration of OEM equipment with plant systems.
Operator interfaces were built in FactoryTalk View Enterprise, with over 200 standardized HMI screens providing real-time visibility into machine status, alarms, and production performance.
Packaging systems were integrated using PackML and the Contec CPIP standard was used, ensuring consistent communication and operation across OEM machines.
The industrial IT layer included virtualized environments and data platforms such as SQL Server, VMware, FactoryTalk Historian, AssetCentre, and Transaction Manager, supporting data collection, traceability, and performance analysis.
Additional scope included implementation of a cause-and-effect safety matrix, support for safety validation, and integration of a system for automatic removal of defective products.
The project covered the full lifecycle, from engineering and design to commissioning and operational qualification.
