Manufacturing control improvements to streamline operations and unify machine interfaces
As production environments evolve, maintaining consistent automation standards across equipment becomes essential for efficiency and long-term maintainability. Contec supported a plant-based food manufacturer in implementing several targeted improvements within its production environment to simplify equipment configuration and standardize machine control.
The project focused on optimizing hygienic design, improving interoperability between packaging machines, and introducing a consistent operator interface across the production line. By building on the existing Siemens automation platform and AVEVA visualization environment, the enhancements helped streamline operations while supporting future integration initiatives.
Project Highlights:
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Simplified plant equipment configuration aligned with hygienic design principles
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Reduced complexity of Cleaning-in-Place (CIP) procedures
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Standardized communication between packaging machines using PackML
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Unified machine control interface within the ArchestrA HMI platform
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Improved diagnostics, monitoring, and operational consistency
The challenge
Balancing operational improvements with stable production
Over time, variations in equipment configuration and machine control can increase system complexity and make operations harder to maintain. In this facility, several opportunities were identified to simplify the installation while aligning automation practices with modern industry standards.
The packing line also required more standardized communication between machines to improve diagnostics and enable better production monitoring. At the same time, operators needed a clearer and more consistent interface for machine control.
All developments had to be implemented within the existing automation infrastructure while maintaining stable production operations.
Our approach
Targeted automation improvements across three operational areas
Contec implemented three focused improvement projects within the existing automation environment, which is based on Siemens S7-400 PLC systems combined with an AVEVA visualization and historian platform.
The first improvement addressed hygienic design by simplifying the plant equipment used for Cleaning‑in‑Place (CIP) operations. The reduction in product variety made it possible to rationalize CIP configurations, resulting in an installation that is easier to manage and operate. This streamlined approach supports hygienic design principles while reducing cleaning time and cleaning‑fluid consumption.
The second enhancement introduced PackML (Packaging Machine Language) tags on the packing line. PackML provides a standardized communication structure between packaging machines, allowing consistent machine states and improved machine-to-machine integration. This also boosts diagnostics and enables more structured performance monitoring.
The third initiative focused on standardizing filler machine control within the Archestra Human-Machine Interface (HMI) environment. By integrating filler controls into the Archestra platform, operators gained a unified and intuitive interface for monitoring and controlling machines. This reduces training requirements and ensures consistency in machine operation across the production line.
