1. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Tweet About It Using #PSUG Flexible Batch Solution Simplifies Formulation and Recipe Changes Cybertrol Engineering Tim Barthel, Lead Engineer Doug Jaques, Technical Director November 2014

2. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

3. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

4. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Cybertrol Engineering Overview  Founded 1996  50 Employees, 34 engineers  Rockwell Automation SP (Control/Process/Information)  Automation and IT Services  UL508 Panel Shop  Thousands of projects for 400+ clients

5. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

6. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Abstract  New Ice cream manufacturing facility  Flexible batching with over 100 source/batch/destination tanks  Virtualized/fault tolerant server environment  Corporate formulas imported into site specific recipes  FactoryTalk ® Batch utilized for flexibility  Interface into FactoryTalk Batch allows formulation and recipe changes without programming changes

7. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG End User Overview  New plant built to be largest in the world  Global food manufacturer  400+ employees at new facility  Ice cream manufacturing facility  Four ice cream filling lines with three freezers per line  Twelve novelty lines and expanding  Four batching cells – each with three individual batching units  Corporate recipe management interface required  2000+ mix-proof valves – arbitration between production and cleaning critical  Robust infrastructure needed for 24-7-365 operation

8. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

9. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Robust Plant Floor Controls  Operation runs 24-7-365  Minimal maintenance requirements  Programming standards  Ease of installation  Localized Troubleshooting

10. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Robust Controls – Design Solution ControlLogix ® PAC’s – EtherNet/IP IO  1756-L7x PAC Controllers  CENTERLINE ® 2100 MCC’s - PowerFlex ® VFD’s  1734 Point I/O  EtherNet/IP field instruments  GuardLogix ® EtherNet/IP

11. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Batching Process Functionality  Accurate use of raw ingredients with different analytical values to produce the highest quality product with the least cost formulation of ingredients on hand  Multiple source tanks with various raw ingredients to multiple storage destinations throughout the batching process utilizing mix proof valve arrays  High volume output with minimal workforce

12. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Batching Process – Design Solution  Direct and seamless integration with the ControlLogix platform

13. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Batching Process – Design Solution  Arbitration of device paths controlled at server and controller level to help ensure product and cleaning solution does not intermix  Process and cleaning operation controlled through FactoryTalk ® Batch

14. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Recipe Formulation Functionality  Corporate recipe structure that needed to be integrated into the batching formulation without engineering or programmer intervention  Frequent formulation changes from R&D – daily uplinks to corporate database

15. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Recipe Management System Integrated with FactoryTalk Batch - Solution  Interface to FactoryTalk Batch utilizing Microsoft ® SQL for recipe management and scheduling

16. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Accurate Reporting  Reporting ingredient usage – critical for inventory control  Reporting of cleaning cycles – critical for proper verification of quality  Simplified access with additional data

17. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG FactoryTalk Batch Event-based Reporting - Solution Batch Reporting

18. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG FactoryTalk Batch Event-based Reporting - Solution CIP Reporting

19. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG FactoryTalk Batch Event Based Reporting - Solution Full Batch Event Reporting

20. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Zoned Safety Across Many Areas  Many rooms  Common “safe zones”  Large distance between areas

21. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG GuardLogix ® Safety - Solution  Safety  GuardLogix allows logical zoning for safety utilizing Ethernet/IP Zone B Zone A STOP Okay to RUN Ethernet infrastructure in place STOP Activated

22. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Design Challenge – Proper Server Infrastructure  Server system required for operation  FactoryTalk Batch/SQL  Isolation of applications  Redundancy  Backup and Recovery

23. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Virtualization with Fault Tolerance - Solution  VMware ® virtual server infrastructure  High Availability/Fault Tolerance  Shared storage and scheduled backups

24. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

25. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – The S88 Model Design Strategy  The Instrument Society of America S88 Batch Protocol Standards provides a framework to define process and automation hierarchy. S88 compliance also provides an organized methodology in the use of ordered sets of information using defined terminology.  The overall process consists of one or more process stages.  Each process stage consists of one or more process operations that in turn may consist of one or more process actions.  The control of the process is similarly described as a procedure that is comprised of one or more unit procedures. Each unit procedure may contain one or more ordered operations that each may contain one or more ordered phases.

26. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – The S88 Model Design Strategy  Physical Area Model in FactoryTalk Batch developed from P&IDs as well as operational requirements.  One-to-one correspondence between FactoryTalk Batch equipment modules and Phase Manager phases in PAC.  Phase operation conforms to S-88 state model. =

27. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – The S88 Model Design Strategy  Batch sequence is controlled from the FactoryTalk ® Batch server.  Sequence changes are made without any program changes in the PAC.  Recipe format is Sequential Function Chart (SFC).  Easy to create and/or follow complex sequences.

28. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – Installation  New facility – plant and production lines came up piece by piece.  System built for full production – each cut in had to be done while previous lines in operation stayed running  Plant-wide Ethernet in place first with network interface panels for all areas installed for future phases for communication infrastructure  Batch area model designed with all units, and phase manager programming in PLC in place to allow for cut in

29. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Design and Implementation – Production Startups  Recipes not available for scheduling until released for production within FactoryTalk ® Batch Recipe Editor and web application

30. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Agenda Success Story System Design and Implementation Engineering Decisions Abstract / End User Overview Cybertrol Overview

31. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Success Story  Now is largest ice cream plant in the world  Easy to use scheduling and recipe management allows even new operators to make batches properly  Interlocking through FactoryTalk Batch and ControlLogix protects operation from production and chemical mixing  Highly available system is supported remotely

32. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Success Story You Scream I Scream We ALL Scream For:

33. Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Tweet About It Using #PSUG Learn more at www.cybertrol.comwww.cybertrol.com Tim Barthel tbarthel@Cybertrol.com Phone: (763) 519-7833 November 2014