Data Analytics: Driving Innovation in Pellet Manufacturing
Interstates recently completed an analytics project for a prominent animal feed producer that demonstrated the transformative power of data-driven solutions. The project was focused on implementing a “golden batch” analysis system aimed at optimizing the client’s pellet production processes by identifying the best operational parameters for various formulas.
The client’s primary goal was to better utilize process data to identify opportunities for process improvements. According to Dan Riley, Analytics Manager at Interstates, “Our team worked closely with the client to define what success looked like for them, which involved pinpointing the conditions under which their production process achieved maximum efficiency without encountering issues like equipment plugging or instability.”
Mapping Data for Functional Improvements
Interstates’ analytics team delivered a comprehensive solution that included research, evaluation, design, and integration services. This project involved mapping data from AVEVA systems with relevant Microsoft SQL Server lookup tables and developing a functional user-requirements document that describes the client’s system architecture, data connectivity, and specific triggers for batch analysis.
The project scope included documenting use cases, developing a proof of concept for golden batch analysis, and deploying the solution to the Pi Historian at one of the client’s key production sites. Interstates’ solution was designed to grow and change according to the client’s needs, allowing for future expansion across multiple sites. “We designed this project with scalability in mind,” says Riley. “The client has already asked us to propose on deploying this system to seven additional sites next year.”
Fine-tuning for a Golden Batch
One of the primary challenges of this project was identifying and capturing the optimal operational parameters for different pellet production formulas to maximize throughput and efficiency. Convincing the client that the proposed architecture would not only work but was also the most optimized for performance was another hurdle. “We spent a significant amount of time collaborating with the client’s stakeholders weekly to answer questions and refine the technical aspects of the solution,” Riley says.
Interstates developed a golden batch analysis system that utilized AVEVA PI to collect, analyze, and visualize critical process parameters. “The concept of the golden batch for this client was focused on finding the best-performing production run with consistent stability across key metrics like temperature, steam, and motor load,” Riley explains. Event frames in the Pi Asset Framework recorded each pellet run, capturing the highest throughput within a stability window. The system automatically updates and stores the best critical parameter values for each recipe, providing operators with real-time feedback in order to optimize production.
Real-time Feedback Reduces Inefficiencies
Interstates’ successful implementation of the golden batch analysis proof of concept resulted in significant improvements in pellet production efficiency. The client now benefits from increased throughput, reduced operational inefficiencies, and enhanced decision-making capabilities. Real-time feedback and detailed visualization tools allow the client’s operators to continuously optimize the production process, setting a foundation for future scalability and deployment across other sites.
This initiative gave the client quantifiable benefits such as increased throughput by optimizing critical parameters for each recipe, reduced operational inefficiencies through integrated analytics, and real-time feedback. It improved data accuracy and consistency with automated data collection and analysis. Additionally, decision-making capabilities were enhanced because the client now has detailed visualization capabilities and can analyze historical production runs. Looking ahead, this animal feed client will be able to scale their golden batch analysis system to other production lines or sites, replicating the benefits across their organization.