Doubling Production Through Industrial Automation & Analytics
Country Maid, based in West Bend, IA, has long been known for its Butter Braid® pastries and cake rolls, which are popular fundraising products. Over the past 10+ years, Interstates has collaborated with Country Maid to overcome production capacity and efficiency challenges at its manufacturing plant. For this project, Country Maid wanted to increase production, reduce labor, and boost efficiency in order to meet increasing consumer demand. High-tech automation solutions provided by Interstates helped Country Maid meet these goals, significantly improving operations without the need for physical expansion.
Achieving Real Results
Increase Production Capacity: Doubled output without additional labor.
Enhance Efficiency: Reduced mixing time by 23% and increased line speed by 14%.
Increase Cost Savings: Saved $120,000 on equipment and reduced labor costs.
Improve Quality Control: Ensured consistent product quality through advanced industrial analytics.
Challenges
- Increase Throughput: Country Maid needed to boost production without expanding the facility. They faced high demand but lacked the space for larger mixers.
- Manual Processes: The existing production process was labor-intensive and prone to inconsistencies. Operators handled everything manually, from batching to data entry.
- Data Collection & Analysis: There was no automated system for tracking production data. Country Maid lacked real-time insights and control over their production parameters.
- Quality Consistency: Variability in product quality due to external factors like temperature caused repeated problems. Ensuring the pastries had consistent texture and quality was difficult.
Solution
Interstates proposed the implementation of the PlantPAx process automation system from Rockwell Automation. PlantPAx includes a portal for visualization, analysis, and reporting, offering the client detailed documentation capabilities and advanced alarm options. The solution also includes a process historian, highlighting production trends.
With PlantPAx, operators can access real-time data on various role-based dashboards. The tool allows them to strategize improvements for each batch based on various parameters such as temperature and dough consistency.
The total solution we provided Country Maid included the following:
- Consultation and Planning: Initial discussions and facility walkthroughs to understand the client’s process and identify improvement areas.
- Automation Implementation: Integration of FactoryTalk batch, View SE, Rockwell power controls, and new controllers.
- Data Analytics: Using FactoryTalk software for real-time data tracking and reporting.
- Efficient Line Setup: Fully automating the existing line and adding a second line without expanding the facility. This comprehensive approach transitioned Country Maid from a manual to an automated production process, significantly enhancing efficiency and output.
Return on Investment
Implementing advanced automation at this facility was transformative for Country Maid’s operations. They experienced substantial improvements in production capacity and operational efficiency. Automation allowed them to meet higher demand without expanding the plant footprint, saving significant construction and engineering costs. Additionally, they achieved more consistent product quality through advanced data analytics, which provided valuable insights for real-time decision-making.
- Production Capacity: Country Maid doubled their output, meeting high demand without additional labor or facility expansion.
- Efficiency Gains: Mixing time was reduced by 23%, and line speed increased by 14%, optimizing overall production processes.
- Cost Savings: The client avoided $120,000 in equipment costs and saved over $45,000 annually in labor costs.
- Quality Control: They achieved consistent product quality through advanced industrial analytics, addressing issues such as temperature variability that can affect dough consistency.