Optimizing Pellet Production with Advanced Analytics
Interstates recently partnered with a leading animal feed producer to implement a golden batch analysis system with the goal of optimizing the client’s pellet production processes. The project involved leveraging the AVEVA PI system to capture, analyze, and visualize critical operational parameters, resulting in significant improvements in throughput and efficiency.
Achieving Real Results
Increased throughput by optimizing production parameters.
Reduced inefficiencies with real-time feedback and actionable insights.
Improved data accuracy and consistency.
Enhanced decision-making capabilities through detailed visualization tools.
Challenges
- Data Integration Complexity: Integrating AVEVA systems with Microsoft SQL Server threatened to disrupt the seamless data flow required for visualization.
- Real-Time Analysis Requirements: It was imperative to develop a system capable of providing real-time feedback to operators so they could make immediate adjustments.
- Operator Engagement: Operator feedback needed to be prioritized in order to refine the system and ensure practical usability.
- Scalability: The system design had to include scalability for future deployment across other sites and production lines
Solution
Interstates developed a golden batch analysis system utilizing the AVEVA PI system, which involved creating event frames in the Pi Asset Framework to record pellet runs and capturing the highest throughput within a stability window. This system provided real-time feedback to operators, enabling them to continuously optimize production processes. Interstates’ integrated solution included automated data collection, aggregation, and visualization using FactoryTalk Historian, Pi Asset Framework, and Pi Vision.
Return on Investment
- Increased Throughput: Optimization of production parameters led to consistently higher product output.
- Reduced Inefficiencies: Real-time feedback allowed for immediate adjustments, minimizing downtime and process errors.
- Improved Data Accuracy: Enhanced data integration provided consistent and reliable metrics for decision-making.
- Enhanced Decision-Making: Detailed visualizations and actionable insights enabled operators and stakeholders to make better choices and improve strategic planning.