Alpla - Arla, Aylesbury

In the Autumn of 2012 ICA were tasked with designing and commissioning the empty bottle supply control system for ALPLA as part of the new Arla dairy built at Aylesbury. This formed part of Isoma Conveyors Ltd contract to supply the hardware.

Phase 1 consisted of 6 lines (with a further 2 lines added in January 2014) each with its own Siemens S7-300 PLC. Safety is controlled via a Wieland Samos unit providing zonal control circuits to PLd across all lines. A further Siemens S7-300 PLC is used as a data concentrator for all the status and control signals for display on the plant HMI’s.

The HMI’s provide line mimics, alarm handling, communication interfaces and logging for all the lines. Separate HMI runtimes are provided on two PC’s, one for report handling and one as an engineering PC.

Conveyor control is provided by Siemens G120d drives meaning that the control panels could be greatly reduced in size as all the VSD control is mounted in the field. Redundancy is provided for network (Profinet redundant ring), power and control supplies to these drives by using ring circuits, meaning a drive can be isolated and removed without affecting the rest of the line.

ICA provided commission engineers to site from May 2013 to March 2014 for phase one and then from January 2014 to August 2014 for phase 2. Ongoing support to site is provided by remote access.

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