In the highly competitive baked goods manufacturing sector, being prepared is key. Having your process control systems and production lines fully up to date is essential for staying competitive. When a market-leading baked goods and mixes specialist sought to boost productivity, it turned to long-term partner Promtek for a comprehensive solution.
Decades of Partnership and Expertise
The client, a leading UK manufacturer of baked goods and mixes based in the Midlands, operates with family values guiding its approach. With over a century of expertise in flagship baked products and ingredients, unmatched global manufacturing capabilities, and widespread distribution, the company is a global leader in bakery solutions.
Promtek has been the company’s primary process control partner since 1993, completing numerous successful projects. In this latest endeavour, Promtek faced the challenge of enhancing the weighing process while minimizing downtime and production disruption.
The Importance of Modern Weighing Systems
An advanced weighing system leverages modern hardware and software to achieve accuracy and efficiency. Such systems typically comprise load cells supporting weigh vessels, a junction box, and a weigh controller. Accuracy can be impacted by issues such as load cell calibration and environmental forces. Selecting the correct technology is crucial to maximising system performance and achieving the desired results.
Introducing Promtek’s StoraWeigh9000 Platform
Promtek’s StoraWeigh9000 platform not only met but exceeded the customer’s requirements. This process automation solution is a robust process control system designed to handle any bulk material process. It operates on all major Programmable Logic Controller (PLC) hardware, offering unmatched flexibility.
Key Production Line Improvements
Promtek implemented several enhancements to optimize the production line:
- Downscaled Hand Additions: Reduced bins from six to three, decreasing pipework in the factory.
- Upgraded Blow Lines: Installed modern vacuum exhausters with ‘soft start’ motor starters, enhancing energy efficiency and extending motor lifespan.
- System Rewiring: Segmented control panels for better-defined operations.
- Enhanced Graphics and Remote Access: Installed high-definition graphics for improved monitoring and enabled remote access, offering greater flexibility for technical support and remote work.
Benefits of Lean Manufacturing Upgrades
These upgrades resulted in numerous benefits:
- Increased weighing accuracy with new vessels.
- Improved raw material delivery efficiency through upgraded control panels.
- Reduced manual handling, creating additional factory floor space.
- Lower maintenance costs due to reduced pipework and energy-efficient vacuum exhausters.
- Enhanced system reliability, contributing to long-term cost savings.
Efficient Software for Optimised Operations
The system now includes configurable multi-speed setpoints to control raw material transfer speeds. The upgraded process control systems streamline production and reduce downtime in the event of a breakdown.
Ongoing Support and Recognition
Promtek’s engineers worked closely with the client throughout the upgrade process. In addition to modernizing the weighing process, Promtek provides 24/7 customer support for part replacements and servicing. The success of this project earned first place in the Food Processing Magazine’s annual awards.
A Word from Promtek
Charles Williams, Managing Director of Promtek, stated: “It’s incredibly gratifying when a long-standing customer entrusts us with system upgrades. Our collaborative approach ensures tailored solutions. This project significantly enhanced productivity for our client, and we’re proud to support their growth for years to come.”
About Promtek
Promtek Ltd, a family-run business established in Staffordshire in 1972, specializes in designing and integrating process control systems for bulk material handling industries. Their expertise spans weighing, blending, and batch manufacturing processes of all scales. Promtek’s solutions integrate seamlessly into MRP systems and are supported by 24/7 service.
In 2021, Promtek partnered with PEMAC, adding asset and maintenance management solutions to its cutting-edge process automation technology.
