CHALLENGE
One of the leading companies operating in the fertilizer production and agricultural-horticultural solutions sector decided to build a new factory in Germany in order to meet growing market demand. Due to the high requirements regarding reliability, safety, scalability, and precise process monitoring, the Investor entrusted the project execution to the company responsible for supplying the production machinery and technology, while ANIRO acted as a subcontractor responsible for the design and implementation of the complete control system.
The scope of work included both the design phase (development of electrical systems based on the provided P&ID diagrams) and the implementation phase — primarily involving the delivery and installation of 19 linear meters of automation control cabinets for the production technology, as well as ten local control cabinets. Additionally, the project included the construction of the main SIVACON switchgear, preparation of cable routes, technological cabling, installation of control devices, and system commissioning.
SCOPE OF WORK
Electrical System Design
Technical Documentation
Preparation of detailed electrical schematics based on P&ID diagrams, taking into account the specifics of the production process and technological requirements.
Power Distribution
Design of the power distribution system, including the main SIVACON switchgear, to ensure stable and uninterrupted power supply to all areas of the factory.
Control and Automation System
PLC and I/O System
Implementation of the SIEMENS S7-1515F controller together with the distributed ET200SP I/O system.
Operator Interface
Creation of local operator stations based on HMI panels, providing intuitive and convenient operation of individual process stages.
SCADA and ERP Integration
Implementation of the zenon SCADA system (COPA-DATA) with bidirectional data exchange with the SAP/ERP system, enabling ongoing recipe management, production reporting, and inventory control.
OT/IT Infrastructure
Development of a complete OT/IT solution based on the SCADA<->PLC<->OT/IT<->SAP architecture, ensuring continuous recipe management, production reporting, and inventory control.
Remote Access and Support
Implementation of a VPN remote access system enabling rapid service support for PLC, HMI, and SCADA systems without the need for on-site visits, significantly reducing response times in the event of downtime or failures.
Drives and Switching Equipment
Drive Systems
Application of LS Electric frequency converters and LS Electric SSM soft starters for controlling motors of key production machinery, including mills, granulators, and conveying systems.
Switching Equipment
Use of SIEMENS solutions, including molded case circuit breakers, motor protection breakers, contactors, and modular equipment, to ensure high reliability and flexibility of the installation.
Control Voltage Distribution
24 V DC power distribution based on WEIDMULLER solutions, ensuring stable and safe power supply throughout the system.
Production Monitoring and Control System
Product Identification
Implementation of a solution based on SICK barcode scanners for monitoring the flow of raw materials and finished products.
Data Integration
Automatic transfer of production and inventory data to the SCADA and ERP systems, supporting efficient resource management.
Main Power Supply and Cable Infrastructure
Main Switchgear
Design and installation of the SIVACON (Siemens) switchgear responsible for power distribution across all factory levels.
Cable Routes and Cabling
Comprehensive preparation of cable routes and execution of technological cabling throughout the four-story facility.
IMPLEMENTATION RESULTS
As a result of the implementation of the designed control system and integrated management software, the Investor gained a fully automated and optimized production process meeting the highest industry standards.
BENEFITS FOR THE INVESTOR
High Level of Automation
Thanks to the implementation of the SIEMENS S7-1515F controller and distributed ET200SP I/O modules, the system remains flexible and easy to expand, enabling efficient adaptation of the production line to changing technological requirements and growing market demands.
SAP/ERP Integration
The integration of the zenon SCADA system with business management tools streamlines production cycle management, automates reporting, and increases transparency throughout the supply chain.
The connection between the zenon SCADA system and business tools, implemented through a dedicated OT/IT infrastructure based on the SCADA<->PLC<->OT/IT<->SAP architecture, improves production cycle management, automates reporting, and provides greater transparency across the entire supply chain.
Safety and Reliability
The comprehensive system solutions implemented by ANIRO — including Rittal control cabinets, LS Electric frequency converters, LS Electric SSM soft starters, and the SIVACON switchgear — ensure continuous operation of key production line components, minimizing downtime and the risk of failures, while meeting the highest quality standards confirmed by ANIRO’s many years of experience.
Energy Savings
High-efficiency drive systems and advanced control solutions contribute to optimized energy consumption, resulting in lower operating costs.
Scalability
The modern system architecture allows for easy future expansion of the factory infrastructure and the addition of new functionalities without disrupting ongoing production.
SUMMARY
Thanks to its many years of experience in designing and implementing comprehensive automation systems, ANIRO successfully fulfills all Investor requirements. The implemented solutions ensure efficient production process management while enabling continuous monitoring of key performance indicators and optimal planning for the future development of the facility.