Industries such as food and beverage manufacturing and consumer packaged goods (CPG) production are fast-moving environments, with high traceability and proof-of-quality requirements alongside  throughput demands. As such, automation offers a lot of benefits to operations — so changes to existing systems, or implementing new ones can be seen as a source of risk, rather than opportunity. Here, Sam Kirby, a Solutions Engineer for Novotek UK & Ireland, looks at how manufacturers in the food, beverage and CPG sectors can reliably and rapidly extend automation deployments. 

The food and beverage industry has a long history with automated systems. In fact, one of the first fully automated production processes was that of an automatic flour mill, in 1785. The industry has generally kept abreast of automation developments since then, allowing it to keep ahead of ever-growing demand. Similar is true of CPG production, particularly in recent years, as product innovation has become a key business strategy.

CPG and food and beverage production tend towards automation because, in both sectors, much of the workforce is at the field level. As such, connecting systems to gain greater visibility into equipment health, output performance and product quality is invaluable. This is nothing new; engineers have been undertaking such projects for years, In particular, firms in these sectors have firmly established the benefits of connectivity and supervisory control and data acquisition (SCADA) systems. 

“Efficient HMI” Concept – being delivered by GE Digital.

Experience serving the industrial sector has shown that in the most productive environments, SCADA systems present screen to operators that are easy to interpret. By having the operator’s work foremost in screen design, they can be up to 40%  more effective in spotting issue that require technical teams to resolve. Engineers can then respond faster to events on the production line. GE Digital has been delivering templates intended to support this “Efficient HMI” concept as part of their IFIX HMI/SCADA system. 

The templates, refine HMI displays to focus on the most critical information related to executing the work. This decluttered interface improves operator effectiveness in regular operation, and makes it easier to spot issues exceptions, with means improved situational awareness, and more focused reactions to such issues. The overall effect is a higher level of productivity, on measures such as machine utilisation, throughput and quality.

Following this approach, IFIX also features preconfigured sample systems that are aimed at elements of the food, beverage and CPG industries. For example, Novotek can supply the IFIX software with a preset tailored for juice plants, with a display that provides an overview of processes from raw material intake to filling and packaging. Beverage production engineers can run this system immediately following installation to gain an immediate assessment of how production is performing. Even where adaptation is needed, the templates provide working examples of both the efficient look-and-feel, and of the most modern approaches to the technical configuration underneath it all. So engineers and IT teams get a practical hand in furthering their technical knowledge, smoothing the adoption of new versions and related modern development tools. 

It’s not unusual for engineers to believe that preset templates might not adequately fit their unique operations, yet we’ve found that the preconfigured settings often provide a substantial benefit. Of course there is no substitute for testing this directly, which is why Novotek and GE Digital offer CPG companies and food and beverage manufacturers a free demo of IFIX to see how effectively the templates suit them. 

Automation may not necessarily be something new for the food, beverage and CPG sectors, but its continued evolution brings with it new implementation challenges and operational complexities. Novotek values the work by GE Digital on the Efficient HMI concept and application templates as they offer useful tools to customers to help them modernise quickly and safely. And by sharing the methods and example applications, the customer’s IT and engineering groups are given a helping hand in building a bridge from the technical realities of long-established SCADA systems to a more modern solution. 

As the UK’s industrial base continues to adapt to changes in business models, supply networks and trade environments, there’s an opportunity to tap into a massive hidden resource – the install base of HMI/SCADA systems deployed everywhere from power plants to food processors. Many of these systems were implemented in the 90s and 00s as part of the first wave of productivity investments – by supplying a way to visualise the critical elements of complex machines and processes, industrial firms improved the effectiveness of their front-line workers and supervisors, as well as the reliability of their operations. However, rather than a desire to gain a more operational and competitive advantage, the pattern of investment during the previous 20 years has been driven by the feeling of “forced need.” As we’ve aided several clients with improvements to their SCADA systems, we’ve seen two things that influence their choice to upgrade:  

And an unfortunate sub-theme is common – we’re often told that any upgrade “must keep the system the same as the operators are used to”. No changes. No adoption of new functions. No assessment of whether current engineering practices could lead to a better, more maintainable footprint. “Convert the application and get it running again” is the instruction of the day. Even in cases where a firm has run an assessment of different providers and switched to a new SCADA vendor, they’ve then asked to have their old application replicated, rather than taking the upgrade work as a chance to consider what new capabilities might be delivered by the more modern SCADA platform that’s replacing the one from 20 or 30 years(!) ago.  

From the operations leaders’ perspectives, the core mission – make the product; keep the assets running – is the same, and it can be hard to step back, and consider whether the automation and systems around the operation should work the way they always have. And when vendors supply a laundry list of new features or technical updates, it doesn’t necessarily give an operational, maintenance or other non-technical leader compelling information in the right terms for them to see the value in taking that pause to step back and consider a broader approach to what first looked like a “forced necessity”. 

If we had the opportunity to be face to face with every as they took that step back, here’s what we recommend they consider: 

Where vendors spend their SCADA product development dollars IS driven by YOUR needs (yes, some technical, but many more are user/functional focused). Just a few examples would include: 

Using the more modern SCADA could save you time, effort and budget that would otherwise be spent on competing/overlapping new systems.  

OK – this one goes a little deeper into some technological details but stay with us! 

As firms pursue the value that may come from adoption of big data platforms and machine learning or analytics, they often launch data acquisition projects that without understand how existing plant systems part of the landscape can be, rather than driving additional tech into a plant where it may not be needed. 

Often, the IT and HQ operations teams don’t realise that their existing SCADA could accelerate these initiatives.  

Security – the elephant in the room 

It’s true that this is a topic that can cause people’s heads to throb before a discussion even gets started. But we’re going to skip all of the technical details and simply accept that improving cyber security postures is a priority for practical reasons, including: 

• Yup – there are bad actors. Anyone remember the last round of Wannacry incidents? 

• There are increasingly heavy regulatory burdens around certain industries or sectors 
• To the above point, I hear many of you exclaiming “But my firm isn’t part of Critical National Infrastructure!”. That may be true, but we’re even seeing scenarios where brand owners or retailers are insisting that their suppliers be able to prove that they have a solid cyber security position – as that’s seen as an indicator that they’ll be less subject to disruption, one way or another… 

Again, vendors haven’t been idle. It may take some basic work on the applications you have, but if you’ve at least invested in a current version of your SCADA, you’ll be able to take advantage of what’s noted below. 

Another area where IT teams struggle is understanding what can be done at the SCADA layer to meet security goals. As a result, they may consider some unique (and often extreme!) techniques and approaches that may be more difficult and expensive than needed. 

Click here to see what our vendors now have available! iFIX Secure Deployment Guide.

Don’t just “keep it current” – Upgrade!

Given the breadth of functions, capabilities, and technological upgrading that SCADA providers have implemented, it’s probably safe to argue that there’s more “in the box” that might be employed in areas that matter. And we’ve even reserved the details of the important technical things, such as development speed, part and code reusability, and so on, for another time! And we believe that looking at their SCADA with fresh eyes and thinking about what the current platform CAN do – rather than what the 20-year-old application created on the legacy platform from 1992 IS doing – is the key to gaining some new operational gains. And the route to those benefits can be faster to follow, making other digital projects speedier as well. 

The UK Met Office announces a new A–Z of storm names every September, officially beginning the new storm season for the UK. In winter 2021, the Met Office named the first two storms in as many weeks, with projections from mid-December expecting that a further six storms would hit the country leading into the new year.

Despite the predictability of storm season, the impact on utilities companies routinely causes significant problems. In the wake of Storm Arwen on November 26 2021, approximately 3000 homes in northern England remained without power for more than a week. This reflects the challenge of harsh seasonal weather on utilities companies — a challenge that is only set to escalate as global climate change makes erroneous weather events a more common occurrence.

Unsurprisingly, an excessive surplus of water can cause problems in the water network. If assets such as pumping stations become flooded due to a high volume of rainfall or overflowing surface water sources, it can cause further flooding in domiciles and office spaces. It’s for this reason that water and sewage companies are obligated under the Water Industry Act 1991 to ensure their systems are resilient and that the area they serve has effective drainage.

Yet ensuring resilience in the water network is no simple task due to the size of the network and the number of distributed assets. It’s for this reason that water operators depend upon supervisory control and data acquisition (SCADA) systems at remote sites and, increasingly, an effective data management and control platform. The local control systems are necessary to accurately monitor and control equipment, but an effective overarching system makes it possible to remotely address issues as they arrive.

For example, Novotek routinely works with water companies across the country to help them establish more effective automation setups to facilitate remote decision-making in a streamlined, efficient manner. One of the challenges that arises frequently is that of data silos, where field engineers may have access to pertinent equipment health or performance data that is valuable but inaccessible to other teams. Fortunately, this is best — and easily — addressed with an overarching system that collects data once and presents different views to different stakeholders.

Not every system will be well positioned to provide flexible data views to users and be capable of ensuring effective response to floods. Ideally, an industrial automation platform should also feature effective data visualisation, as well as predictive analytics that can use locally collected data to anticipate the likelihood of asset damage or outage. These attributes allow operators to easily coordinate an effective and rapid response to seasonal flooding as it occurs, at the most vulnerable or at-risk parts of a network before further problems ensue.

As winter storms continue to become more frequent and impactful, water operators must be increasingly prepared to combat the effects and maintain uptime of network assets. Automation has long been a necessity due to the scale of operations, but the effectiveness of automation deployments has never been so important.