Soap Manufacturer –
Christina May

The Challenges

Christina May needed a partner who could:

• Understand and interpret the requirements of the existing plodder panel and control system.
• Provide a full specification and design for the new system.
• Build, assemble and deliver the new panel.
• Install and commission the plodder.

The manufacturing process included the writing of a bespoke PLC program to control the new panel.

The Details

Christina May’s operation includes a range of machinery and equipment from various manufacturers of varying ages.

To begin with, we were asked to look at ‘Line 1’, where the raw materials go in (soap noodles and scent) and are processed in a mixer. The product is then processed through a plodder and compressed into a continuous bar that is cut and stamped, ready for packing and distribution.

And it was the plodder that was the problem!

Its ancient control panel had an antiquated Programmable Logic Controller (PLC), and various components had been wired around or disconnected completely. Numerous wiring adaptations had also created a nest of jumbled cabling and several seriously overloaded components.

The dilemma was this: the machine was becoming less reliable and frequent faults made replacement a priority, but also downtime needed to be kept to a minimum.

Our challenge was to replace the panel with minimum disruption, while converting an old system and control philosophy, and retaining the high production levels AND complying with all relevant regulations and safety guidance.

We were also tasked with installing a comprehensive safety system to ensure the machine’s safe operation and the required level of safety across the production line.

The Solution

We provided the complete solution Christina May were looking for.

We applied our experience of working with customers to develop a specification for a panel or control system. And once the specification was agreed, we used our CAD software to design the system, putting the approved solution into manufacture at our Sussex-based workshop.

Our team of highly trained engineers then installed and integrated the completed panel.

The new panel was installed on the production line within the shutdown deadlines, and on schedule.

As experts in machine safety, we can also provide risk assessments in accordance with BS EN 13849 and ensure that the finished control system abides by all relevant safety regulations.

The Project: The Timeline

Pre-manufacture

We were introduced to the project in mid-2022, meeting the owner and manager onsite to understand how the machine and existing panel operated.

We then produced a basic specification that was honed through further discussions with the customer and their machine operators. The specification was translated into a control philosophy, and the finished documents were approved by Christina May.

Our inhouse PLC engineers got on with writing the control program for the new PLC, a Siemens S7-1200 with additional IO cards. And we tested the program on completion using simulations, passing it on to the inhouse panel builders for production.

We used our CAD software, SEE Electrical, to produce the panel drawings which we built in accordance with BS EN 60204 & BS EN 61439.

Other regulations and standards involved in the production process include BS7671:2018, the Machinery Directive, the Low Voltage Directive, the Health and Safety at Work Act, COSHH Regulations, and the Provision and Use of Work Equipment Regulations (PUWER).

Manufacture

Our specialist automation suppliers provided all required components and we put the panel into production at our workshop, where our qualified engineers built the panel.

On completion, we carried out a full Factory Acceptance Test (FAT) to ensure that the panel hardware and software is operating correctly before dispatch to site. It’s all part of our rigorous quality control process.

On Site Installation

As keeping downtime to a minimum was paramount, we agreed a shutdown window of shortly before Christmas 2022 to enable installation.

On the first day, our engineers arrived on site and began isolating and removing the old control panel.

At this very early stage, we immediately found several components with serious thermal damage.

Once the old panel and cabling was removed, our engineers began installing the new containment and cabling for supplying the machine from the new control panel. We also installed all new sensors and actuators on the plant, enabling the process to become fully automated when coupled with the new control system and program.

The panel was delivered to site, inspected on arrival and installed on the plodder in its final position. The new cabling was made off into the new panel, and all dead testing was carried out.

Commissioning & Training

On completion of testing, we livened up the new panel and carried out the commissioning test. All functions and systems were tested and verified.

Randoll Industrial engineers then worked with machine operators to run materials through the machine, ensuring all systems were operating correctly.

During the commissioning process, our engineers fine-tuned the machines sensors and automation program to achieve optimum production.

On completion of the commissioning process, the client and operators were given training on the newly installed system.

Safety

We provide the new panel with a Pilz safety relay, incorporating 2x proximity switches on the doors to the vacuum chambers, and push button emergency stops on the panel and around the plant providing a global emergency stop.

We integrated the safety system of the machine downstream in the production line. And we designed and installed the system in accordance with BS EN 13849, and to comply with the requirements of the Electricity at Work Regulations 1989 and the Provision and Use of Work Equipment Regulations 1998 (PUWER).

The new system gives the client peace of mind that they have fulfilled their duty to ensure that machinery is safety to use for their employees.

Adding Value

Our excellent communications and flexible approach throughout the project enable us to recommend several enhancements and modifications.

This included replacing a capacitance sensor with a distance sensor on the infeed conveyor for the process control. This prevented the issue of material sticking to the capacitance sensor and causing delays. Our new non-contact system gives an accurate level of the infeed within the hopper, a more precise control of the material stream and ensures reliability.

We also recommended the installation of a Human Machine Interface (HMI), allowing operators to control the process, adjust system settings and monitor progress at a glance. This functionality was not available on the original machine, and has improved production, allowed close control of the process, and informed the operators of faults faster.

The Randoll Team

Our team is perfect to partner with Christina May as we’re highly qualified in industrial automation.

We have deep knowledge of industrial electrical systems and all our engineers are first and foremost time- served electricians.

We ensure each engineer is then further trained in specialist areas, as well as achieving the C&G 2391 Test and Inspect qualifications, and the C&G 2396 Design.

Our PLC engineers are trained in Siemens automation products, including the S7-1200 PLC used for this project. We also hold CMSE (Certified Machine Safety Expert TUV Nord), and our engineers are all trained in electrical safety of machinery.

All of this experience is put to work in the commissioning process, improving automation of the machines, increasing output, decreasing risk, and saving cost.

Randoll & Christina May: The Future

Since project completion, we’ve been working closely with the team at Christina May to integrate a second production line using machinery the client has from various manufacturers.

This Line 2 project will effectively double output, marking major business growth for Christina May.

We also continue to support Christina’s May’s other plant on a day-to-day basis and they continue to consult us on planned upgrades and alterations.