Case Studies
Figure 1: Global Controls Solutions LLC (GCS), a system integrator, helped achieve a food supplier’s goal of improved energy efficiency with an industrial Ethernet network, Profinet, to improve overall operational efficiency. One of the control panels for the refrigeration system is shown. Courtesy: Global Controls Solutions (GCS)
Case Studies February 2, 2019

Profinet network, control system upgrade helps reduce energy costs

A system integrator deployed a Profinet industrial Ethernet network and programmable logic controllers (PLCs) for a food supplier looking to expand its facility. The integrator used the Ethernet network to improve communications and optimize operational efficiency for $125,000 in annual energy savings.

By Nelly Ayllon Lazo
DTE Calvert City (DTECC) in Kentucky chose Cross Company to migrate the APACS DCS to a full Siemens PCS 7 system implementation. Courtesy: Siemens Industry Inc.
Case Studies January 30, 2019

Case study: DCS migration challenges and obstacles for process manufacturer

An industrial utility service company in Kentucky needed to upgrade and migrate its distributed control system (DCS), which came with a few challenges.

By Josh Dalzell
Case Studies August 21, 2017

Robots solve assembly line production challenges

Inside Machines: An electronics manufacturer with double-digit product rejection rates used a collaborative robot that was controlled and monitored in a cloud-connected system to handle soldering, drilling, silicone dispensing, and light assembly. This helped rejects fall to near zero and increased production efficiency almost fivefold.

By Brian Dillman
The steel industry is under increasing pressure to minimize running costs and one manufacturer in Brazil was able to repair two impellers through reverse engineering. Courtesy: Sulzer
Case Studies April 19, 2017

Reverse engineering reduced repair time, costs for steel manufacturer

A steel manufacturer that needed two impellers repaired found a solution through reverse engineering that was faster and more cost-effective.

By Rafael Ribeiro
Total project savings for using a Profinet-based industrial Ethernet system rather than hard wiring was $106,654, said Mike Prokop, CMSE, LSO (certified machinery safety expert, laser safety officer) and chief electrical engineer with Taylor Winfield Tech
Case Studies April 12, 2017

Ethernet cuts automation hardware, labor costs, errors

Think Again about digital networks: A redesigned automated industrial process with the goal of improving safety and efficiency saved $106,654 in hardware, design, and installation costs by using an industrial Ethernet protocol instead of hard wiring, not counting a two-thirds reduction in potential errors or other project benefits.

By Mark T. Hoske
The travelling batcher drive is designed for unloading the batch into each load out silo. Courtesy: Yaskawa America Inc.
Case Studies April 7, 2017

Matrix drives reduce energy consumption for transporter system

Inside Machines: Industrial matrix drives were used for a transporter system retrofit to reduce energy consumption and costs by creating a more maintenance-free mechanically integral distribution system. New system regeneration capabilities for two motors saves an estimated $1,500 per year.

By Mike Grant
Figure 3: Inside the control panel: Each test stand is controlled via a PLC (center left) and a Delta Computer Systems RMC75P motion controller (center right). The PLC and motion controller are connected via Profibus (the purple cable).
Case Studies December 4, 2016

Controller for crane testing

Inside Machines, hydraulic control: Verifying load parameters when testing mobile cranes is important to verify quality, which matters for functionality and safety. New testing systems included installing new proportional servo valves and high-performance, electro-hydraulic motion controllers.

By Richard Meyerhoefer
Case Studies September 9, 2016

Packaging operation increases by half with planning, wireless, mobility

Cover Story: System integrator upgrades a cherry packaging operation at Prima Frutta, for a 50% production increase, using Ethernet, wireless, and mobility technologies, along with extensive planning and simulation.

By Laura Kelm and Jason Kieffer
Jason Kieffer, project manager for Industrial Automation Group (IAG), holds the electrical schematics for one of the electrical panels used in the Prima Frutta Linden cherry packing facility upgrade. Image courtesy: Echo Media Productions
Case Studies September 9, 2016

Prima Frutta Linden cherry packing facility: Project and installation technology details

Project and product details follow in a major Industrial Automation Group (IAG) and Prima Frutta upgrade to Prima Frutta’s Linden cherry packing facility. Questions and answers cover controllers, sensors, actuators, Ethernet, wireless, timeline, and advice.

By Jason Kieffer and Mark T. Hoske
Figure 3: Flexible support programs offer agreed service levels rather than prescribed quantities of materials and labor. Courtesy: Honeywell Process Solutions
Case Studies July 11, 2016

Surviving a control system migration project

Control system migration projects can provide significant value to industrial operations by ensuring a smooth transition to newer technology with virtually no changes to physical wiring or intellectual property.

By John Rudolph