Mondelez International, Daim, Control System Upgrade

The Opportunity

Following more than 20 years of continuous production, the company decided to completely overhaul its production automation system, in order to meet growing global consumer demand, as well as providing greater manufacturing flexibility.

Given the high plant utilisation and the age of the plant control system, Daim needed a solution that would ensure the reliable, flexible and enhanced production of the Daim chocolate bars.

The facility, built in 1993, was becoming increasingly costly to maintain and the supply of spare parts had become an issue. The system was unreliable, with unexpected downtime and the risk of a major breakdown that could completely stop production. In addition, the system was inflexible, preventing some improvements and on-going product development initiatives.

The Solution

Daim commissioned adi Automation to provide a number of upgraded solutions, including a complete electrical, control and software re-write, which would see the entire legacy control system and panels replaced and the process operational interface streamlined. High demand for the product meant that working during the allocated four-week shutdown period could not be exceeded, since this would directly affect deliveries to Daim’s customers.

As a result, crucial project management planning was essential for success, as well as the need for a major training programme for Daim’s staff, linked to extensive pre-testing, ensuring the proposed solution was fit for purpose and could be commissioned with a high degree of confidence. A further key recommendation from adi Automation was to remodel the automation process to the international S88 batch standard, providing a common method of defining the process plant in automation terms and giving greater consistency across processes.

The S88 standard also provides an ideal platform for adi Group’s new wireless based Track & Trace system, which tracks raw ingredients through to finished product. This considerably reduced manual effort, with the automated batch reporting system giving further improved efficiencies and reliable product traceability.

The Benefits

• Full turnkey control system upgrade during an ambitious four-week plant shutdown deadline.
• Close working partnership with Mondelez colleagues as well as our technology partners in Germany. The integrated team approach was key to the project’s success.
• The S88 model approach and methods deployed during the early design phases reaped many benefits during the testing and validation stages, offering improved flexibility for the future.
• The early production results have shown an increase in production efficiency, far above what was originally anticipated.
• adi Automation met all Daim’s objectives and is now delivering on-going support, through a servicing and maintenance contract, which includes remote technical support.

Due to the detailed planning and dedicated work from everyone on the team, installation and commissioning was delivered according to plan across the four week shutdown. The smooth install and excellent solution is testament to the team at adi Automation.

Lars Rörström, Business Development and Engineering Director, Daim