Nestlé, Worldwide

As a competence center for infant milk powder, Nestlé Research Konolfingen is continuously developing the plants. Thus, findings from many realized plants were used to optimize the existing standard solution. The improved software was then implemented on three lines via remote connection and tested together with the customer.

A few years after the first mixer line had been equipped with the standard software, this also happened on two other lines. While the standard was specified on the software side, the amount of discussion in the run-up was nevertheless unusually high. On the one hand, the time window for commissioning was repeatedly postponed. On the other hand, many details of the mechanical and electrical design had to be clarified again and again, which minimized the surprises at commissioning.

An additional feeder was added to a mixer line that had been equipped with the standard software five years earlier. Due to the planned only short conversion, thorough preliminary clarifications were necessary. The extension of the software was done by us via remote connection.

An additional ingredient was added to a batch mixing plant. This required adjustments to the PLC & HMI, which could be made via remote access.

The feeder for a powder that is notoriously difficult to dose was equipped with the latest technology. The standard solution established for mixing processes could also be used for dosing into a spray drying tower.

Two batch mixing plants in Nunspeet (NL) with various raw materials for EHP & Alfamino production. Increased safety and traceability requirements were the biggest hurdles to overcome.

In the newly built factory in Mexico, we were able to realize various sub-processes in addition to the automation of the standardization process. In this project, tipping and dissolution of different salts, transfer into the storage tanks up to the correct dosing into the standardization tanks was realized. Also the storage and transfer of oils as well as the commissioning on site was part of this project.

This project was the heart of the newly built factory in Mexico in the liquid process. It included the software development and commissioning of three vacuum mixers as well as five standardization tanks, in which the product with all ingredients is dosed, mixed and prepared for the onward transfer to the drying process. Impressive are the unusual dimensions of the standardization tanks, each with a volume of 250m3, as well as the approximately 18km of piping that runs through the entire factory.

In a completely newly built factory for Infant Formula, we were able to execute the entire powder part. From the tipping of raw materials and their conveying, to dosing in liquid and powder processes, powder handling after the spray tower, a system for filling into storable containers that had probably never been realized before, to our standard mixer solution, we covered the spectrum. The commissioning offered all kinds of surprises and room for improvisation with the locally built electrical cabinets and the unusual relaxed way of working of the Mexican colleagues.

The standard application for continuous mixing was used here for the first time in a Nestlé factory in the Philippines. A mixing line was equipped with an additional feeder and brought up to the latest state of the art. As always, something also had to be added and improvised around the standard to take account of factory-specific features.

Another application for our standardised powder dosing was the liquid line and spray tower of a newly built factory for Infant Formula. While most of the processes were carried out by contractors, our highly sensitive part was embedded in them.

Three identical batch mixing lines for Infant Formula were implemented in a new factory in Indonesia. Our part comprised the so-called core part, i.e. the highly precise weighing of the various ingredients and the subsequent mixing. Our standard solution, which we had previously developed with specialists, was also used here. The pre- and post-process as well as the entire hardware was implemented by a local integrator.

The standard solution for Infant Formula dosing and mixing developed with the then PTC Konolfingen was implemented in two lines. The new location with its wishes and customs was challenging for us. However, the standard solution was able to establish itself further and the constant further development served the high demands on product safety.

In Pakistan, two batch mixer plants were automated. As a standard integrator of such plants, we repeatedly have the pleasure of developing and commissioning such applications worldwide.

The second application of the standard solution for batch mixing developed with specialists from PTC Konolfingen was carried out with a different plant manufacturer compared to the first. Thus, it had to be shown that our software works equally reliably independent of the mechanical solution. Here, too, the control cabinet construction was done locally, which required a little more support for us during commissioning.

After a standard solution for batch mixing has been developed with specialists from PTC Konolfingen, the first project in the Netherlands came about. This had to prove that the software also existed in a productive environment. In addition, further requirements were added with the plant constructor and the customer, which could be implemented to everyone's satisfaction after commissioning.

After a standard solution for continuous mixing has been developed with specialists from PTC Konolfingen, the first project in the Netherlands came about. This had to prove that the software also existed in a productive environment. The hardware, including control cabinet construction, was procured by the customer. Our task here was limited to the software and its commissioning.

In the existing evaporator plant, the sterilization process and the cleaning sequence were optimized so that the sterilization and cleaning time could be significantly reduced and the process made safer. In addition, the flow controls of the product were optimized.

For a completely new production line for Infant Formula in Indonesia, a standard software application for a falling-film evaporator was developed together with specialists from the then PTC Konolfingen. The installation was put into operation in an on-site commissioning. Further applications of the standard application are in use at various production sites worldwide.

For a completely new production line for Infant Formula in Indonesia, a standard software application for a CIP station (Cleaning in Place) was developed together with specialists from PTC Konolfingen. The installation was put into operation in an on-site commissioning. Further applications of the standard application are in use at various production sites worldwide.

When the factory was newly built, the product dissolving, inline dosing and subsequent evaporation were designed and a Functional Design Specification (FDS) was created. Based on this FDS, the PLC and control system (Siemens and WinCC Professional) were implemented after the review. Commissioning was carried out in a separate project.