Reduce unplanned downtime of your plants from multiple days to a few minutes

Automation upgrades are products or solutions that cover all food categories. They improve the performance of the equipment, secure the product quality, safety and ensure vital life cycle management of the equipment.

Upgrades & Migration

Upgrades & Migration

Obsolescence IT/OT

Obsolescence IT/OT

Life Cycle Assessment

Life Cycle Assessment

Key Benefits

Operational efficiency

Increase uptime while reducing operating costs.

Production capability

Improve or increase production without investing in a new line.

Modernization

Extend lifetime of the equipment, replacing obsolete components and/or software.​​

Environmental impact

Reducing consumption, emissions and the use of harmful substances

Advanced digital connectivity

Advanced digital connectivity enables integration, data handling and remote trouble shooting

Upgrades & Migration

Step by step approach to reap benefits of investment

1. Start with upgrading the PLC in a CIP station


2. Then upgrade plant level PLC and user interface
3. In phases add remaining site PLCs

4. Finally add a MES layer


5. Add extra functionality with Error-preventing & Material Tracking

Plant SLC Migration to Tetra Pak PlantMaster

Customer challenges


  • Lack of data collection into centralize database for visualization
  • Legacy & standalone systems
  • Quality Issues

Benefits


  • Automatic data collection for visualization & insights
  • Newer functionalities, features, system integration & flexibility
  • Quality control and traceability

Product Information

General Information

New Control System BPU

New Control System BPU

UG name New Control system
System Tetra Pak Pasteurizer, Tetra​ Pak Indirect UHT,
Tetra Pak Direct UHT/Tetra Therm® Family​
Tetra Pak Aseptic Tank/Tetra Alsafe​
Tetra Pak Standardization unit/Tetra Alfast
Implementation time  System related (5-10 days)
Value Category Operational efficiency and Life cycle management

Product proposition:

  • Siemens TIA S7-15xx controller or Control logix 1756-Lx.
  • B&R panel pc with latest TPM 6.5 Intouch Modernapp user interface.
  • New electrical panel and electrical connection.
  • Update technical, operator and electrical documentation if applicable & available in electronic version.
  • Delivery and installation of the hardware and software.
  • Recommissioning.
  • Operator training.

Value proposition:

  • Higher performance and responsiveness.
  • Improved process and parameter visibility.
  • Extended Life time. Hard and software supported by Tetra Pak.
  • Fast automation support via standardized automation platform.
  • Ability to integrate new I4.0 technologies.
  • All essential functions you need are included, such as data logging, recipes, alarms, trends and audit trail, operating manuals.

General Information

GE 90-30 Series

GE 90-30 Series

RK name UK Repl. GE90-30
System All FMs and DEs with GE 90-30 PLC
Package Affected All
Implementation time  ~16 (avg)
Value Category Capability

For more info refer to GE90-30 Deployment Team Site


Product proposition:

  • replacement of back plate, CPU and power unit of the GE-Fanuc 90-30 with the new Rx3i

Value proposition:

  • release UK Repl in order to address the obsolescence of the GE-Fanuc 90-30 PLC series and extend the lifetime of the equipment.

General Information

Beijer TPOP “E” series 



UG name Beijer TPOP “E” series 
System • BULF BPU:
Tetra Alsafe®
Tetra Alcip®
Tetra Therm® Lacta
Tetra Therm® Drink
Tetra Therm® Flex
Tetra Therm® VTIS
Tetra Therm® Visco
• Local solutions.
Implementation time  1 day
Value Category Operational efficiency and Life cycle management

Product proposition:

  • X2 pro 15” operator panel.
  • Electrical connection.
  • Update HMI program.
  • Update technical, operator and electrical documentation if applicable & available in electronic version.
  • Delivery and installation of the hardware.
  • Adapter plates for mounting.
  • Recommissioning

Value proposition:

  • Higher performance and responsiveness
  • Improved process and parameter visibility (15” panel and higher resolution)
  • Extended Life time. Hard and software supported by Tetra Pak
  • Ability to integrate new I4.0 technologies
  • All essential functions you need are included, such as data logging, recipes, alarms, trends and audit trail

General Infromation

Control Panel Upgrade for Tetra Pak Separator

Control Panel Upgrade for Tetra Pak Separator

UG name Control Panel Upgrade
System Tetra Pak Separator
Implementation time  5-10 days
Value Category Operational efficiency

Product proposition:

This upgrade replaces obsolete separator control equipment.


Sourcing spare parts and supplying support for obsolete equipment may take a long time, if at all possible. A modern control system, on the other hand, secures spare part supply availability, and significantly shortens the downtime in case of a component failure. The upgrade also introduces a modern HMI and safety features, and enables function extensions and easy integration in the plant control system.


Each upgrade is customized to your needs and includes all necessary components, installation, re-commissioning as well as updated documentation.


Value proposition:

  • Secures reliable, safe and user-friendly operation
  • Minimizes risk of downtime
  • More user-friendly operation
  • Improves machine monitoring

General Information

ALCIP Upgrade

UG name New Control system
System ALCIP 10/ALCIP 100/3rd Party CIP

▶  Old ALCIP Units

• PLC – (SLC, Sattcon & S7-300 Platform)

• HMI – (Beijer-E series, PV Standard or Proface)

• Network – DH+ or RS232

▶ Obsolete hardware – no support for repair or spares

▶ No reporting and data logging available

▶ Obsolete hardware – no support for repair or spares

▶ More time to troubleshoot and diagnose

Implementation time  Varies on Site size and pressure lines
Value Category Operational efficiency and Life cycle management

Product proposition:

  • Automation Platform, Rockwell – ControlLogix, Siemens – TIA Portal, HMI, RA – Panel View Plus-15”( ALCIP 10)
  • Siemens – TP1500 (ALCIP 10), B&R (Intouch Classic/ModernApp) ALCIP(100)
  • Network (Ethernet/IP, ProfiNet), Prepared for full integration (TPM 6.5.10)
  • Central & ALCIP PLC on same platform, Reports generation for analysis & optimization*
  • New electrical panel and electrical connection.
  • Update technical, operator and electrical documentation if applicable & available in electronic version.
  • Delivery, installation of the hardware and software and recommissioning of CIP Station and objects
  • Operator training

Value proposition:

  • Improved process and parameter visibility
  • Advance automation system with higher life cycle
  • Latest platform with possibility for integration to central control system
  • Less downtime / faster implementation
  • CIP reports can be obtained
  • Ease in analysis & troubleshooting due to standard programming & latest technology
  • Fast automation support via standardized automation platform.
  • All essential functions you need are included, such as data logging, recipes, alarms, trends and audit trail, operating manuals.

Obsolescence IT / OT

IT Hardware & Software Upgrades

Customer challenges


  • Prone to breakdowns and longer lead-time to restoration
  • Non-IT compliance (cybersecurity threat)
  • Compatibility with new software

Benefits


  • Reduce unplanned breakdowns and catastrophic failures
  • IT Compliance
  • Increase scalability

Product Information

General Information

New Central Room Control System

UG name New Central Room Control System
System Obsolete IT HW/SW

▶  IT Assets have limited life

• Windows 7 and earlier

• Server 2008 and earlier


Obsolete Aveva(earlier Wonderware) Software

▶  Wonderware Intouch Version

• Intouch 2014 R2 and earlier (v11.0, v10.6, v10.5, v10.1 and earlier)

Implementation time  Varies on Site size and pressure lines
Value Category Operational efficiency and Life cycle management

Product proposition:

• Hardware

• New IT equipment (Physical or Virtualization)

• Software and Licenses

• Upgrade Aveva Intouch / WSP to latest version

• Microsoft OS latest compatible version

• MS SQL /Office , if applicable

• Migration & Verification of application

• Resolution Change to Full HD (optional)

• Delivery, Deployment (Onsite / Remote) and of the hardware / software and verification of plant operation


Value proposition:

• Extended Life time

• Better Performance, System Stability and Continuity

• Support from OEM for new product for upcoming few years

• Maintaining IT Compliance

• Securing Capital Investment

• Readily Support and Service available

• Faster recovery & support in case of breakdown

General Information

Microsoft Servers Product Life Cycle

Release Release date End of life Extended Support
Windows Server
2019 Datacenter
November 13, 2018 January 9, 2024 January 9, 2029
Windows Server
2019 Essentials
November 13, 2018 January 9, 2024 January 9, 2029
Windows Server
2019 Standard
November 13, 2018 January 9, 2024 January 9, 2029
Windows Server
2016 Datacenter
October 15, 2016 January 11, 2022 January 11, 2027
Windows Server
2016 Essentials
October 15, 2016 January 11, 2022 January 11, 2027
Windows Server
2016 Standard
October 15, 2016 January 11, 2022 January 11, 2027
Windows Server
2012 Standard
October 30, 2012 October 9, 2018 October 10, 2023
Windows Server
2012 Datacenter
October 30, 2012 October 9, 2018 October 10, 2023
Windows Server
2008 Small Business
Server Standard
November 21, 2008   January 14, 2020
Windows Server
2000 Datacenter Server
November 13, 2000 June 30, 2005 July 13, 2010
Windows Server
2000 Server
March 31, 2000 June 30, 2005 July 13, 2010

Extended support for Windows XP ended on April 8, 2014 and Windows 7 ended on January 14, 2020. If you are still using Windows 7, your PC may become more vulnerable to security risks.


Reference Links:

https://docs.microsoft.com/en-us/lifecycle/products/windows-server-2019
https://docs.microsoft.com/en-us/lifecycle/products/windows-server-2016

General Information

SQL Database Product Life Cycle

Lifecycle dates

The following table provides an approximation of lifecycle dates for SQL Server products. For greater details and accuracy, see the Microsoft Lifecycle Policy page.


lifecycle dates

https://docs.microsoft.com/en-us/sql/sql-server/end-of-support/sql-server-end-of-life-overview?view=sql-server-ver15r-release-dates-and-lifecycle/

General Infromation

Intouch Software Life Cycle

lifecycle dates

MAINSTREAM
SUPPORT
The first phase in the Product Support Life Cycle.
This phase begins upon the Date of General Availability and
continues for a period of three (3) years.
EXTENDED
SUPPORT
The second phase in the Product Support Life Cycle.
Upon retirement of the Mainstream Support phase, the
Extended Support phase begins and continues for a
period of two (2) years.
MATURE PRODUCT
SUPPORT
The third and final phase in the Product Support Life Cycle.
Upon retirement of the Extended Support phase,
Wonderware software products enter into the Mature Product
Support phase, which continues until product retirement
PRODUCT
RETIREMENT
Occurs when a particular product is no longer available for
sale and no longer distributed.

https://industrial-software.com/training-support/product-versions/

Life cycle assessment

Life Cycle Assestment Strategy

Assessment


First and most important phase of the migration process is a thorough analysis of existing control system


Yearly

Software


Next phase is starting to work on converting the application logic.

5-10 years

PLC


Change of obsolete PLC.


7-10 years

Visualisation


In the next phase you change your HMI and operator panels.


4-6 years

IO, Buses & Filed devices


Changing IO is a big investment.


15-20 years

Step by step approach to reap benefits of investment


1. Asset Audit

➜ Site Visit
➜ Asset Documentation update


2. Performance Audit

➜ Automation health check
➜ Backups


3. Status Report

➜ Lifecycle status
➜ Asset performance


4. GAP Analysis

➜ Identify critical elements in system
➜ Identify obsolescence
➜ Inventory management
➜ Training requirement

Lifecycle Service Agreement

Secure your automation installed base


1. Automation Assessment Audit (Yearly)


➜ Hardware evaluation & obsolescence planning
➜ Software version compatibility check
➜ IT / OT infrastructure


2. Backup Services
(Twice / year)


➜ PLC, HMI & Network backups
➜ Revision control
➜ Archiving


3. Maintenance Services
(Twice / year)


➜ Alarms, events & log check
➜ Software patch update
➜ Panel services
➜ Drawing / documentation revision
➜ PLC health check

45% lower product waste in high automation plants

45% lower product waste in high automation plants

Automatic processes, real time measurements and smart functions in high automation plants showed a whopping 45% lower overall product waste in production over 4 years compared to plants with low automation.

20% fewer packaging line stops in high automation plants

20% fewer packaging line stops in high automation plants

Highly automated dairies showed 20% higher OEE than dairies with low automation. And highly automated juice production plants showed 7% higher OEE than their less automated counterparts.


The higher the complexity of the plant and SKUs, the more plant performance could be improved with automation.

11% less packaging material waste in high automation plants

11% less packaging material waste in high automation plants

Highly automated dairies showed fewer stops in production and filling, which also means a lot less packaging material goes to waste. That’s good news for the bottom-line and for the environment.


In this study, highly automated dairies had 11% less packaging material waste than their less automated counterparts.

Reduce overall quality sampling defect rate by up to 96%

Reduce overall quality sampling defect rate by up to 96%

By digitalizing quality sampling in dairies, overall random defect rate per 10,000 packages was reduced by up to 96%.

Join our upcoming webinars

We welcome all food and beverage professionals. Our agenda covers a wide range of aspects and topics of interest. Let us share our expertise to help make your food and beverage operations more efficient and profitable.

Stay ahead of the industry

Sign up to receive Tetra Pak’s newsletter.



HIDE