Projects
Most of projects here described were not developed by OZZY Automação, they were developed by Julio Cesar Lovatel, Engineer and Director of OZZY Automação, through previous employment experiences.
At the end of each project here described there is a note saying who developed the project and what Julio Lovatel role was.
The projects descriptions were simplified in this page. For more information about them please contact us.
Milk Reception, Pasteurization and Sterilization
This project was developed to Parmalat (Carazinho-RS-Brazil) where the milk reception, pasteurization and sterilization were fully automated.
The process consist in 4 reception stations, where the milk is unloaded from the trunks and transferred to 2 tanks. From those tanks the milk is transferred to one of the 11 storage tanks, passing through one of the 4 pasteurizers on the way. From the storage tanks the milk is sent to be bottled passing through one of the 8 sterilizers on the way. The process also has a CIP which is done after every batch.
Two redundant S7-400 PLCs from Siemens were used to control over 2000 IO points distributed on the plant with ET200 and redundant Profibus-DP. The control system also has 2 OP-27 HMIs and an iFix SCADA.
Project developed by Zentrum Automação Industrial
Role: PLC and HMI programming, commissioning and start-up.
Conveyor Control and Production Recording
This project was developed to Inghams Chicken (Bolivar-SA-Australia) and was responsible for controlling the conveyors and production recording in a poultry processing factory.
After the operators finish packing the chicken pieces they are put way in a cardboard box, which is placed on conveyors after full. This cardboard travels through the factory until gets to the "GEMS" where it is going to be weighted, have its production data recorded (date, time, line, weight) and directed to its destination (reject, freezer 40 min, 90 min or fresh).
The control was done with a Control Logix from Rockwell with over 200 IO points distributed on a DeviceNet network. For safety control a Guard IO from Rockwell was used. A HMI and Citect SCADA were used too.
Developed by Machinery Automation & Robotics
Role: PLC, HMI and SCADA Commissioning and start-up.
Conveyor Control and Production Recording
This project was developed to Inghams Chicken (Bolivar-SA-Australia) and was responsible for controlling the conveyors and production recording in a poultry processing factory.
After the operators finish packing the chicken pieces they are put way in a cardboard box, which is placed on conveyors after full. This cardboard travels through the factory until gets to the "GEMS" where it is going to be weighted, have its production data recorded (date, time, line, weight) and directed to its destination (reject, freezer 40 min, 90 min or fresh).
The control and safety were done with a Guard Logix from Rockwell with over 700 IOs points distributed on a Ethernet/IP network. A HMI and Citect SCADA were used too.
Developed by Machinery Automation & Robotics
Role: Project Management, PLC, HMI and SCADA Programming, Commissioning and Start-up.
Conveyor Control and Production Recording
This project was developed to Inghams Chicken (Murrarie-QLD-Australia) and was responsible for controlling the conveyors and production recording in a poultry processing factory.
After the operators finish packing the chicken pieces they are put way in a cardboard box, which is placed on conveyors after full. This cardboard travels through the factory until gets to the "GEMS" where it is going to be weighted, have its production data recorded (date, time, line, weight) and directed to its destination (reject, freezer 40 min, 90 min or fresh).
The control and safety were done with a Guard Logix from Rockwell with over 560 IOs points distributed on a Ethernet/IP network. A Citect SCADA was used too.
Developed by Machinery Automation & Robotics
Role: Project Management, PLC and SCADA Programming, Commissioning and Start-up.
Conveyor Control and Production Recording
This project was developed to Inghams Chicken (Thomastown-VIC-Australia) and was responsible for controlling the conveyors in a poultry processing factory.
After the product is cooked the conveyors take the pieces through all different machines which are responsible for packing, labelling and bundle the finished product.
The control and safety were done with a Guard Logix from Rockwell with over 300 IOs points distributed on a Ethernet/IP network. A Citect SCADA was used too.
Developed by Machinery Automation & Robotics
Role: Project Management, PLC, HMI and SCADA Programming, Commissioning and Start-up.
Effluent Treatment Plant
Este projeto foi desenvolvido para Fruki em Lageado - RS - Brasil e consiste no controle dos equipamentos destinados a fazer o tratamento de efluentes da planta antes de retorná-lo ao meio ambiente.
O CLP controla bombas, válvulas e uma centrífuga, controlando os diferentes estágios do processo.
Para o controle foi utilizado CLP S7-300 da Siemens com entorno de 50 pontos de IO. O controle é feito por botoeiras e uma IHM.
Sistema de Controle Desenvolvido por Zentrum Automação Industrial.
Responsabilidade: Programação, Comissionamento e start-up do PLC e IHM.
Conveyor Control
This project was developed to Tooheys - NSW - Australia and it changed the way the pallet conveyors work as a new line was added along with new conveyors.
As per the addition of a new line the layout of the conveyors had to be changed. It was involved the rearrange of some IOs, adding extra points to control the new conveyors and change most of the program.
A S7-300 PLC from Siemens was changed.
Developed by Machinery Automation & Robotics
Roll: PLC Programming and Commissioning
CIP and Fermentation Commissioning
This project was developed to Bluetongue Brewery at Warnervale - NSW - Australia and involved the commissioning of a CIP and fermentation process relocated from other plant.
Part of a brewing process was disassembled from one plant for a third company and reassembled at this new plant. The whole IO and process logic hat to be tested again. Some of the control had to be added in a existing SCADA.
For control and safety a PLC S7-300F from Siemens with over 300 IO points was used. The modified SCADA was a WinCC from Siemens.
Developed by Machinery Automation & Robotics
Role: Project Management, Programming and Commissioning.
Rice Plant
Project developed to JOSAPAR (Pelotas - RS) where an entire rice processing plant was automated.
It was involved in the project all rice transportation inside the factory, including the truck unloading, taking through all different machines to dry, peel, select, store and pack. The project involved lots of conveyor control, with different routes end interlock between them as some times the same equipment could be used in different scenarios.
A Siemens PLC S7-300 with around 1500 IO points, an IHM also from Siemens and a Elipse SCADA were used in this project.
Developed by Zentrum Automação Industrial
Role: PLC and HMI Programming, Commissioning and Start-up.
Grain Plant
This project was developed for a grains cooperative in Guarapuava - PR, mostly soy and corn and were responsible for a small dry and storage automation.
The project comprehended all grain transportation inside the plant, including the truck unloading, taking through all different machines to dry, select and store.
A Siemens PLC S7-300 with around 300 IO points and an Elipse SCADA were used in this project.
Developed by Zentrum Automação Industrial
Role: PLC and SCADA Programming, Commissioning and Start-up.
Milk Reception, Past. and Sterilization
Conveyor Control + GEMS - Bolivar
Conveyor Control + GEMS 2 - Bolivar
Conveyor Control + GEMS - Murrarie
Conveyor Control - Thomastown
Beverage Effluent Treatment Plant
Upgrade in a Conveyor Control
CIP & Fermentation Commissioning
Rice Plant
Grain Plant
Integrated Gas Cylinder Test
This project was developed to BOC gases at Wetherill Park -NSW -Australia site for the integrated cylinder test shop.
Two brand new recycling lines (aluminium and steel) were fully automated. In each one of the lines a robot does some of the testing and put and remove the cylinders from two new machines designet to remove and replace de valves on the cylinders; and a shot-blast, an ultrasonic testing machine, pin stamping machine, a powder coating machine, two ovens, a cooler, and a shoulder band machine were integrated to the line. An overhead conveyor takes the cylinders through the machines.
Each line was controlled by two S7-300F PLCs pluse a S7-200 or S7-300 PLC per machine, which were fully integrated with Profibus-DP. A WinCC SCADA was used to interface with the operator.
Developed by Machinery Automation & Robotics
Role: PLC programming and start-up.
Compressed Air Drier
This project was developed to Copesul (Brasken now) in Triunfo - RS - Brazil and was responsible for replacing a relay controlled compressed-air drier in a petrochemical plant by a PLC.
The logic hat to be extracted from the electrical drawings and implemented in a SLC PLC from Rockwell. The push-buttons were replaced by a HMI with some extra diagnostics.
Developed by Serrano Automação.
Role: PLC and HMI Programming and Start-up.
Safety Alarm Annunciator
This project was developed to Copesul (Brasken now) in Triunfo - RS - Brazil and was responsible for replacing a relay controlled compressed-air drier in a petrochemical plant by a PLC.
A RSView SCADA from Rockwell with a redundant Ethernet network communicating OPC with a DCS server was responsible to annunciate all critical alarms.
Developed by Serrano Automação.
Role: SCADA Programming, Commissioning and Start-up.
Integrated Cylinder Test Shop
Compressed Air Drier
Safety Alarms Anunciator
Water and Sewer Control and Data Logging
Project developed to Mackay council in Queensland, north of Australia. The water and sewer pumping stations were controlled by a stand-alone controller obsolete and without any alarm and data logging system.
A new digital radio network was installed and each pump station received a RTU and a radio to communicate with the master station through the repeater. The protocol used Ethernet (DNP3). Some of the stations were configured with a peer-to-peer communication, like between the water bores and the reservoir.
Each one of the RTUs was programmed to control the pumps even in a network failure, with duty/standby rotation, automatic/manual control and data logging.
Schneider RTUs and Trio Radios were used along with ClearSCADA.
Developed by Radtel.
Role: Project Management, RTU, Radio and SCADA Programming, Commissioning and Start-up.
Water Supply and Dam Control
Project developed to Nambucca Head council in New South Wales, Australia. A new dam was built to increase the water storage capability.
The water pumped to town comes from 6 bores placed on the river bed, which are influenced by eventually droughts in Australia. A new panel was installed to control de pumps. RTUs and radios were installed at the dam and two different reservoirs. When the reservoirs are full, the pump stations send the water to the dam. When the reservoirs are empty the pump stations send the water to them. During the drought period the dam supply the water to the town.
An Omron PLC and Radtel RTUs were used in this project.
Developed by Radtel.
Role: Project Management and PLC Programming.
Radio Network and SCADA Upgrade
Project developed to Forster council in New South Wales, Australia. The water and sewer radio communication between the RTUs and the control station was upgraded to a digital radio network.
All radios and repeater were replaced by digital radio devices to supply a better network. The RTUs were kept the same. The SCADA was upgraded too. All previous functionality were extracted from the old system and kept in the new one, plus lots of new features available now due tu its new digital network and advanced SCADA software.
Trio Radios were used along with ClearSCADA.
Developed by Radtel.
Role: Project Management, Radio and SCADA Programming, Commissioning and Start-up.
Water & Sewer Control and Data Logging
Water Supply and Dam Control
Radio Network & SCADA Upgrade
Bacteria Counting Control
This project was developed to BTF Biomerieux in Sydney - NSW - Australia and was responsible to interface and control several parts in this small machine.
Some of the control were the mixer, sipper (vacuum), the carousel (servo motor) and the interface with the machine, where a high-speed input card had to be used to count and detect the frequency response sent by the machine.
For the control and interface with the operators a S7-300 PLC and HMI from Siemens were used. All devices, including the servo motor were connected through Profibus.
Developed by Machinery Automation & Robotics
Role: Project Management, PLC, HMI and Servo motor Programming, Commissioning and Start-up.
Cosmetic Batch Control
This project was developed to O Boticário in the city of São José dos Pinhais - PR - Brazil where the whole recipe editing, execution and logging were automated.
The recipe is created in an Excel spreadsheet and uploaded to the SCADA. At the recipe there are many types of steps that can be created like heat, cool, mix, rest and add ingredient. When a product is going to be made, the operator download the chosen recipe to a selectable reactor. For some of the steps the system execute automatically, like cooling, heating and mixing. When a ingredient needs to be added the HMI (one per reactor) show the ingredient and how much of it. All the operator has to do is add it and confirm on the HMI.
For the control a S7-300 from Siemens with over 300 IO points, 8 HMIs also from Siemens and an Elipse SCADA were used.
Developed by Zentrum Automação Industrial
Role: PLC and HMI Programming, Commissioning and Start-up
Bacteria Counting Control
Cosmetic Batch Control
Tobacco Drying Machine
This project was developed to Universal Leaf Tabacos in Salta - Argentina and was responsible to dry out tobacco leafs through vacuum and heat.
Up to 10 pallets with tobacco leafs are positioned on a chain conveyor which takes them into the machine through one side and remove them by the other side. With the pallets in the machine, the doors are closed and through controlled heat and vacuum the leafs are dried.
It was used a S7-300 PLC and an OP27 HMI from Siemens.
Developed by Julio Lovatel
Role: PLC and HMI Programming and Start-up.
Robotic Tobacco Packing and Palletizing
This project was developed to British American Tobacco in East Gardens - NSW - Australia and involved 3 new packing and palletizing lines previous done manually.
Each one of the lines have 2 robots, one for packing and one for palletizing. Two machines were also designed and built, one carton erector and one to arrange the tobacco cartons in such way that the packing robot can pick up a complete packing layer at one time.
For each line a S7-300, a S7-200 and an IHM were used, all from Siemens.
Designed by Machinery Automation & Robotics
Role: PLC and HMI Programming, Commissioning and Start-up.
Tobacco Drying Machine
Tobacco Packing and Palletizing
Pallet Barcode
This project was developed to Kimberly Clark in Mount Gambier - SA - Australia and was responsible to stick the same barcode in 2 sides of a pallet.
In total 9 robots palletize the plant production, some of them palletizing up to 9 different products at the same time. After the pallet is complete it moves along the conveyors until gets to the stretch wrapper. The barcodes had to be placed on top of the wrapping. In some of the lines the stretch wrapper program was modified to stop in the last turn and place the barcode, in others a rotating conveyor was installed after the wrapping to do task.
Lots of barcode readers were installed to identify the product and confirm the barcode was placed correctly.
It was used SICK barcode readers connected through Ethernet-IP with a new SLC PLC from Rockwell and with another 11 existing PLCs from Rockwell too. Seven HMIs from Rockwell also were changed .
Developed by Machinery Automation & Robotics
Role: PLC and HMI Programming and Start-up.
Pallet Barcode
This project was developed to Kimberly Clark in Ingleburn - NSW - Australia and was responsible to stick the same barcode in 2 sides of a pallet.
In total 3 robots and a palletizing machine palletize the plant production. After the pallet is complete it moves along the conveyors until gets to the stretch wrapper. The barcodes had to be placed on top of the wrapping. For the robotic lines the stretch wrapper program was modified to stop in the last turn and place the barcode, in the palletizing machine the pallet was tracked along the conveyor a 2 barcode printers were installed.
The barcode printer was responsible to read and identify the product, the PLC gives the trigger to print and place.
No new PLCs were used in this project, however 8 existing SLC PLC from Rockwell were modified.
Developed by Machinery Automation & Robotics
Role: PLC Programming and Start-up.
Pallet Barcode
This project was developed to Kimberly Clark in Ingleburn - NSW - Australia and was responsible to soldering the stretch wrap film on the way out of the machine.
As some times the wrapping film wasn't staying firm on the pallet and was following over the barcodes, a soldering device was installed on the stretch wrappers. A hot wire attached to a swing arm was installed on the way out of every stretch wrapper in the plant.
No new PLCs were used in this project, however 4 existing SLC PLC from Rockwell were modified.
Developed by Machinery Automation & Robotics
Role: PLC Programming and Start-up.
Robot Upgrade
This project was developed to Kimberly Clark in Ingleburn - NSW - Australia and was responsible to replace a old palletizing robot for a new one.
A old ABB robot was replaced by a similar new one from the same brand. Everything else was kept the same, including the gripper. The program was developed using the Palletizing Power Pack from ABB, where the whole program is done graphically.
Developed by Machinery Automation & Robotics
Role: Robot Programming and Commissioning.
Pallets Barcode - Mount Gambier
Pallet Barcode - Ingleburn
Stretch Wrapping Film Soldering
Robot Upgrade
Food & Beverage
Oil & Gas
Water & Sewer
Pharmaceutics
Tobacco
Transformation
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