Old Meets New
The Angaston site has five bottling lines with the main production on two glass bottling lines which were last updated in the early eighties. The remainder of the lines are used for sparkling, cask and other miscellaneous packaging tasks.
“While various pieces of equipment were added over time the layout of the bottling lines were set up more than thirty years ago and due to obsolescence and reliability issues we made the decision to pull everything out and start from scratch with the bottling line. We also needed to upgrade the depalletisers that move the glass from pallets onto the line and address our aging conveyors,” said John Ide, manager – winery operations, at Yalumba.
“One of our key goals was to separate our material flow in and out of the line and hence forklift movement in the main operational areas,” he explained.
The project was taken to tender and as a result of their extensive experience in the food and beverage industry, together with their innovative approach and design for the bottling lines, FOODMACH was awarded the project.
FOODMACH designs and manufactures user-focused automation for FMCG and industrial manufacturing customers, delivering fully integrated equipment and packaging lines for maximum productivity. They offer customised solutions for packaging machinery design, manufacturing, controls and service. FOODMACH’s Robomatrix® hybrid palletising system fully utilises the Allen-Bradley® ControlLogix® platform and FactoryTalk® View SE, and according to FOODMACH, has become the gold standard of high-speed beverage palletisers in Australia and abroad.
The first bottling line contained predominantly existing equipment that was relocated with new controls, a new conveyor and new palletisers, while line two was a completely new line with a new de-palletiser, filler and packer. The existing labeller and palletiser were retained.
FOODMACH’s key responsibilities were to provide the overall automation and control systems for the bottling lines as a whole, design, supply all the conveying and to manufacture two new glass depalletisers. Careful consideration of the control interfacing between each machine on the line teamed with appropriate conveyor design and buffering is essential to delivering the highest possible line efficiencies.
According to Gavin Alder, software manager, FOODMACH, “Having worked with Rockwell Automation previously, we knew that their control system would be the best choice for this application in regards to integration, programming and commissioning. We have developed our software standards around OMAC/PackML and using our proprietary line control software all neatly wrapped up in Add On Instructions we can develop and deploy systems quickly and consistently. Programming becomes drag and drop.