Centralized control for 70 autoclaves with one-click configuration replication and RFID operator login.
Industry: Manufacturing (Pet Food)
Quick Facts
| Attribute | Value |
|---|---|
| Customer | Landguth Heimtiernahrung GmbH |
| Facility | Ihlow, Germany |
| Autoclaves | 70 units across multiple halls |
| Operators | 140+ working 24/7 in three shifts |
| Tags | 1,500 points per autoclave + unlimited supervision |
| Development | 4 months for first application |
| Test Period | 3+ years before full rollout |
| Integrator | Rohrbach Elektrotechnik GmbH |
The Challenge
Challenge: Modernize monitoring for approximately 70 autoclave control systems that were separated from one another, requiring individual configuration with no centralized information.
Specific pain points:
- 70 autoclaves each configured separately (stand-alone applications)
- Previous Software-PLC based system from autoclave manufacturer had become obsolete
- No centralized information about processes
- Changes required walking to each autoclave with USB stick
- Could not meet requirements for central control functions
- Data could not be sent or received where needed
- Needed fast modernization without downtime — retrofit one autoclave at a time during ongoing operation
Impact: Wasted time on individual configuration, no process visibility, impossible to get real information from decentralized data.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Field | Siemens S7-1500 PLC per autoclave | I/O modules, RFID reader, dot-matrix scanner |
| Local HMI | Industrial PC + FrameworX | Process visualization per autoclave |
| Central | FrameworX Supervision | Manage all 70 autoclaves from one location |
| Database | Central SQL | Production data, alarms, event logs, archiving |
| Identification | RFID + Dot-matrix scanner | Basket and batch tracking |
Scale
| Metric | Value |
|---|---|
| Autoclaves | 70 units |
| Operators | 140+ (24/7, three shifts) |
| Tags per Autoclave | 1,500 points |
| Supervision System | Unlimited tag license |
| Development Time | 4 months (first application) |
| Test Period | 3+ years |
Products Sterilized
- Cans
- Pouches
- Shells
- Other containers
- For premium dog and cat food
Central Control Features
| Feature | Description |
|---|---|
| Visualization | Real-time process displays |
| Alarming | Centralized alarm management |
| Production Data | Complete batch tracking |
| Status Data | Machine utilization monitoring |
| Recipe Data | Cooking program management |
| Trending | Setpoint vs actual value analysis |
Integration Points
- Upstream: Filling lines
- Downstream: Labelers, palletizers
- Batch tracking of transport baskets
- Path optimization (future: filling line to next free autoclave)
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| Centralized Configuration | One-click replication to all 70 autoclaves |
| Siemens S7 Native Driver | Quick and efficient PLC communication |
| Online Changes | Cooking programs, recipes, user admin during production |
| Central SQL Database | Production data, status, alarms, event logs archived |
| RFID Integration | 140+ operators log in via RFID chips |
| Code Behind | Custom-tailored screen functionality |
| Automatic PDF Generation | Production logs shared with stakeholders |
The Results
Reduced Risk and Error — Automatic checks reduce operating errors and management time vs old system
Less Downtime — Changes to cooking programs, recipes, user admin during ongoing production
Immediate Data Availability — All data contributes to monitoring and optimization
Faster Batch Completion — New batches complete much more quickly
Easier Operation — Autoclaves much easier and faster to operate
Eliminated USB Walks — Changes now automatic, no more walking to each autoclave
Real-time Sensor Logging — Setpoint vs actual values for performance monitoring
Leak Detection — Up-peak and down-peak curve analysis enables responsive monitoring
Complete Audit Trail — All alarms, parameter changes logged
Machine Utilization — Detailed logging identifies downtimes and production reserves
Reduced Cooking Time — Process optimization through data analysis
Customer Testimonials:
"The implementation of FactoryStudio by Rohrbach Elektrotechnik has enabled us to easily operate and control the autoclaves from a central location. The operability of the autoclaves has greatly improved. In addition, the flexibility of the system is optimal for our requirements."
— Landguth Heimtiernahrung GmbH
"Leveraging the Code Behind feature in FactoryStudio displays enabled us to create powerful displays with custom-tailored functional capabilities on a screen-by-screen basis."
— Hans-Peter Hermann, Senior Software Engineer, Rohrbach Elektrotechnik
Resources
Download case study: CaseStudy_Autoclave.pdf
This case demonstrates centralized autoclave control with one-click configuration replication for 70 units and 140+ operators.
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