Plant-wide data collection with multi-language support and embedded SQL logging for dairy operations.
Industry: Food & Beverage (Dairy)
Quick Facts
| Attribute | Value |
|---|---|
| Customer | Zenchenko IK |
| Products | Yogurt, Milk, Kefir, Sour Cream |
| PLCs | 4 Siemens S7 (each with local HMI) |
| Development | 3 weeks |
| Languages | Russian, German, English |
| Integrator | KSA (Germany) |
| Database | Embedded-encrypted SQL (included) |
The Challenge
Challenge: Create an automated system to collect data from across the entire dairy, including the milk supply, flash pasteurizer, tank farm, and CIP-station (cleaning) sections from four independent PLCs.
Specific pain points:
- Four independent Siemens S7 PLCs with local HMIs needed unified monitoring
- Production areas wet — not a good environment for PC stations
- Production Manager, Foreman, and office personnel needed remote overview
- Required production and efficiency reports for pasteurization of milk and cream
- CIP documentation needed for compliance and operator awareness
- Multi-language operators (Russian, German, English)
Project Goals:
- Provide operations overview for management away from wet production areas
- Generate production and efficiency reports for pasteurization processes
- Record CIP settings (acid, caustic, or both) with historical documentation
- Demonstrate proper heating and thermal processing procedures were followed
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Field | 4 Siemens S7 PLCs | Local HMI for Start/Stop, parameters |
| Central | FrameworX SCADA | Plant-wide data collection, reports |
| Database | Embedded-encrypted SQL | All data logging (no additional DB needed) |
| Clients | Office workstations | Remote monitoring away from wet areas |
Process Areas Monitored
| Process | Function | Key Data |
|---|---|---|
| Milk Supply | Milk delivery to two tanks | Temperature, level, total processed |
| Flash Pasteurizer | Heat to reduce germ count | Temperature control, circulation |
| Tank Farm | Heating/mixing for milk, cream, products | Storage monitoring |
| CIP Station | Clean-in-place for pipes, tanks, heaters | Acid/caustic settings, cleaning records |
Development Efficiency Features
| Feature | Benefit |
|---|---|
| Excel Copy/Paste | Tag, alarm, data collection configuration |
| Symbol Library | Graphical objects linked for global changes |
| Native PLC Drivers | Siemens S7 communication built-in |
| Integrated Suite | No additional software needed |
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| Multi-Language Support | Russian, German, English switching for operators |
| Embedded SQL Database | Encrypted data logging included — no external DB cost |
| State-of-the-Art Engineering | Reduced development to 3 weeks |
| Excel Integration | Copy/paste configuration tables |
| Symbol Library | Linked graphical objects for global updates |
| Integrated Suite | Graphics, data collection, .NET scripting, diagnostics, reports, PLC drivers |
The Results
3-Week Development — State-of-the-art tools dramatically reduced SCADA development time
Cost Savings — Embedded-encrypted SQL database eliminated external database costs
Multi-Language Operations — Operators learn system quickly in native language
Remote Monitoring — Management oversight away from wet production areas
Compliance Documentation — Reports demonstrate proper thermal processing procedures
CIP Tracking — Operators know what's been cleaned with historical documentation
No Training Required — Project completed successfully without attending training classes
Customer Testimonials:
"I selected FactoryStudio from Tatsoft for the project, because of the modern technologies at its core, and my desire to get away from using old legacy products like InTouch or WinCC. I wanted to work with a really new product. KSA trusted in me to choose the right software to serve the purpose, and FactoryStudio greatly satisfied our needs."
— Alexander Berthel, Berthel Automatisierungstechnik
"All my questions to the Tatsoft support were answered within 24 hours. Without attending a single FactoryStudio training class, I was able to finish the project successfully!"
— Alexander Berthel
Resources:
Download Case Study: CaseStudy_DataLogging.pdf
This case demonstrates dairy plant data collection with multi-language support and embedded database for compliance documentation.
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