Mobile iPad control for feed research within contaminated hazard level II environments.
Industry: Food & Beverage (Feed Research)
Quick Facts
| Attribute | Value |
|---|---|
| Customer | Cargill Feed Safety Research Center (FSRC) at Kansas State University |
| Facility | O.H. Kruse Feed Technology Innovation Center |
| Classification | Only hazard level II feed research center in the world |
| Mobile | Native iPad/iPhone control |
| PLC | ControlLogix with native driver |
| Integrator | The Lakeland Companies (1,200+ volunteer hours) |
The Challenge
Challenge: Monitor and control equipment throughout the facility and within potentially contaminated areas where salmonella and other pathogens are present for feed safety research.
Specific pain points:
- Hazard level II environment with salmonella and other bacteria present
- Need to control system remotely from outside contaminated production areas
- Traditional fixed workstations not suitable for contaminated environments
- Research requires modifying feed production variables while monitoring experiments
- Thousands of domestic and international feed industry professionals participate in educational programs
Impact: Without mobile control, personnel could not safely monitor and adjust feed production variables within contaminated research areas.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Control | ControlLogix PLC | Feed conditioner, VFDs, equipment start/stop |
| SCADA | FrameworX Server | Central monitoring and control |
| Mobile | iPad/iPhone (native) | Control from contaminated areas via disposable plastic bags |
| Classroom | Windows computers | Remote monitoring and education |
Mobile Contamination Protocol
- iPads protected in disposable plastic bags that seal shut
- Users carry devices through contaminated environment
- Plastic shield disposed of in decontamination area when done
- Enables safe mobile control within hazard level II areas
Feed Research Process
- Steam infused with ground corn
- Pressed into pellets for animal feed (cows, pigs, goats, sheep)
- Pathogens (salmonella) introduced for research
- Experiments to develop extraction/elimination methodologies
- System parameters modified to examine effects on feed quality
Equipment Control
- Two VFDs controlling feed conditioner speed
- Start/stop capability for any piece of equipment
- Production variable modification
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| Native iPad/iPhone Support | Control from within contaminated areas |
| Native ControlLogix Driver | No third-party interface needed |
| Tag Import | Uses ControlLogix tags and data structures directly |
| Windows to iOS Deployment | Develop on Windows, deploy to iPad without additional engineering |
| Remote Monitoring | Classroom access for education and safe operation |
The Results
Safe Contaminated Area Control — Personnel modify feed production variables while on the move in hazard areas
Classroom Access — Remote control from the cleanliness of quiet classroom environments
No Third-Party Interface — Native ControlLogix driver eliminated middleware
Reduced Configuration Time — Direct tag import from ControlLogix eliminated manual configuration
Cross-Platform Deployment — HMI screens developed for Windows deploy to iPad/iPhone without additional engineering
Industry Showcase — International groups visit to see the system; major change from previous capabilities
Educational Platform — Hands-on learning for students entering feed and grain industries
Customer Testimonials:
"I can't tell you how many people have come through this building. International groups are very interested. We like showing it off. The system is a big change from what we had; everybody appreciates it quite a bit."
— Joel McAtee, Feed Mill Manager, O.H. Kruse Feed Technology Innovation Center
"The ability to develop the HMI screens for use on Windows computers and then easily deploy them to iPads and iPhones without additional engineering was fantastic!"
— Mark Spindler, The Lakeland Companies
Resources:
Download case study: CaseStudy_GrainManagement.pdf
This case demonstrates mobile iPad control for feed research operations within hazard level II contaminated environments.
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