Portfolio

$3 million dollar relocation of three productions lines from NJ to NC. This included disassembling of 3 extruders and mixers along with all auxiliary equipment. The expansion included the design and installation for the electrical and mechanical systems needed for the increased production and added load to the existing plant systems. During this phase all lines were installed, automated and integrated into the existing plant control system. This project was completed in 6 months 3 months ahead of schedule allowing production to start 3 months ahead of schedule.

Designed and installed a custom Barcode system with SAP integration to control inventory and quality through all phases of manufacturing. All aspects of the process are controlled by via this system ensuring the production of consistent and high quality finished goods. All receiving, production and shipping transactions are logged into SAP throughout process eliminating redundant data entry and human error by either scanning needed data entries or transferred from the SCADA system.

Redesigned and reprogrammed multiple plant blending and extruding operations combining them into a plant wide control system with the ability to access any application from any shop or desktop pc eliminating the need for a central control room. The system was composed of 5 blending and 3 mixing lines utilizing common liquid and powder bulk ingredient systems each feeding an extruder. This system involved programming, networking, servicing 21 PLC systems and redundant SCADA systems.

We have completed many projects involving extruder control systems. The control systems varied in complexity. From simple manual control systems utilizing push buttons and single loop controllers. More advanced systems incorporated with PLC’s and Operator Interfaces controlling heat zones die temperature, extruder rpm, pump/pressure control loops, etc. These upgrades have translated into increased production and reduction in downtime. Machines include extruders, blenders, flywheel cutters, die cast, injection molding, trim presses and many more.

Developed numerous systems for data logging and system reporting. Various data collection methods have been used according to client infrastructure and requirements. Systems have involved communicating with existing or installing new PLC systems for data manipulation. Storing and displaying of data has been accomplished using various SCADA systems or Visual Basic including popular packages such as Ignition, FPMI, Wonderware and others. Data has been stored locally or to a central data server utilizing MySQL or Access.