Margarine production line modernization
A legacy Siemens S5 system was modernized to S7-1500 and WinCC. Operators select process operations instead of controlling each valve and motor individually.
Client task
Modernize Siemens S5 controls, introduce an HMI and production logging, and retain familiar manual-control options.
My responsibility
I independently handled analysis, PLC/HMI development, IPC logging, integration and commissioning. Main commissioning took place during weekend shutdowns.
Result
S5 replaced by S7-1500 and WinCC, with more automated operations, fewer manual actions, clearer visualization and production traceability.
Technical solution and scope
The task
Modernize a production system operated largely through physical switches, introduce a primary HMI and production logging, and retain familiar manual-control options.
System scope
Approximately 60 motors/pumps, up to 100 valves, around 60 operations and 15 tanks/process units. Temperature and level signals and distributed PROFINET I/O. S7-1500, ET 200, WinCC Comfort HMI and a Debian-based Siemens IPC.
My responsibility
I independently handled existing-system analysis, PLC architecture and programming, HMI development, IPC logging software, equipment interfaces, testing, commissioning and subsequent improvements.
The solution
A modular ISA-88 / S88-based architecture. Operators select an operation and the PLC manages the associated equipment. Original three-position switches remain selectable Automatic / Off / Manual On overrides. Weighing, temperature and liquid flow/volume systems were integrated; functions of additional Schneider controllers were consolidated into the main PLC.
Commissioning around production
Main commissioning took place during weekend shutdowns. Further tuning, debugging and additional functionality were introduced during production or short available maintenance windows.
Result and scope boundaries
More automated operations, fewer manual actions, clearer visualization and better production traceability, with maintainable software for future expansion. The architecture is recipe-ready, but recipe management was not implemented. Functional safety was outside this project’s scope.
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