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Coca-Cola Amatil |

Executive Summary

Coca-Cola Amatil (CCA) is one of Australia’s leading beverage providers with over 500 beverage brands worldwide. Market dominance is driven by product diversification and commitment to consumers, communities and innovation in the marketplace. These market drivers according Chief Executive Officer Muhtar Kent have evolved to sharpen external focus on the marketplace underpinned by greater speed, productivity and effectiveness. The comprehensive metering and monitoring package provided by Buildings Evolved is in line with the brands proactive strategy of fine tuning its operations.

Out Performers Pty Ltd were the contracted agents for which Buildings Evolved were commissioned to deliver metered data from an existing system sent to a web-based monitoring program across 5 sites. The infrastructure project ultimately provided a complete picture of Coca-Cola’s energy and utility consumption across their Australian operations and is currently being utilised to drive efficiency and productivity programs.

coca-cola_amatil

Location: Australia

Industry: Beverage Manufacturer

www.ccamatil.com

Business Drivers

Industry

The beverage industry is becoming increasingly competitive. Sugar-based sodas and juice sales are in decline year over year. Whilst there is a push to diversify into the growing ‘healthy’ drink market, opportunity exits through technology to streamline operations for competitive advantage.

Design

The project gives CCA granular data over resource consumption at the operational level through a web-based platform. Offering end-users specific reporting capabilities and strategic operations high-level information for decision making processes predicating efficiency programs.

Implementation

New electricity and utility meters were interfaced into the existing SCADA system. The data feeds are propagated through the addition of metering throughout physical sites to combine utility electricity interval and billing data, as well as water and gas from a GSM via a DataTaker DT80 data logger sent to the Out Performers EMS web-based monitoring platform. Input sensors types include electricity, water and gas; while output sensors include anything connected to the existing SCADA system – steam and compressed air flow rates as well as temperatures of critical systems including chillers and boilers.

Outcomes

  • CCA will have the capacity and data paths to use the Out Performers EMC web-based platform
  • Analysis and reporting of performance and outcomes within the Northmead factory through the EMC
  • Detailed data from SCADA across all metrics captured by and sent to the EMC platform via the DT80
  • The Data Taker DT80 was configured and maintained by Out Performers EMC
  • Capacity to expand to other facilities for cross-portfolio benchmarking
  • Capacity to expand the data path to include other metrics sourced from additional metering points or other production metrics sourced from PLC/SCADA

Business Drivers

Industry

The beverage industry is becoming increasingly competitive. Sugar-based sodas and juice sales are in decline year over year. Whilst there is a push to diversify into the growing ‘healthy’ drink market, opportunity exits through technology to streamline operations for competitive advantage.

Design

The project gives CCA granular data over resource consumption at the operational level through a web-based platform. Offering end-users specific reporting capabilities and strategic operations high-level information for decision making processes predicating efficiency programs.

Implementation

New electricity and utility meters were interfaced into the existing SCADA system. The data feeds are propagated through the addition of metering throughout physical sites to combine utility electricity interval and billing data, as well as water and gas from a GSM via a DataTaker DT80 data logger sent to the Out Performers EMS web-based monitoring platform. Input sensors types include electricity, water and gas; while output sensors include anything connected to the existing SCADA system – steam and compressed air flow rates as well as temperatures of critical systems including chillers and boilers.

Outcomes

  • CCA will have the capacity and data paths to use the Out Performers EMC web-based platform
  • Analysis and reporting of performance and outcomes within the Northmead factory through the EMC
  • Detailed data from SCADA across all metrics captured by and sent to the EMC platform via the DT80
  • The Data Taker DT80 was configured and maintained by Out Performers EMC
  • Capacity to expand to other facilities for cross-portfolio benchmarking
  • Capacity to expand the data path to include other metrics sourced from additional metering points or other production metrics sourced from PLC/SCADA

Building Shared Values

Consultation in quality technological systems - Identify value, ethos and culture necessary to drive efficiency and discover innovations

Requirements

Proactive governance is key to CCA’s competitive advantage. The overarching requirement of the metering and monitoring package to facilitate a better understanding of where energy is being consumed, and what the output of various services is in order to determine plant efficiency.

  • Installation of a range of electrical, gas flow and water flow meters
  • New meters will be interfaced to the existing SCADA system
  • Data feeds Out Performers EMS web-based monitoring platform (Switch Platform)

Technical Overview

  • There exists SCADA/PLC network at each control point on the line
  • This network point can be split by use of an industrial network switch
  • The resultant spare PLC network ports are used to connect up the electricity meters
  • The proposed meter is a Northern Designs Rail 350 IP model electricity meter
  • Northern Designs is the preferred brand due to flexible communications options including TCP/IP as well as prior experience with the product
  • The combination of energy meters with their associated outputs from counters already existing on SCADA will provide plant efficiency measurements, e.g. KWh per unit produced

Metering equipment installed

  • 18x Northern Designs Rail 350 IP meters
  • At each metering point, there is existing SCADA network point that shall be split by the use of 13x Moxa EDS205 5-port industrial DIN Ethernet switch
  • That the Out Performers EMC team shall supply and commission the DataTaker DT80 data logger. Installation shall be covered by this contract on the basis of a supplied shelf in an existing data rack, with supplied SCADA network connection and power (specifically excluding enclosures/other accessories)
  • That the CCA engineering team develop the ActivPlant OPC server to poll the metering and monitoring devices for connection to the PLC

Main Utility Connections

Electricity – On side of HV shed – connection by supply authority of Modbus module, subsequent connection and programming to SCADA. Subject to approval by Acumen Metering.

Water – Connection to existing supply authority meter pulse output connection, programming and testing by Sydney Water. A pulse signal sent by the unit at Sydney Water defined intervals. Subject to approval by Sydney Water.

Gas – Connection via Jemena flow compensator direct to intrinsically safe GSM data logger by Aegis. Subject to approval by Jemena.

OPTIMISING TECHNOLOGY

Develop organisational goals - translate problems into opportunities through technology to deliver value and return-on-investment

INTELLIGENCE IN BUSINESS

Turning data into knowledge at a building and portfolio level - provide business solutions that are specific and actionable

The Solution

CCA manufacturing facilities have as standard equipment; a Citect 7.2 SCADA system alongside ActivPlant PLC.  By connecting the new metering points to the existing PLC system, significant value is added to the engineering teams on site by providing them with high frequency data.  Less frequent data, typically 5 or 15-minute interval data is sent to the Out Performers EMC (Switch Platform) via a Data Taker DT80 data logger for higher level analysis and reporting requirements.  This system will allow a rich data set to be sent to the EMC, and it is here that the data will be turned into knowledge, through sophisticated data browsing and analysis tools, along with alerts and alarms, and a large collection of stock reports.

Summary

The comprehensive metering and monitoring package provided by Buildings Evolved forms part of CCA’s proactive governance strategy; 1) Deliver an intuitive and easy to comprehend user interface (UI) for the entry of data and to better understand consumption in relation to plant and equipment 2) To provide timely and accurate data facilitating monitoring, analytics and reporting systems for end-users 3) To facilitate high-level strategic operations decision making processes over performance and efficiency programs.

The overarching technology strategy delivers easy access to prudent information in discernible forms. Its method and delivery is at the forefront of machine data technologies and user centric systems predicating efficiency programs for competitive advantage. The resulting technologically driven outcomes are a reflection of a company in forward motion.