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KP Snacks Case Study

Case Study: Wheat Crunchie Fryer Control Panel Replacement
Control Panel Replacement
(Siemens PLC upgrade)

Market Sectors: Food & FMCG

Project Description: One of MCS Control Systems customers, KP Snacks in Teesside, needed a Specialist Systems Integration Contractor who could successfully replace an obsolete and unreliable business critical control panel for their Wheat Crunchie Fryer , upgrading the safety systems at the same time. The Control Panel included an upgrade to a Siemens S7-1500 PLC, new safety systems, a TP1200 HMI, with the system controlling new Siemens G120 drives on Profinet, and MCS renewing all the necessary wiring. The software was written using TIA Portal

Approach: This project was deemed to be the most risky replacement project ever undertaken by KP Snacks as it involved replacing a complete control panel, not just a component within the panel such as a PLC.

MCS Control Systems have a proven methodology, developed over the years, for upgrading and replacing business critical systems spanning many industry sectors including; Food, FMCG, Automotive, Aerospace, Utilities, Process, Construction Products, and Building Services.

The system was fully re-tested against an agreed site acceptance test specification, and following comprehensive training of KP Snack’s operatives and technicians, the Fryer was put back into service half a day ahead of schedule.

Results:At the end of the project, John McGuire , Process Engineer, commented: “I'd like to pass on my sincere thanks for the excellent work completed by MCS on the above project. The job had the potential to be extremely testing due to the condition of the original panels and the lack of available information. It would be fair to say that this was the highest risk upgrade project that I have been involved in to date”

“All of your staff involved in this work have been a credit to MCS but Russell deserves a special mention for the effort and expertise he put into the job to ensure that the project was a success and that the equipment was available for production ahead of schedule”



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Market Sectors

MCS Control Systems are active in many differing arenas, take a look by clicking on a link below.

Project Management & CDM 2007

Logistics/Materials Handling

Automotive & Manufacturing

Process & Utilities

Food & FMCG