Fonterra Machine Servo Control Upgrades

Rockwell Automation NZ Ltd
Fonterra Te Rapa Butter Line Upgrade
1 Month

This project involved the removal of existing DC motors and controllers that were used to control the sequencing of a butter packaging line. This upgrade was required to meet continued export growth and to increase plant efficiency.

A redesign of the existing control cabinets was needed to create space for the new servo drives. The existing control wiring was also simplified substantially.

Our brief also included the design and manufacture of motor adaptor plates so that the new servo motors would fit the existing machine mounts and couplings.

The project had to be completed in a short time window when the factory was shutdown for annual maintenance.

After the project was commissioned from production records it was found that the butter line output from this one machine had doubled giving our client substantial productivity gains.

Work carried out included:

  • Disconnect and remove existing DC motors and encoders on butter line.
  • Disconnect and remove DC drives and associated controls from control cabinets.
  • Design new control cabinet layout and power distribution.
  • Installation of new servo drive axis controllers and control terminations.
  • Installation of servo cables out to butter line room.
  • Mechanical adaptation plate design to assist with new motors connecting to original DC motor mounts and couplings.
  • Commissioning installation and assisting Rockwell Automation engineers.

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