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SIEMENS Totally Integrated Automation in the Pasta Plants SIEMENS the partner for the Flour SIEMENS Totally Integrated Automation in the Pasta Plants SIEMENS the partner for the Flour Mill and Pasta Plants II World Wide Pasta Congress Venezuela October 2000 PAGE 1 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants PRESENTATION PROGRAM ►Introduction ►Concept ►Requirements ►Solution SIEMENS Totally Integrated Automation in the Pasta Plants PRESENTATION PROGRAM ►Introduction ►Concept ►Requirements ►Solution ►Communications ►Information management ►Advantages ►Conclusions II World Wide Pasta Congress Venezuela October 2000 PAGE 2 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants INTRODUCTION (1) The automation of pasta SIEMENS Totally Integrated Automation in the Pasta Plants INTRODUCTION (1) The automation of pasta plants had in these last years an important evolution. The programmable controllers are able to integrate all the process control functions into a PLC and now into PC integrating through Profibus, peripherals as inputs/outputs, drives, intelligent devices and operator panels The actual scenario is characterized by a Totally Integrated Automation Concept using a common hardware/software platform standard networking to satisfy the customers demand. II World Wide Pasta Congress Venezuela October 2000 PAGE 3 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants INTRODUCTION (2) The Totally Integrated Automation SIEMENS Totally Integrated Automation in the Pasta Plants INTRODUCTION (2) The Totally Integrated Automation Concept consists in integrating under a single automation system, three important areas which till now were automated separately as: Semolina silos (upstream) Pasta production (mainstream) Packaging and warehousing (downstream) Totally Integrated Automation (T. I. A. ) is performing process control, recipes handling, lots scheduling, products tracing, traceability, warehousing and web connectivity. II World Wide Pasta Congress Venezuela October 2000 PAGE 4 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants PLANT FLOW SCHEMATIC DIAGRAM Mainstream Milling SIEMENS Totally Integrated Automation in the Pasta Plants PLANT FLOW SCHEMATIC DIAGRAM Mainstream Milling Upstream Mixing Silos Drying Extrusion Cooling Downstream Semolina Silos Press Packaging Raw Material Wheat Receiving II World Wide Pasta Congress Venezuela October 2000 Palletizing Utilities PAGE 5 Warehousing Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants PLANTWIDE ISSUES Controller Distributed I/O Data SIEMENS Totally Integrated Automation in the Pasta Plants PLANTWIDE ISSUES Controller Distributed I/O Data management HMI Configuring/Programming Communication PCS Drives / Field devices Milling Wheat Receiving Semolina Press Extrus. Silos II World Wide Pasta Congress Venezuela October 2000 PAGE 6 Drying Cool. Packaging Utilities Palletizing Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ARCHITECTURE STRUCTURE Enterprise Resource Planing Manufacturing SIEMENS Totally Integrated Automation in the Pasta Plants ARCHITECTURE STRUCTURE Enterprise Resource Planing Manufacturing Execution System Process Control System Field Automation Semolina Silos Extrusion, Drying, Cooling, Utilities II World Wide Pasta Congress Venezuela October 2000 Handling, Packaging Palletizing, Warehousing PAGE 7 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ► THE CONCEPT T. I. A. SIEMENS Totally Integrated Automation in the Pasta Plants ► THE CONCEPT T. I. A. means design the plant automation introducing a new concept that has to consider the factory in its entirety. Production flexibility, costs control and total quality approach are successful key points for small and large companies. The target is to change a production process from a critical factor to a qualifying factor. To perform a complete control of all the different production phases starting from raw materials receiving and forwarding to the finished products. TIA is given an important contribution in terms of costs reduction, for revamping and new pasta plants II World Wide Pasta Congress Venezuela October 2000 PAGE 8 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants PASTA PLANT WIDE ARCHITECTURE Wincc Client SIEMENS Totally Integrated Automation in the Pasta Plants PASTA PLANT WIDE ARCHITECTURE Wincc Client ERP Wincc Client Engineering stations MES Ethernet TCP/IP, 100 MBit Wincc Server Industial Ethernet TCP/IP, 100 MBit Wincc Server Milling Plant Water treatment Fieldbus system PROFIBUS AS-Interface Grain Receiving Waste water treatment Milling Compessed air Sieving Wincc Server Flour Silos Short pasta line Long pasta line Packaging Flour silos Press Bridge Handling Palletizing Last floor silos Press Foot Packaging Warehousing Silos floor Grinding Cooling Wheighing Sistem Boiler Flour silos Press bridge II World Wide Pasta Congress Venezuela October 2000 Palletizing Ground floor Cutter Spreader Pre dryer Dryer Cooling/ Storage PAGE 9 Cooling Storage Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ► PLANT REQUIREMENTS Real time monitoring SIEMENS Totally Integrated Automation in the Pasta Plants ► PLANT REQUIREMENTS Real time monitoring of process variables through supervisory system, and relevant corrective actions in order to guarantee high quality. Client/server technology to address information of concurrent process to Control Room and plant Information Room in order to maximize the sinergy. Communication and interoperability of production areas (orizontal way) and other plant departments (vertical way) Production data provided simply and clearly to the decision level II World Wide Pasta Congress Venezuela October 2000 PAGE 10 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ► AUTOMATION SOLUTION SIMATIC S 7 SIEMENS Totally Integrated Automation in the Pasta Plants ► AUTOMATION SOLUTION SIMATIC S 7 controllers with distributed ET 200 M, drives technology and field instruments linked through Profibus. SIMATIC OP panel for distributed visualization and monitoring Drives Technology WINCC supervisory system based on client/server architecture with Industrial Ethernet networking SIMATIC Industrial Software integrated through all Project Phases II World Wide Pasta Congress Venezuela October 2000 PAGE 11 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants SIMATIC Controllers More than just PLC's SIEMENS Totally Integrated Automation in the Pasta Plants SIMATIC Controllers More than just PLC's • S 7 300 , S 7 400 H • I/O ET 200 M , ET 200 S • Operator Panels OP 27 , OP 37 • Profibus and Ethernet Cards II World Wide Pasta Congress Venezuela October 2000 PAGE 12 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants DRIVES TECHNOLOGY II World Wide Pasta SIEMENS Totally Integrated Automation in the Pasta Plants DRIVES TECHNOLOGY II World Wide Pasta Congress Venezuela October 2000 PAGE 13 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants WINCC SUPERVISORY SYSTEM The Multi Client SIEMENS Totally Integrated Automation in the Pasta Plants WINCC SUPERVISORY SYSTEM The Multi Client server architecture A Multi Client provides a common view of the process data of distributed servers in one picture all the measured value archives, e. g. in one curve window all the message archives the pictures/picture windows of different servers II World Wide Pasta Congress Venezuela October 2000 PAGE 14 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants Win. CC WEB TECHNOLOGY VENEZUELA H. SIEMENS Totally Integrated Automation in the Pasta Plants Win. CC WEB TECHNOLOGY VENEZUELA H. Q. Win. CC Goes Web INTERNET USA Plant II World Wide Pasta Congress Venezuela October 2000 Operation and monitoring of the plant via the Worldwide Web MEXICO Plant PAGE 15 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ENGINEERING STARTS WITH TOP-DOWN DESIGN OF SIEMENS Totally Integrated Automation in the Pasta Plants ENGINEERING STARTS WITH TOP-DOWN DESIGN OF YOUR SYSTEM THE SIMATIC MANAGER IS THE SINGLE TOOL TO COORDINATE THE COMPLETE TIA SYSTEM CONFIGURATION - Overall plant architectural structure - Control strategy - Operator visualization - Local operator panels - Peer communication - Field devices, including transmitter parameteriz. - 3 rd Party PROFIBUS devices Plant / System Unit Operation Equipment Group Device / Loop II World Wide Pasta Congress Venezuela October 2000 PAGE 16 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants AUTOMATION SYSTEM TOPOLOGY FOR LONG PASTA SIEMENS Totally Integrated Automation in the Pasta Plants AUTOMATION SYSTEM TOPOLOGY FOR LONG PASTA LINE WIN CC INDUSTRIAL ETHERNET PRESS BRIDGE PRESS FOOT S 7 400 OP OP PRESS REMOTE I/0 ET 200 EXTRUSION SCREW UP TO 4 DOSING SYSTEM PROFIBUS-DP SPREADER REMOTE I/0 ET 200 MIXER II World Wide Pasta Congress Venezuela October 2000 DRYER/PREDRYER COOLING/STORAGE REMOTE I/0 ET 200 FAN CHAINE MOTOR PAGE 17 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants REDUCED INVESTMENTS IN THE PASTA PLANT SIEMENS Totally Integrated Automation in the Pasta Plants REDUCED INVESTMENTS IN THE PASTA PLANT DISTRIBUTED I/O SAVE WIRING COSTS Distributed I/O systems save up to 20% of the wiring costs: Sav ings in w iring Cost for wiring 20% II World Wide Pasta Congress Venezuela October 2000 cos ts èA family of distributed I/O systems provides the right I/O for the right application and reduces wiring costs èdistributed motor starters and drives used in the pasta lines allow distributed wiring of the power bus PAGE 18 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ►COMMUNICATIONS (1) Each supervisory station can SIEMENS Totally Integrated Automation in the Pasta Plants ►COMMUNICATIONS (1) Each supervisory station can handle supervision functions of the entire plant in addition to graphic pages, recipes handling, data archiving real time/historical trending, alarming. Comunication and interoperability are key factors for data flow from orizontal way to vertical way. To achieve production flexibility , for successful growth, of small, medium and large companies II World Wide Pasta Congress Venezuela October 2000 PAGE 19 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ►COMMUNICATIONS (2) With T. I. A. SIEMENS Totally Integrated Automation in the Pasta Plants ►COMMUNICATIONS (2) With T. I. A. concept and relevant networking /communications we can assure data flow from process level to supervisory and management level, from incoming raw materials to the finished products. It means : - Right info - To right people - At right time - At right place In any kind of pasta plants II World Wide Pasta Congress Venezuela October 2000 PAGE 20 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants TYPICAL SYSTEM TOPOLOGY FOR PASTA PLANT SIEMENS Totally Integrated Automation in the Pasta Plants TYPICAL SYSTEM TOPOLOGY FOR PASTA PLANT WINCC Multi Client ETHERNET WINCC SERVER IND. ETHERNET SHORT PASTA LINE PROFIBUS DP II World Wide Pasta Congress Venezuela October 2000 SHORT PASTA LINE PROFIBUS DP PAGE 21 LONG PASTA LINE PROFIBUS DP Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants DATA MANAGEMENT STANDARD INTERFACING APPROACH VERTICAL SIEMENS Totally Integrated Automation in the Pasta Plants DATA MANAGEMENT STANDARD INTERFACING APPROACH VERTICAL INTEGRATION – TCP/IP, @a. Glance, ODBC, SQL, OPC, Net DDE. . . – Web Browsers, intra / internet. . . – Gensym bridge. . . – SAP R/3 PP-PI… HORIZONTAL INTEGRATION – Ethernet, PROFIBUS, , ASi-Bus II World Wide Pasta Congress Venezuela October 2000 PAGE 22 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ► INFORMATION MANAGEMENT MES and ERP SIEMENS Totally Integrated Automation in the Pasta Plants ► INFORMATION MANAGEMENT MES and ERP Connectivity in order to have plant information and management decision support Process optimization and data analysis Web connectivity for remote information and production control Certified module for linking to SAP II World Wide Pasta Congress Venezuela October 2000 PAGE 23 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants COMPLETE INFORMATION MANAGEMENT WITH INFOPLUS. 21 SIEMENS Totally Integrated Automation in the Pasta Plants COMPLETE INFORMATION MANAGEMENT WITH INFOPLUS. 21 Cross-Company Resource Planning ERP Supply Chain Management & Business Systems Draft Model Operation Intelligent Production Systems Profound Process Knowledge Management Integrated Software and Services Platform Independence PCS II World Wide Pasta Congress Venezuela October 2000 Process Control Systems MAIN FEATURES: - process data acquisition - data analysis - process optimization - certified module for linking to SAP MAIN BENEFITS: - improved production quality - improved process diagnostic Field Instrumentation & Operating Control PAGE 24 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ► THE ADVANTAGES It is able SIEMENS Totally Integrated Automation in the Pasta Plants ► THE ADVANTAGES It is able to satisfy adequately the requirements to operate and manage integrally the plant. It trasforms the process control into plant production control with a single system solution. It is garanted quality and HACCP certifications It can begin from a minimum architecture of one to several lines, of a small to a large plant. It reduces costs and spreads the investments according to plant growing, with an interesting pay back. II World Wide Pasta Congress Venezuela October 2000 PAGE 25 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants INCREASING EFFICIENCY IN THE PASTA PLANT SIEMENS Totally Integrated Automation in the Pasta Plants INCREASING EFFICIENCY IN THE PASTA PLANT E. U. ADVANTAGES: The Totally Integrated Automation advantages are the followings: èCentral control room to control upstream, mainstream and downstream areas data production è Repetitive quality and relevant improvement è Fast trouble shouting (more lines availability) è Less Spare parts (maintenance costs reduction) è Energy saving II World Wide Pasta Congress Venezuela October 2000 PAGE 26 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants COSTS REDUCTION IN THE PASTA PLANT SIEMENS Totally Integrated Automation in the Pasta Plants COSTS REDUCTION IN THE PASTA PLANT ENERGY SAVING Due to optimization of motors control according to production needs (less power consumption using drives technology) OUTPUT QUALITY Repetitive quality and relevant improvment , due to integrated process control and less reject during shape change LESS HUMAN RESOURCES II World Wide Pasta Congress Venezuela October 2000 Fast trouble shouting , less spare parts, resources optimization due to T. I. A. concept, central control room, diagnostic systems, intelligent allarms PAGE 27 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants ► CONCLUSIONS T. I. A. concept SIEMENS Totally Integrated Automation in the Pasta Plants ► CONCLUSIONS T. I. A. concept will give an important contribution in terms of costs control and cost reduction. T. I. A. concept will increase the possibility to build up new plants in new geographical areas where there are new markets with less specific experience The experience tipically of the Mediterranean countries is now available using T. I. A. concept in the ROW. By using T. I. A. both the pasta lines manufacturer and pasta producer can achieve important market advantages. II World Wide Pasta Congress Venezuela October 2000 PAGE 28 Competence in Pasta Plant Automation

SIEMENS Totally Integrated Automation in the Pasta Plants SIEMENS Thank for your attention Contact SIEMENS Totally Integrated Automation in the Pasta Plants SIEMENS Thank for your attention Contact E-mail to II World Wide Pasta Congress Venezuela October 2000 A&D Competence Center Food & Beverage - Mill &Pasta Antonio Rossetti : phone +39 02 66762933 Massimiliano Andreoli : phone +39 02 66762889 fax +39 02 66762916 antonio. [email protected] it massimiliano. [email protected] it PAGE 29 Competence in Pasta Plant Automation