Tray Hardener Controls Upgrade

An Ice Cream manufacturer was experiencing anguish over the age of the controller on their Tray Hardener. The company’s busiest season was fast approaching, and they were experiencing issues with the control system on the Tray Hardener.

The Tray Hardener controller needed to be replaced without negatively impacting production. The installation effort was to be regulated to one weekend. The system consisted of approximately 150 I/O points and included controls for ammonia and circulating fans.

CDSL designed a control panel with Flex I/O cards, utilizing an existing ControlLogix controller and ControlNet network. CDSL re-wrote the PLC program in A-B Logix 5000 format from a printout of the old code.  The new panel was installed adjacent to the existing control panel to expedite the wiring required to be performed during the limited downtime.  CDSL was on-site to commission the system as soon as the wiring had been completed.

CDSL found a way to upgrade the critical system for the plant within a limit non-production time. The project to replace this critical system allowed the plant to eliminate a production risk during their busy season.