FRITSCH: Software prevents input errors

Software prevents input errors

To make operation as simple and intuitive as possible, FRITSCH has developed a new, performance-related control system.

+The equipment manufacturer supports the digital transformation in the bakery industry by continuously developing its systems; for example, in machine control, digital services and remote maintenance have seen upgrades. The objective is to offer manufacturers of all types of baked goods the possibility of producing goods with fewer and fewer employees. This is also necessary, says FRITSCH, because it is becoming increasingly difficult for many companies in the industry to find suitable personnel. “The shortage of skilled workers increases the risk of malfunctions and unplanned equipment downtime due to operating errors,” explains Michael Gier, head of FRITSCH World of Bakery. “After all, you need qualified personnel to understand the interaction of the various components of a bakery line and to be able to control the numerous parameters.”

To ensure that good results in terms of both quantity and quality can be achieved on the lines of medium-sized manufacturers, the software specialists and dough technologists at FRITSCH have developed a new control system for the industrial IMPRESSA series but also for the PROGRESSA series, including the LAMINATOR 700, which is designed for medium output requirements. “Our goal is to make operation as simple and intuitive as possible,” says Wolfang Stegmaier, project manager for digital development at the company. “The prior knowledge required for operation should be reduced to a minimum and input errors should be prevented as far as possible by the software itself.”

Performance-based management

The new concept means that the system is controlled according to output. “For example, if a customer wants to produce 5,000 croissants per hour, he simply enters this performance specification on the display and the system then calculates all the necessary parameters to achieve this result,” explains Michael Gier.

Until now, the settings were technically based, meaning that the operating personnel had to know exactly how the laminating line works and how adjusting a parameter affects the overall result. “With the new control system, numerous basic programs and corresponding performance parameters are available for different products, where only a few parameters, such as the roll gap and layer numbers, need to be readjusted to achieve the desired result,” says Gier. According to him, the combination of three operating levels, of which the operator only needs to master two, and the preset basic programs have another advantage: any operating errors can be detected more easily and rectified more quickly. This reduces downtime and increases the overall efficiency of the plant.

Clear division of the operating levels

To be able to produce an optimal dough sheet for each product, numerous parameters can be set and components adjusted on the LAMINATOR 700. “After discussions with customers, dough technologists and software developers, we came to the conclusion of setting up three different operating levels,” explains Wolfgang Stegmaier. The first level provides a general overview of the system. The second level contains the various components of the line, which can be monitored and adjusted by the staff during ongoing production. The third level is used for fine adjustment and is primarily intended for dough technologists. Michael Gier: “For the operators, the first and second levels are primarily relevant; on the third level, our experts or those of the customer make adjustments for fine-tuning the products that can be produced on the line.”

Visualization creates transparency

The developers attached great importance to the fact that all working components networked with each other. For example, the drives are connected to the control system via a bus system. “Operation is via a 15-inch screen that is permanently installed on the LAMINATOR 700,” reports Wolfgang Stegmaier. “The concept provides a clear overview of the individual components of the system.” The visualization on the display of the system enables the respective user to quickly control the required operating level and to clearly recognize the individual machine parts”, he adds.

Baked goods manufacturers can grant their employees personalized access to the operating levels and components via a log-in. “In practice, we have found that the master password for a system was sometimes known throughout the company,” says Michael Gier. “With the new control system, the user can log on to the machine using his ID card.” The operator is assigned the required access rights with his badge when he is created in the control system. They are therefore clearly defined. This increases the safety of the system and reduces operating errors.

Drives coordinate with each other

To further simplify operation, the programs for producing dough bands are preset for specific products. “This means,” explains Wolfgang Stegmaier, “that when a new recipe is created, not all parameters have to be reset. The employee only has to set certain specifications such as the line output, the number of folds as well as the roller gap.” This significantly reduces the time required for setting up a new product. In the process, the software checks whether a desired performance change is even feasible. “The drives virtually coordinate with each other in terms of their performance and, if necessary, regulate themselves to that of the smallest drive.” According to the company, this ensures high and consistent product quality. +++

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