BIOPROD Project - SARIA Group

- BIOPROD Project SARIA Group

Group SARIA Bio Industries specialized in biomass recycling operates in 10 European countries, has 110 sites, 50 out of which are industrial ones.

The group employs over 4,000 people with 1,400 employees in France.

SARIA Industries belongs to the SARIA Bio Industries division of the Rethmann group, a global company specialized in logistics and environment.

Supervision, manufacturing process control, performance improvement, ascending and descending traceability thanks to the COOX platform and its several MES modules.

The SARIA Industries group is today a major player in the biomass recycling. This area is perfectly in line with the current initiatives of maximum food resources preservation and waste-to-energy projects.

Driven by development needs, the group has undertaken revamp and expansion projects at all of its sites, which makes it possible to anticipate most stringent requirements in terms of security, quality and traceability while improving the performance of its equipment.

General information For many years the know-how of SARIA Industries lies in manufacturing of food, feed, products for fertilizer producers or the chemical industry.

The group has managed to incorporate major technological advances while strictly complying with regulatory, health and environmental requirements.

SARIA Industries’ activities comprise 4 areas of expertise : rendering, which ensures destruction of materials representing a risk for health or environmental safety; food processing, which recycles products from animals; oleochemistry that recycles animal fats and energy – recycling of biomass into fuel or electricity.

Context The industrial challenge of the BIOPROD project is based, in large part, on its rapid multi-site deployment (more than 10 sites) and integration of control, command, supervision and MES functions while preserving the specific characteristics of each site. Some of them have very similar processes and others – very different ones.

Different stages of the meat grinding or mechanical separation procedure, for example, do not need the same level of automation: identification is a stage performed manually, grinding is an automated stage and weighing can be considered as a semi-automated stage.

Moreover, the same operation may have a different level of automation depending on the site. An operation, which is manual today, may become automated tomorrow to improve productivity or facilitate traceability.

Consequently, there is a great interest to set up a system that processes manual and automated operations the same way.

Scope

dozens of pieces of equipment of the same kind.

In comparison with other solutions this technology thus makes it possible to save a considerable amount of time when implementing a project. In case of this multi-site project all the know-how integrated into the models can be directly reused.

The functional scope at all the sites is very vast. It includes a control and command system (Schneider Electric automation equipment), supervision (humanmachine interface, recording and displaying measurements, alarm management), startup and monitoring of operations associated with production orders, their traceability, management of materials and workshop inventory as well as ascending and descending genealogy of raw materials, finished products and co-products.

Material flow monitoring The COOX solution by ORDINAL Software that was chosen for the whole project includes different modules containing a large number of required essential functions for both supervision and MES in the form of standard configurable components such as « batch record » or « genealogy ». The following will be provided in response to flow material specifications of a manufacturer requiring minimum information described below:

.

More. specific functions are implemented by programming (JavaScript and Java languages) making use of the whole range of the platform capabilities (integration into the application HMI, Intranet deployment, use of programming interfaces).

Modeling In the COOX solution, all similar pieces of equipment of a facility use the same model. The model, a tank, for example, has numerous facets : - graphical parts, operations like heat and mix, traceability of these operations, taking into account transfer of materials and performance indicators such as OEE. Each facet is defined by settings even if it is possible to expand the model capacities by programming.

The model definition is in conformity with the ISA-95 standard and is done only once even if there are

Solution generalization Availability of libraries of equipment models and specialized functions that are almost ready for use results, of course, in generalization of the solution, even at sites that were not included in the initial scope. With rapid implementation comparable to setting up of minimum control functions a greater functional range is available thanks to the models.

Project deployment Of course, it took several months to develop equipment models, to set up standard functions and develop specific functions and then to set up and validate the first large-scale site. Deployment of the BIOPROD project was then carried out at a rapid pace, which took from three to four months for large sites with deployment of the solution at smaller sites being carried out in parallel.

Uniformity of the sites that could seem a great obstacle to the approach using a high level of modeling thanks to SARIA’s detailed specifications and OET, the principal integrator of the project.

Interview with M. Thomas de Verdelhan – Industrial Manager – Kervalis – Groupe SARIA -