A food processing equipment manufacturer needed a complete control system for a new industrial tray washing line. The project covered the full cycle from control program design through on-site commissioning and ongoing optimization.
The Challenge
The washing line is a multi-subsystem installation with several interconnected components that must operate in coordination:
- Transfer system — automated tray handling and positioning
- Washing station — tray cleaning with controlled wash cycles
- Safety and communication system — safe operation across all subsystems
- Control panel with HMI — centralized operator interface
Each subsystem has its own I/O requirements, safety considerations, and operating sequences. The control system needed to coordinate all of them while providing operators with clear visibility into the process.
Yuriy’s Work
Yuriy delivered the controls-engineering scope across multiple engagement phases:
Design Phase
- Functional design for all subsystems
- Siemens PLC programming with safety integration (ProfiSafe)
- Operator HMI development for process monitoring and control
- Drive integration for conveyor and wash motors
Startup and Commissioning
- On-site startup across 3 equipment units
- Sequential commissioning of each subsystem
- Process tuning and speed optimization
- Operator training
Ongoing Support
- System integration with third-party equipment (Atomha)
- Performance optimization — line speed doubled through control tuning
- Continued troubleshooting and tune-up support
- Digital twin development using PLC-Lab for offline testing
Technology
- PLC: Siemens S7-1200 F-CPU (safety-rated)
- Safety: ProfiSafe integrated safety
- Drives: SEW variable frequency drives for conveyors
- HMI: Siemens operator panel
- Simulation: PLC-Lab digital twin for offline testing and development
- Programming: Structured Text (IEC 61131-3)
Results
The washing line has been in production use with ongoing optimization support. After the initial commissioning, Yuriy integrated additional third-party equipment and doubled the line speed through control system tuning alone — no mechanical changes required. The digital twin built in PLC-Lab allows program changes to be tested offline before deployment to the live system.
Industry: Food Processing
