Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Anchor GlassReduces Energy Costs with Information - Enabled PlantPAx Solution

Kyle FiebelkornBatch and Furnace Manager

Brad DownenMES Project Manager

Agenda

Introductions

Company Overview

Making a Glass Bottle

Goals

Operational Benefits

Cost Benefits

Wrap Up / Q&A

AGEN

DA

Introduction

Kyle Fiebelkorn – Batch and Furnace Manager Anchor Glass Container – Shakopee, MN

Brad Downen – MES Project Manager Stone Technologies

Audience – How Many ... End Users System Integrators Rockwell Automation® Distributor Other

PRESENTERS Experience with…

PlantPAx® Operations PlantPAx® Development

Anchor Glass Container - Background

Anchor Glass A leading North American manufacturer of glass containers with annual revenue of approximately $550 – $600

million and employing approximately 2,000 people. 6 glass manufacturing facilities, consisting of 11 furnaces and 31 lines 2 Oxy/Gas furnaces, 9 Gas/Air Reversing furnaces Lots and Lots of bottles!!!! Up to 600/min => 300,000,000 bottles/yr

Controls History 1986-1995 – Deployed Leeds and Northrup Micromax DCS controls system throughout the company 2003* – Established new corporate standard HMI and Controls with Rockwell Software® RSView®32 and

ControlLogix® processors 2012 – Adopted Rockwell Automation PlantPAx controls strategy layered with Rockwell Software’s interface

solution: FactoryTalk® View SE, FactoryTalk® Historian SE, FactoryTalk® Alarms and Events, FactoryTalk® VantagePoint®

COM

PANY O

VERVIEW

Anchor Glass – What we are doing

Convert crunched, recycled glass or raw materials into a liquid Create a stream of lava and condition the stream of lava to a consistent temperature and weight Physical items to control

Burners (many, many) Pressure (helps prevent flames from shooting out) Glass Level (weight of the bottle) Electric Boost Reversal (conserves heat)

MAKIN

G A G

LASS BOTTLE

FurnaceForehearth(3)

Hole located here drops the gob of glass to make the bottles

Original Goals with replacing old DCS system

Provide more intuitive operator interface

Better Data

Tighter Controls

Configurable!!! (especially for reversals)

Better historical data for analysis (both Process & Alarming)

Better Alarming. Manageable (Alarming without overwhelming noise)

Extendibility: capable of expanding to other areas of plant

Remote access – Corporate viewing

Low maintenance

PROJECT

Operational Benefits

Improved visibility of both current status, but also monitor operational trends Many more alarms providing detailed notifications…..but manageable too Minimized need for controls engineer HMI with detailed sequencing allows fine tuned process enhancements to achieve

more energy efficient operations Consistent faceplates so training of operator was minimal Process tuning (PID) provides much finer or coarser adjustments

BUSIN

ESS

VisibilityO

PERATION

AL BENEFITS

VisibilityO

PERATION

AL BENEFITS

VisibilityO

PERATION

AL BENEFITS

Usable & Detailed AlarmsO

PERATION

AL BENEFITS

Configurable via HMI (Controls engineers not needed)O

PERATION

AL BENEFITS

Consistent Faceplates – Minimal TrainingO

PERATION

AL BENEFITS

Motor Operated Valve Limit Switch PID

“Show Me the Money”CO

ST BENEFITS

18 months in operation – Early results (Savings are contributed to both new bricks and better controls)

Gas Savings Total ~ 350 dekatherm/day

~$6/dekatherm => 350*$6.00*365 = $766,500 / yr

Electrical Savings Total ~ 12,000 to 15,000 KWH per day

~$0.077/KWH => 12,000 * $0.077 * 365 = $337,260 / yr

Longevity: Typical furnace is rebuilt every 10-12 years. Early signs show furnace may last 1-1/2 to 2 years longer. Estimate of $1M/year goes to the bottom line.

“Based on my experience with this system, I would contribute an average of 15% of the cost savings to having the better controls systems on the furnace”…Kyle F. 2015

Soft costsCO

ST BENEFITS

More time to focus on tweaking the process vs. learning system Pinpoint trouble areas quicker Recognize operational trends and patterns easier Less labor required for maintenance

COM

PANY O

VERVIEWStone Technologies

$15M 2014 revenue 61 full-time employees Average 20% year over year growth for past 10 years

Stone Technologies, founded in 1996, is a national system integrator providing automation/control, information (MES) and operational consulting solutions. Based in St. Louis, MO with resources in 15 states/ 1 province.

Employee BusinessSatisfied people deliver successful projects and provide long-term continuity

Stone Technologies long-term relationships built on performance, trust, & keeping promises.

Average 95% employee retention rate for the last 10 years

The technical staff has an average of 22 years of experience

Of our top 20 clients (by services revenue) since the inception of the company 15 years ago:Doing business with ALL of them today

Average relationship is over 9 years Average of 50 projects per client Average adding 2 – 3 new clients a year

We have paid employee bonuses every year since inception Our best revenue generating tool is the successful delivery of projects

CON

TACT US

Contact Information

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

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