Recent Projects

This is where we'll announce some details of our most recent projects. Unfortunately we are unable to show a complete list, but this page will give an indication of the work we undertake.

PLC Upgrades at a Cider Manufacturer, Somerset

An Apple Mill and a Filter System were upgraded from a Siemens S5 to a Siemens S7 PLC System.

Bi-Annual Conductivity Probe Calibration at a Fruit Juice Manufacturer, Somerset

During a plant shut-down we calibrate about 100 conductivity probes across the plant, from CIP sets to UHT Plants.

Additional 3 RFU Tanks at a Cider Manufacturer, Somerset

The addition of 3 new RFU (Ready For Use) Tanks for a new product was designed and tested on a a Siemens S7-1500 PLC System and incorporated into an existing InTouch SCADA and Siemens S5 PLC System.

Yoghurt Plant, Ireland

The software for a complete Yoghurt Plant on a Siemens S7-300 PLC and 3 HMI's were designed and tested in-house for Tetra Pak CPS Ltd.

White Chocolate Line at a Cocoa and Chocolate Manufacturer, Nottinghamshire

Working as a subcontractor for Moody Automation and Stephenson Control Systems this project involved the software for a new Siemens S7-300 PLC and new controls on an existing InTouch SCADA as well as comms to a number of existing Siemens S7-400 PLC's to control a new White Chocolate Line. Included in the design were Festo remote I/O and pneumatics, Greenbank Load Cells and Siemens drives all on Profibus.

UHT Plant Servicing at a Fruit Juice Manufacturer, Somerset

A major project for us has been the continued servicing of juice UHT plants. This has involved resealing valves and pipe joints on a 2 weekly basis for about 25 UHT plants.

New Mixing Lines at a Wet-Wipe Manufacturer, Worcestershire

The software for an Allen-Bradley SLC505 was modified to increase from 1 mixing line to 3 mixing lines and add 2 additional finished product tanks. The control systems, which comprised of an InTouch SCADA and InBatch on a Windows NT environment, was also virtualised onto new hardware. This was a project managed by Process Concept Ltd.

Batching Control Panel at an Ingredients Manufacturer, Worcestershire

This panel was designed to the customers specification for the control of batching and temperature.

Temperature Probe Calibration at a Cider Brewer, Ledbury

The bi-annual calibration of the temperature probes at this site ensures the accuracy required by their auditors.

2 Cheese Towers and CIP Set, Australia

This project involved sourcing new equipment for the 2 Cheese Towers and a second hand CIP Set, which required refurbishing, as well as building 3 new PLC controlled panels. A further requirement was  providing the software for the 3 Allen-Bradley SLC 5/04 PLC's and the 3 PanelView Plus 600 HMI's, which was developed and simulated in the UK before the equipment was to be shipped to Australia.

Cream Tank Automation at a Dairy, Channel Islands

The further development of an existing job involved wiring and controlling the temperature of 7 Cream Ageing Tanks, with analogue temperature inputs and chilled water valve control. The panel wiring, Allen-Bradley PLC software and SCADA was all undertaken over a weekend for E-Glen Projects Ltd.

Calibration at a Large Winery, Avonmouth

The on site calibration of temperature, pressure, conductivity and flowmeters for the production lines was performed over a number of weekends.

New Bucketwheel Gearbox on the 3 Stacker/Reclaimers at an Iron Ore Port, South Africa

This 3 stage project required separate visits for each machine to modify and commission the software for a new bucketwheel gearbox, with its associated brake and fluid coupling.

Commissioning and Instrument Set-Up at a Cider Brewer, Ledbury

This work required one engineer for a prolonged period of time to commission and set-up instruments on a new plant being built in Ledbury for Universal Beverages Limited.

CIP Relocation and Refurbishment, Frome

The filler CIP from a dairy in Leeds was relocated and refurbished for tanker cleaning. The set is controlled by a Siemens S7-315 PLC with an OP25 HMI.

PLC Upgrade at a Whisky Bottling Plant, Motherwell

This CIP set at a whisky bottling site had an existing S5 PLC control system. The panel and PLC system was upgraded to an S7-314 PLC and a TP177 HMI with new links to Intouch Scada.

Replacement Control Panel at an Ingredients Manufacturer, Worcestershire

A thirty year old panel controlling a Jam Plant was removed and replaced with a new Mitsubishi FX2N PLC controlled panel with 2 Beijers E610 HMI's. The changeover happened over a weekend with minimal disruption to the site and ready to restart production on the Monday morning.

Homogeniser Relocation to a Dairy, West London

An homogeniser from a decommissioned site was incorporated into the existing control system with Siemens S5 PLC's and an Intouch Scada system. Again this job was project managed by Process Concept Ltd.

CIP Relocation and Refurbishment at a Dairy, Cornwall

The Raw Milk CIP System from Dairy Crest, Totnes was relocated, refurbished and converted into a 2 separate set's for Raw and Finished cleaning at a dairy in Cornwall by Sycamore Process Engineering. Again we undertook the panel refurbishment, the conversion of the control system from an Allen-Bradley SLC 5/04 to a 5/05 and the software for a Red Lion G310 touch-screen HMI and installed the site wiring and pneumatics.

Control Software at a Dairy, Hampshire

Working for Whitland Engineering this project involved the doubling of the existing site capacity and we produced the control software on a number of Allen-Bradley SLC500 PLC's and an Intouch Scada system for routing and CIP.

CIP Relocation and Refurbishment at a Dairy, Gloucestershire

Following the closure of the Dairy Crest site a Totnes, their Tanker Bay CIP System was relocated, refurbished and converted into a 2 channel set by Sycamore Process Engineering. We undertook the panel refurbishment, the conversion of the control system and software from a stand-alone Allen-Bradley to integrate the CIP into an existing Siemens S7-300 system with an MP370 touch-screen HMI and installed the site wiring and pneumatics.

Conveyor Control at a Dairy, South Wales

Working for Moody Systems this project involved the control of 14 conveyors and communication to a Dawson filler and 2 Graham labellers using a Mitsubishi FX1N PLC.

CIP Upgrade at a Dairy, Channel Islands

This project involved upgrading an existing 3 Channel CIP Set previously using 3 Mitsubishi F2 processors, to a new Allen-Bradley SLC5/05 and an RS View Scada. Also on this project, we built the new control panel and assisted with the site wiring. This project was managed by Sycamore Process Engineering.

Fruit Puree System, Worcestershire

This project on a Mitsubishi FX1N PLC with a Beijer's E610 HMI, involved the control of 2 cooking/mixing tanks, ingredients vessels, an homogeniser, a cooling tank and a filler. This project was managed by Moody Systems.

Water Recovery at a Bakery, Belgium

Here the aim of the project was to drastically reduce the amount of water sent to drain. By modifying the process to re-use flush water in the process this was achieved.

Monitoring Milk Usage Flowmeters at a Dairy, Devon

With the installation of 3 new flowmeters and re-using 2 existing flowmeters, all with new displays, detailed milk usage on each filler can now provided to the site.

Organic Milk Routing and Segregation at a Dairy, West London

The PLC's and in the Intouch Scada system were modified to allow the routing of Organic Milk from tanker intake to glass bottle ensuring the segregation of the Organic Milk from the Non-organic Milk. Again this job was project managed by Process Concept Ltd.

New Mixer at a Bakery, Lancashire

With a new mixer at site, a new panel and modification to the existing software was required to incorporate this new mixer into the existing control system, which is based on a Mitsubishi A3 PLC and Intouch Scada.

2nd CIP Set at a Leading Soft Drinks Manufacturer, North London

A second conversion of a Siemens S5 PLC to an Allen-Bradley ControlLogix PLC and VersaView graphical user interface for an existing CIP system was the core of this project. Again this job was project managed by Process Concept Ltd.

Modify CIP Routing at Uniq, Evercreech

This involved modifying the existing network of Allen-Bradley SLC 5/04's and Intouch Scada for the Apple Filler, Conserve and Cheesecake Lines with the installation of new Guisti Tanks for Sycamore Process Engineering.

Display Production Route Prestarts at Baxters Food Group, Fochabers

Working directly for Baxters this project continued the development of the site's Intouch control system in their Riverside Factory, which is networked to 7 Allen-Bradley PLC's over DH+. The main purpose of this project was to display the status of all the prestarts for each production route on the Scada, to enable quicker fault finding and less downtime when starting production.

Sterile & Chilled Air onto Finished Milk Tanks at a Dairy, Devon

This project involved adding a valve to each Finished Milk Tank and interfacing with an Air Handling Unit designed and project managed by Filtration Engineering Ltd, to enable sterile and chilled air to be applied to the tanks.

The software was modified in the existing Filler CIP PLC, an Allen-Bradley PLC 5/40, with interfaces to the existing GEM controlled Finished Milk PLC and the site SCADA system running on RS View.

Modifications to AVM CIP Set at a Dairy, Gloucestershire

Working with Carlisle Process Systems Ltd we modified the software on this existing CIP set controlled by a Siemens S5 942 PLC, to add a second detergent tank and a new fresh water tank.

Stacker/Reclaimer Commissioning at an Iron Ore Port, South Africa

One of the more interesting projects PSS Ltd has undertaken recently, is the commissioning of the semi-automatic and automatic modes of 3 Stacker/Reclaimers in South Africa.

This project as contractors to Metso Minerals Bulk Materials Handling (Bristol), involved commissioning and modifying a Siemens S7-400 PLC and Intouch control system to enable the three Stacker/Reclaimers to stack and reclaim iron ore on a stockyard with minimal operator input.

Stacking: Click here to watch video

Reclaiming: Click here to watch video

While at the site we also got involved with software for the Train Tippler (Car Dumper) and the Dust Extraction Plant.

CIP Set at a Leading Soft Drinks Manufacturer, North London

Installing a new Allen-Bradley ControlLogix PLC and VersaView graphical user interface to an existing CIP Set, which was originally controlled by a Siemens S5, was the main focus of this project. The CIP set cleans 2 filling lines and associated equipment. This job was project managed by Process Concept Ltd.

Plant Component Details at a Dairy, South West London

This project involved further development of the sites existing Intouch SCADA system, to display details of each plant component.

This project involved adding touch areas to each item and popping up screens detailing the item and showing a drawing of its constituent parts and bin locations of the spares.

CIP Set at a Large Winery, Bristol

As a part of a brand new CIP System designed by Process Concept Ltd we provided the software for an Allen-Bradley CompactLogix PLC and VersaView graphical user interface. This 2 channel CIP System cleans over 100 individual tanks and lines.

Last modified: 13-Jan-2023    © Process Software & Service Ltd.    Contact: sales@pssl-uk.com