Dig in! Our comprehensive offer for bakery and confectionary production. Totally Integrated Automation. Answers for industry.

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1 Dig in! Our comprehensive offer for bakery and confectionary production Totally Integrated Automation Answers for industry.

2 An offer to drive efficiency, tailored to the exact needs of your industry. Despite the obvious differences between the bakery and confectionary markets, both industries share one thing in common: an interest in greater efficiency. Our industry offerings are designed to address exactly this. Carefully tailored to your needs, we offer both industries a uniquely comprehensive portfolio of automation, drive, and power engineering technology that covers the entire production process. 2

3 Trends in the baking and confectionary industries Today s baking industry must first and foremost adapt to changing eating habits around the world. The range of available products is expanding and becoming increasingly international. Consumer demand for convenience foods and health products that contain low levels of fats, sugar, and calories is also growing. For the confectionary industry, on the other hand, a highly diversified product range is nothing new. Not only must seasonal requirements be met, confectionary producers also have to cope with often considerable regional variations in consumer tastes. The premium sector is rapidly gathering momentum. And sugar-free confectionary products are big business. No matter how different the trends, both industries face a common challenge: increasing product variety on the one hand and the growing need to cut costs on the other. This requires a production process that is both highly flexible and efficient. We re here to face this challenge with you as your globally present technology partner. Seamlessly integrated, consistently successful Whether you manufacture bakery or confectionary products, the degree of integration and transparency in your production process is crucial for your success. By improving the integration of your company s production-relevant processes, you can make it easier to meet the demands of increased efficiency. We can help you do this. With a thorough understanding of your processes. With comprehensive industry offerings ranging from products and systems to extensive services for the entire life cycle. And with overarching concepts. From receipt of raw materials to goods issue, from field level to ERP level. For you, the result is an optimized workflow capable of delivering perfect quality at reduced costs. So you can enjoy the fruits of your labor just as much as your customers do! 3

4 Exactly to your taste: Solutions to today s challenges Lower life cycle costs, greater flexibility, consistently high quality, and efficient ways to fulfill official requirements based on Totally Integrated Automation and Totally Integrated Power, our portfolio provides the right answers to the challenges currently facing the baking and confectionary industries. Reduce total cost of ownership Rising raw material and energy prices are placing manufacturers of bakery and confectionary products under mounting financial strain. And yet every company has numerous optimization levers at its disposal, particularly in areas such as resource usage, plant availability, and process control. One of the keys to achieving lower costs is realizing comprehensive automation on the basis of Totally Integrated Automation and a broad product range. With simple engineering and minimized interfaces, you can depend on reliable processes that are considerably more efficient in terms of both time and cost. The benefits of this are felt primarily in people-intensive areas such as operation, maintenance, and servicing throughout the entire life cycle of your plants. Achieve greater flexibility Almost no other industry is characterized by such a wide range of consumer trends. The shelves are stacked with all sorts of products in all sorts of packaging. To get in on the act, many manufacturers of bakery and confectionary products adopt a strategy of greater diversification in their portfolio. But this can only work if it is supported by the production process. Safeguard consistently high quality High hygiene and quality standards must be met when manufacturing bakery and confectionary products. In particular, fluctuations in the quality of raw materials make it difficult to deliver the wide range of end products with a consistently high quality. This, too, has been taken into account in our industry offering for the baking and confectionary industries. By systematically networking all production and packaging machinery and storing all data required for quality assurance purposes, we support all food safety and integrity measures. Precise tracking and tracing with added benefits Legislation for foodstuffs makes no concessions. No matter which continent you consider, official requirements are becoming increasingly stringent. That said, directives such as EU 178/2002 or 2005/26/E6 concerning the identification of allergens can promote greater transparency. And companies can use this to their advantage to better understand their own production and business processes and uncover new scope for optimizing these. We support you here with integrated tracking and tracing functions. We can help. For example, with our concepts for standardizing your automation landscape, from the field level to production control level, from raw material input to shipping. 4

5 Totally Integrated Automation Totally Integrated Power The trend is moving away from viewing pieces of equipment and machinery in isolation toward arriving at an integrated automation solution. Totally Integrated Automation embodies this new direction. Our unrivaled range of hardware and software enables you to automate your entire production line, from goods receipt and process/production-related activities right through to goods issue. And integration is not limited to the production process. With a standardized engineering environment, continous and open communication tools, as well as intelligent management systems and IT solutions, Totally Integrated Automation covers all relevant areas. From building automation, energy management and the production control level to maintenance and servicing. Energy costs are becoming increasingly relevant. That s why it s good to know that with Totally Integrated Power, we offer you integrated power distribution solutions that can bring you considerable savings. From medium voltage to the ultimate power consumer Totally Integrated Power is based on integrated, interface-optimized products and systems that are fine-tuned to each other, complemented by communications and software components that connect the power distribution systems to industrial automation or building automation systems. 5

6 Totally Integrated Automation for the baking and confectionary industries Manufacturers of bakery and confectionary products need an integrated, automated production process to boost productivity in the long term. We can help you to accomplish this with the right concepts. So that you can count on smooth processes from beginning to end. Integrated automation Our portfolio covers the entire production process. All products and systems interact smoothly on the basis of Totally Integrated Automation, making it simple to integrate all process steps. The result is a perfectly fine-tuned, consistently transparent production process that incorporates reliable, companywide communication from field to ERP levels. The latest developments in our SIMATIC and SIMOTION automation systems, as well as international industry standards such as Industrial Ethernet, PROFINET, and PROFIBUS, ensure exceptional performance, a high level of reliability, and user-friendly, secure operations throughout. Because our offering fits together so perfectly, you can realize integrated automation concepts more costeffectively and run them more economically. Across all life cycle phases, from planning, engineering, commissioning, and operation to maintenance, servicing, enhancement, and modernization. The selected modular hardware and software components from the standard SIMATIC range can be adapted to suit your specific requirements and plant sizes. This means you can enhance them without difficulty if you increase your capacity or make technological changes. 6

7 Totally Integrated Automation (TIA) for Bakery Maintenance laptop Line overview Plant server Optional: Internet Line operator station Line operator station Central maintenance station Building systems Power supply Mobile operator station Silo management Dough preparation Oven control Freezer Packaging Logistics High-performance control system SIMATIC WinCC provides all the important functions of a high-performance SCADA system, including user management, a user-friendly interface, and integrated systems for signaling, archiving, reporting, and logging. The basic system is flexible and can be adapted to suit your particular control tasks with less engineering needed. Based on central visualization and storage concept for process data in WinCC, we offer additional program packages that help you maintain your plant and monitor all relevant parameters including the assignment of data to production batches and lots. Our OEE DTM (Overall Equipment Efficiency Downtime Monitor) package also makes it easier to identify and analyze the cause of production downtimes. The result is significantly improved plant availability and quality. Plant-wide communication To effectively network all sections of your plant, the open, non-proprietary Industrial Ethernet standard PROFINET offers many advantages that further enhance the responsiveness, reliability, and productivity of your processes. Thanks to standardized interfaces, consistent modularization, and straightforward, plant-wide machine-to-machine communication, distributed automation structures can be implemented much more easily and managed with greater flexibility using PROFINET. We support PROFINET with a comprehensive range of products and systems for this forward-looking standard. Together with our WinCC SCADA system, PROFINET uses rapid transfer rates and its integrated diagnostics concept, for example, to accelerate your response times when unforeseen events occur in production. Simplified engineering Using innovative software tools, we help you plan, commission, and operate your automation landscape. For example, the SIMATIC imap engineering tool combines distributed applications across plants and vendors. In place of conventional, complex programming, SIMATIC imap is used to create graphical configurations and generate the communication software automatically. You benefit from minimal engineering and smoother commissioning. 7

8 8

9 Conserve resources, reduce consumption, produce effectively With rising energy prices and greater awareness of environmental issues, the topic of energy conservation is fast gaining ground. But where do you start? Which measures hold the most potential? With the right solutions for sustainable energy efficiency covering electricity, gas, water, and compressed air we provide concrete answers for industrial and functional buildings. Safe and economical energy transport For low-voltage applications, our Totally Integrated Power offering includes type-tested switchgear and busbar trunking systems as well as modular and compact circuit breakers. These switches use PROFIBUS DP or Ethernet to conveniently transmit switching statuses, trips, and measured values to overall power distribution concepts and automation systems. Reduce operating costs with Power Management Our SIMATIC-based Power Management system is a cutting-edge solution for improving energy efficiency in industry. Featuring a number of harmonized components, it provides full flexibility for optimizing the way you use power and helps you achieve lasting cost reductions. With this solution, you can expect to save up to 20 % on your energy costs. The communications-capable low-voltage switch gear and controlgear, for example circuit breakers, the motor management system, and motor starters, supply your energy data to the higher-level Power Management system. The energy values can be displayed and evaluated comfortably using the WinCC powerrate Power Management premium add-on, which is fully integrated with Totally Integrated Automation and SIMATIC WinCC. The solution therefore not only offers a transparent overview of energy consumption, but also assigns values to cost centers based on their source and provides automatic load management. Since energy consumption is displayed transparently according to media type and the relevant production units of the source manufacturing units, it is often possible to reduce energy purchases or fine-tune these for a given location with simple process optimization measures. Purchase optimization, combined with automatic load management to ensure that purchase limits are not breached, can lead to savings of between 5 % and 10 % on energy costs. Process instrumentation and analysis Our comprehensive offering for your industry sector includes a multifaceted process instrumentation and analysis program. This is designed to meet the particular needs of the food industry and help you conserve valuable resources, from equipment for obtaining accurate and reliable temperature, pressure, flow rate, and fill level measurements to innovative weighing technologies and gas analyzers. Industrial energy management Siemens also provides support for company-wide energy and emissions management. This ranges from the modernization of process installations and heating, steam, ventilation, air-conditioning, cooling, and compressed air systems right through to lighting systems and the renewal of drive technology. This service offering consists of three steps. First, we can identify areas with potential for savings and propose relevant measures together with a cost estimate and amortization times. Next, we offer you a more detailed breakdown of the actual savings potential, including a feasibility study and profitability analysis, an implementation concept, and related documentation. And in the final step, of course, we help you with the technical implementation. 9

10 An A to Z of products from field to management levels With Totally Integrated Automation, Siemens is the sole provider of a comprehensive, integrated range of products and systems for automating the entire production workflow, from goods receipt to goods issue. Totally Integrated Automation reduces the complexity of the automation solution and opens the door to what really counts: optimized interaction between the right combination of individual components without interface problems. What s more, Totally Integrated Automation not only integrates the production process, but rather all areas of the company, from field level up to management level. The result is a perfectly harmonized overall concept that enables greater productivity. 10

11 Process visualization with SIMATIC WinCC SIMATIC WinCC is a PC-based process visualization system that can be used as a stand-alone SCADA system or human machine interface for process control systems. With the right WinCC options or add-ons, the modular, flexible, and fully scalable basic system can be easily adapted to suit the specific requirements of the baking and confectionary industries. Controllers and HMI To enable cost-effective and flexible automation, we offer a complete range of SIMATIC controllers from programmable logical controllers in modular, embedded, and PC-based architectures to distributed intelligence and complete assemblies comprising controllers and operator panels. And with SIMATIC HMI we also provide a one-stop solution comprising a comprehensive range of operator panels and visualization software for machine-specific operator control and monitoring right through to a scalable SCADA system. Motion control Our portfolio of products and systems, which enjoys worldwide success, allows you to master any motion control task competently and efficiently. This is made especially simple by SIMOTION, our innovative and flexible motion control system, which groups motion control, PLC, and technological tasks in one system, bringing you considerable advantages. Industrial communications SIMATIC NET is designed to offer efficient solutions for communications tasks. Count on open, integrated communication in your automation system and leverage the benefits of Industrial Ethernet and PROFINET, end-to-end integration from field level to management level, integration of IT technologies, and wireless connection with Industrial Wireless LAN. Sensor systems Production sensors: With SIMATIC sensors, we offer you a complete portfolio of proven and innovative sensors to meet a wide range of production requirements. From proximity switches and safety sensors through to RFID systems, code reading systems, and vision sensors. Featuring innovative, intelligent products integrated in Totally Integrated Automation, SIMATIC sensors bring gains in terms of productivity, availability, efficiency, and cost-effectiveness. Process instrumentation and analysis: Our portfolio contains an extensive product range for process instrumentation and analysis as well as weighing and metering systems, for example: Measuring equipment for measuring flow rate, pressure, temperature, or fill level Positioners Equipment for process analysis SIWAREX weighing systems Belt scales 11

12 Motor starters and motor management Our SIRIUS motor starters and soft starters are the right choice for switching, protecting, and starting motors. Whether locally in the control cabinet or directly in the field our motor starters can integrate optional, intelligent monitoring functions, including preventive maintenance and Safety Integrated functions. SIMOCODE pro is a flexible, modular motor management system for motors that run at a constant speed in the low-voltage range. It optimizes the connection between the control system and motor feeders, thereby increasing plant availability. Efficient power distribution All SIVACON/SENTRON low-voltage components are part of Totally Integrated Power, our technological platform for integrated, cost-effective, and secure power distribution. With this platform, you have your plant firmly under control, regardless of your specific power distribution needs. For example, by using the SIMATIC WinCC / PCS 7 powerrate Power Management add-on and the SENTRON PAC 3200 and PAC 4200 power monitoring devices, you can introduce transparency and control to your power distribution activities. Frequency converters Our comprehensive portfolio of frequency converters can accommodate the most varied of applications in the beverages industry. This makes SINAMICS the most extensive and most highly integrated range of drives in the world. Covering all power and performance levels, it is characterized by a high degree of flexibility, functionality, and engineering efficiency. From a single drive to coordinated drives, multi-axis drives, and motion control drives for complex tasks, SINAMICS offers the right drive for every field of application. Low-voltage motors Efficient machines need efficient drives. And given that the tasks performed by drives vary, Siemens offers a complete motor program in compliance with the NEMA and IEC standard for use worldwide: Energy-efficient drives Explosion-protected motors Motors that comply with the IEC or NEMA standard Distributed drive technology Industry motors Customer-specific motors Geared motors Geared motors represent a powerful solution for drive-related tasks performed at low speeds with high torque and operate reliably under the toughest conditions. Applications can be run particularly economically using integrated units comprising energy-efficient motors and gearing. Our portfolio includes: Spur gearing Bevel gearing Flat gearing Helical worm gearing Worm gearing Safety Integrated Safety technology that is seamlessly integrated in the standard automation system means considerably less engineering outlay and greater availability. Both machine manufacturers and plant operators arrive at safe, productive machinery more quickly and easily with Safety Integrated. The extensive product range and combination of standard technology and safety technology give you the highest level of flexibility and cost-effective safety solutions for your particular needs. 12

13 We ve got it covered: Service, support, and training We provide you with fast, reliable, and competent support throughout the entire life cycle of your plants with our comprehensive range of services. Online support Our comprehensive online service and support information platform can be accessed at any time and from anywhere in the world using the Internet. Whether you need product support, applications, information about our services, or a technical forum the Web is your first port of call. Technical support In the event of technical queries, we offer expert advice and a wide range of services for our products and systems, tailored to suit your needs. Further information can be found at: Technical consulting We also help you to plan and design your project, from detailed as-is analysis and definition of goals to product and system-related consulting and development of your automation solution. You can obtain more information by Field service For commissioning and maintenance, we offer a number of services to safeguard the availability of your automation systems. Further information can be found at: Software engineering We offer tailored services to help you develop, configure, and implement your automation project. Further information can be found at: Spare parts and repairs Our comprehensive spare parts and repairs service offers you the highest level of operational reliability. Further information can be found at: Modernization Our on-site experts offer competent, sound advice on how to protect your investments in the long term. Further information can be found at: Training Our training centers located all around the world offer tailored training packages for automation technology and industrial solutions. With around 300 classroom courses, we provide training on a wide range of Siemens Industry Sector products and systems. Web-based training, CD-ROMs, and specialist publications complement our standard course offering. Reliable, local support: Siemens Solution Partners We not only rely on our own expertise in the field of systems integration, but also work closely with our Siemens Solution Partners. These selected partner companies are highly qualified in the areas of automation technology and power distribution. Under the heading Siemens Solution Partner Automation or Siemens Solution Partner Power Distribution, they offer you professional consulting and active support in all relevant aspects of your project. Further information about our Solution Partners can be found on the Internet: 13

14 Siemens AG Industry Sector Food & Beverage P.O. Box NÜRNBERG GERMANY Subject to change without prior notice Order No.: E20001-A60-T110-X-7600 DISPO WÜ/19553 GC.GC.93.YFUB Printed in Germany Siemens AG 2009 The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

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