Fruit Cold Treatment Automation Project

Optimizing Fruit Cold Storage for Export Compliance
A mid-sized fruit processing and export company in Southeast Asia aimed to enhance its cold treatment facility to meet stringent international phytosanitary standards for fruit exports. The goal was to automate temperature control, monitoring, and power management in their cold storage units to ensure precise conditions for fruit preservation, reduce energy costs, and improve operational efficiency. The solution leveraged Delta’s AS300 Programmable Logic Controller (PLC), DIAView SCADA system, Delta MS300 drives, and Socomec Digiware power management system.

Customer Challenge:

Precise Temperature Control: Fruits like citrus and apples require specific cold treatment protocols (e.g., sustained low temperatures for days) to eliminate pests and meet export regulations.

2. Energy Efficiency: Cold storage systems are energy-intensive, and rising operational costs needed to be addressed without compromising performance.

3. Real-Time Monitoring: The facility required remote monitoring and control to ensure compliance with temperature logs and quick response to deviations.

4. System Integration: The solution needed seamless integration of control, monitoring, and power management systems for reliability and ease of use.

Our Solution:

1. Precise Temperature Control: Fruits like citrus and apples require specific cold treatment protocols (e.g., sustained low temperatures for days) to eliminate pests and meet export regulations.

2. Energy Efficiency: Cold storage systems are energy-intensive, and rising operational costs needed to be addressed without compromising performance.

3. Real-Time Monitoring: The facility required remote monitoring and control to ensure compliance with temperature logs and quick response to deviations.

4. System Integration: The solution needed seamless integration of control, monitoring, and power management systems for reliability and ease of use.

The company partnered with a Delta Electronics system integrator to deploy an automation solution tailored for their cold treatment facility. The key components included:

1. Delta AS300 PLC:

• The AS300 PLC served as the central control unit, managing the automation of refrigeration units, fans, and other equipment. Its high-speed processing and support for EtherNet/IP communication enabled precise control of temperature and humidity in the cold storage units.

• The PLC’s modular design allowed integration with temperature sensors, actuators, and other field devices, ensuring flexibility for future expansions. Its built-in programming capacity (up to 128k steps) handled complex sequential control for maintaining stable cold treatment conditions.

2. DIAView SCADA System:

• Delta’s DIAView SCADA provided real-time monitoring and control of the cold treatment process. It collected data from the AS300 PLC and displayed it through intuitive dashboards, enabling operators to monitor temperature, humidity, and system status remotely.

• The SCADA system’s alarm management and event-based reporting features ensured immediate notifications for temperature deviations, critical for compliance with export standards. Its VBScript support allowed customized logic for automated responses, such as adjusting cooling intensity.

• DIAView’s compatibility with mobile devices and cloud-based MQTT servers enabled supervisors to access real-time data and generate compliance reports from anywhere.

3. Delta MS300 Drives:

• The MS300 vector control drives were used to regulate the speed of compressor motors and fans in the refrigeration system. Their compact design (40% size reduction compared to previous models) saved space in the control panel, and their support for both induction and permanent magnet motors provided flexibility.

• The drives’ high starting torque and fast response to load changes ensured precise control of cooling systems, maintaining consistent temperatures. The built-in Safe Torque Off (STO) feature enhanced safety by preventing unintended motor operation during maintenance.

• Integration with the AS300 PLC via communication protocols like Modbus and EtherNet/IP allowed seamless coordination between the drives and the control system.

4. Socomec Digiware Power Management System:

• The Socomec Digiware system monitored and optimized power consumption across the cold storage facility. Its modular design enabled precise measurement of electrical parameters (e.g., voltage, current, power factor) for the refrigeration units and auxiliary systems.

• By integrating with the DIAView SCADA, the Digiware system provided real-time energy usage data, helping identify inefficiencies and reduce operational costs. Its alarms for power anomalies ensured quick detection of issues like overvoltage or phase imbalance, protecting equipment and reducing downtime.

Outcome & Impact

1. Improved Compliance:

• The precise control offered by the AS300 PLC and MS300 drives ensured consistent temperature maintenance, meeting international phytosanitary requirements. DIAView’s automated logging reduced manual record-keeping errors, ensuring 100% compliance with export audits.

2. Energy Savings:

• The Socomec Digiware system identified inefficiencies in compressor operation, leading to a 15% reduction in energy consumption through optimized motor control via MS300 drives. Real-time power data integrated into DIAView helped operators adjust settings dynamically.

3. Operational Efficiency:

• DIAView’s remote monitoring and mobile access reduced the need for on-site supervision, cutting labor costs by 20%. The system’s alarm management minimized downtime by alerting operators to issues within seconds.

4. Scalability and Reliability:

• The modular AS300 PLC and MS300 drives allowed the facility to add new cold storage units without major system overhauls. The robust communication protocols (EtherNet/IP, Modbus) ensured stable operation even in harsh environments.

Conclusion

• Seamless Integration: The Delta ecosystem (AS300 PLC, DIAView SCADA, MS300 drives) supported multiple communication protocols (e.g., EtherNet/IP, Modbus), ensuring interoperability with the Socomec Digiware system.

• Compact and Efficient Design: The MS300’s 40% size reduction and screwless wiring simplified installation, while the AS300’s high processing power handled complex control tasks.
• Real-Time Control and Analytics: DIAView’s intuitive interface and reporting capabilities, combined with Digiware’s power monitoring, provided actionable insights for both compliance and cost savings.

• Energy Optimization: The combination of MS300 drives’ precise motor control and Digiware’s power analytics addressed the high energy demands of cold storage, aligning with modern sustainability goals.

This fruit cold treatment automation project demonstrated the power of integrating Delta’s AS300 PLC, DIAView SCADA, and MS300 drives with Socomec’s Digiware system. The solution delivered precise temperature control, significant energy savings, and streamlined compliance, positioning the company as a competitive player in the global fruit export market. The scalability of the system ensures it can adapt to future growth, making it a model for cold storage automation in the agricultural sector.