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            Reference: Food & Beverage

            Matutano-Pepsico Group (Spain)

            Schneider Electric helps Matutano in energy and water savings

            Reference: Food & Beverage ROI in 4 years>20% energy savings, 20 % CO2 emission reduction, 5% water savings

             

            I. CUSTOMER ENVIRONMENT / PROJECT CONTEXT

             

            Customer profile:

            Matutano company, from Pepsico Group is a renowned manufacturer of snacks that leads the snack market with over 700 million bags sold annually through its brands Lays, Ruffles, Doritos, Fritos, and Cheetos Bocabits. They have a staff of more 2,500 employees and a production facility in Burgos. Matutano Burgos is a sensitive and committed to theenvironment and aware of their social responsibility. In 2000 implemented environmental management system and in 2001 it certified according to the environmental quality standard ISO 14001, through which articulates a strategic action plan for reducing water consumption, energy and waste generated during the production process.

             

            Customer objective and constraints:

            Pepsico Group commitment is to develop a sustainable environment, replacing all those resources within its hand and minimizing the impact on the environment.

            This is the reason why Matutano is been involved in that project. Regarding measures to improve its production process, Matutano has achieved a reduction in water consumption of a 38% and aims to achieve by 2015 a reduction energy consumption by 20%.

            Under the umbrella of his new policy, all the group's production plants are immersed in a project to decrease energy consumption by and product line.
            Basically the system consists of the Energy Efficiency data acquisition and processing of energy consumption with objective of providing information that facilitates making decisions for reducing energy consumption. Specifically, acquire data on consumption of:

            • Electricity
            • Water
            • Gas
            • Steam
            • Air 
             

            II. SOLUTION IMPLEMENTATION

             

            Implementation methodology (main phases):

            The main phases were:

            • Project design
            • Implementation
            • Comissioning
            • Testing of the System
            • Training


            In addition, all the works related with project management were carried out by Schneider Electric Project and Services team.

             

            Duration:

            18 months

             

            Solution overview (services, products, systems, architectures...):

             

            Schneider Electric proposes a solution within the scope of Business Intelligence Solutions and Manufacturing Information Systems (MIS). These solutions enable the processes to interconnect plant level with the other business processes, allowing provide a single, consolidated view of information production, consumption, costs.

            A key issue when implementing this solutions is to have quality data on low level, without them, it is possible to reach conclusions that can help make the right decisions. Therefore, it is essential to have a system of plant data acquisition as automated as possible so not to introduce errors in the collection process. The smart devices are key to achieving this goal.
            Also, reliable data is not a guarantee per se same if not available a robust platform, optimized, open and well measured that is capable of storing the data and, in turn, provide new technology to process such data masse. The technology platform should be transparent to user but is the core of the system, ensuring performance and future scalability.

            Finally, the information should be easily accessible and available for flexible means. Static reports are useful for monitoring routine of changing production processes and facilitate detecting a first level of impact but it is essential have reports configured by the user, without reengineering, and open tools that allow for queries not covered in the project development time.

            In order to ensure a total control of the installation consumptions and, therefore, be able to improve the usage of the ressources, it was necessary to install a huge number of energy counters, all interconnected with digital buses:

             

            • Electrical energy: 41 devices PM710
            • Water: 17 Endress+Houser devices
            • Gas: 15 Actaris devices
            • Air: 1 Endress+Houser device
            • Steam: 1 Endress+Houser device


            Communication network

            The devices are plugged in a Modbus serial network. By means of EGX100 Gateways and Connexium switches, all the sub-networks are integrated in a Ethernet plant network.

            Control system

            In head-board of the network, and managing the information before being sent to the supervisor Vijeo Citect, there is aModicon Premium which acquires and conditions all the measures using theoretical and experimental factors of correction.

            Modicon Premium is programmed using Unity software. In the proposed solution, the control Modicon Premium is totally integrated to the platform sg2, which allows:
            · To generate code automatically.
            · To provide the objects that solve the communication and integration of the intelligent devices.
            · To synchronize automatically the Databases of Control and Supervision (Vijeo Citect).

            Supervision system
            The supervision of the system is made with Vijeo Citect software. OFS server is user to enhance the communication between the scada and the Modicon Premium. The system is capable to:
            1. acquire the current values of consumption and totalizers with a temporary frequency and for events.
            2. show on screen the information of consumptions in real time.
            3. offer rapid graphs in real time.
            4. offer a simple and powerful tool to analyze the stored (historical) information of anyone of the consumptions and temporary periods on screen, printer or exportation to office computer tools


            Information system

            Vijeo Historian is the core of the system. Vijeo historian uses standard tools, concretely, the relational Database MS SQL Server and the system of reports MS SQL Reporting Services. The use of this standard tool, combined with technologies that allow to optimize the integration with the subsystem of Supervision, reduces the space needed in disc, improves the performance, guarantees the availability of the information acquired of plant, facilitates the maintenance of the system and reduces the costs of learning. This system and is the link between the plant systems and the corporate systems.

            The application allows to realize multitude of pre-established reports, dynamic reports (configurables by the user) and tools of general intention (MS Excel).

             

            How did we estimate the energy savings (methodology, tools, ...)

             

            Matutano measure energy consumption in real-time by product line. All the energy used is integrated in a single viewing environment: Water, electricity, steam, air, gas. They can allocate costs.

            The energy savings are measured by the customer with help of the system. Each decission he makes has a reflection in the consumptions. For instance, the image shows the gas consumption of two twin lines; the pink line has been modified in order to save gas.

             

            III. RESULTS / ACHIEVEMENT

             

            Customer benefits:

            Productive

            Provides real-time information accurate, reliable and automatically.

            Allows production costs reduction

            Engages the plant information systems and the corporate systems

            Using standard communication tools is possible the interconnexion of devices of different manufacturers

            Future ampliations are possible


            Efficient

            Allows to optimize the usage of natural and energetical resources

            Allows CO2 emissions reduction

            Allows water consumption reduction

             

             

            Customer testimonies (Verbatim):

            "... We opted for the solution of Schneider Electric for being the only provider that we offered a comprehensive solution for measuring all kinds of energy, integrated into a single system. "
            Eduardo Sancho, Technical Responsible of PepsiCo Iberia

            "... Energy efficiency is a priority for us, not only for economic savings but by his commitment what  Matutano has to the environment "
            Jose Luis Salinas, Operations Director of PepsiCo Iberia
             

            Schneider Electric differentiating values VS competitors:

            • We were more expensive than our competitors but it wasn´t a problem. We won it for different reasons:
                 - We identify needs of the customers
                 - We  analyze the importance of project to gave them the best solution. It could be so big.
                 - We Offer quickly a global solution (all the kind of energy integrated in the same control system) with sg2 and Vijeo Citect and Modicon
            • One of the key was the ingenious solution we offered to measure water consumption, no other competitor was able to do it. (We implemented Endress & Hauser and the necessary calculations).
            • Competitors didn't spend time in the main hided pain point of the customer:
            • There is a complex water circuit in Matutano and it is necessary to analyze the application.  May be because they didn´t see the importance of the project at the beginning. They didn´t want  to lose time.
             
             
             
             
             

            Solution breakdown

            Main services:
            • Engineering services: Services
            • Installation
            • Energy saving project implementation including solutions
            • Power Monitoring solutions
            Main products & systems: