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An extra layer of efficiency at Farm Frites thanks to Heveco and Siemens motion control
Food safety, efficiency, and ease of maintenance

Electrical & Electronic (E&E)

Heveco

Genk Belgium

Completion: 2021
Farm Frites Lommel
Lommel,
Belgium
In order to realize the expansion plans of Farm Frites, a Dutch producer of pre-fried, frozen chips, the production line in Lommel, Belgium, for chips of the highest quality had to be renewed and expanded.
Except for a few process steps, the line has been completely rebuilt and expanded. For example, a new drying tunnel, in which fans circulate conditioned outdoor air over a long conveyor belt, has been added.

To save energy, the dryer uses heat recovered from the baking oven, and the temperature control works on the basis of humidity.  At the end of the production process, the chips are successively cooled and frozen.  Here, a mechanical sorting machine ensures that broken and deformed chips are removed. The final product is automatically transported to the cold store in various packaging.

New on the line is an installation to add 'coating' to the chips. With this, certain properties, such as color and taste, can be added, and the fries remain crispy for longer. The installation is in a bypass set-up, in which fries are submerged in a paste. Thanks to air knives, part of the coating can be recovered.

Heveco, the partner of Farm Frites, took care of the complete electrical engineering and automation of the project, including panel construction and software programming of the PLCs.  All machines, including the coating applicator, run on one central control.  An army of about 175 Siemens Sinamics G120 frequency converters ensures an efficient flow. Together with the two main PLCs and the HMIs, these are fully integrated in TIA Portal, which, among other things, ensured a particularly smooth commissioning.  In the technical room, Heveco installed ET 200SP I/O islands for the decentralized periphery. The safety programming is integrated in the Simatic S7-1500 PLCs.
As a solution partner of Siemens, integrator Heveco chose, among other things, for more than a hundred of Sinamics frequency controls. “They are all of the same G120 type, in order to simplify the work of the Farm Frites Technical Service through this standardization in the event of any malfunctions. After all, this way they become familiar with it faster and it also offers advantages for spare parts. The modular concept of these drives – with a separate power and control section – also contributes to ease of maintenance.”
Bart Huygen, co-owner, Heveco.
In addition to doubling the production capacity and expanding with coating options, the renewed production line also excels in food safety, efficiency and ease of maintenance.  For example, less cabling is required, thanks to the high degree of integration between the various components – including safety-integrated.  In addition, this concept – in which the safety functions are fully integrated into the controller – also ensures a perfectly harmonized connection to the Simatic controllers via PROFIsafe. The safety concept also makes it possible to easily place the different drives in safety groups and ensures improved diagnoses. 
The result is shorter commissioning and lower costs due to less wiring and more efficient engineering. The standardization on the Sinamics G120 frequency controls makes the work of the technical service and the management of spare parts a lot easier. 
And thanks to their modular design, the controls are very easy to maintain. The Simatic ET200SP I/O islands pave the way for possible future expansions, while the integrated safety programming guarantees peace of mind and an improved safety concept: the different drives can easily be placed in safety groups. 
Add to that the attention for energy efficiency and recovery, as well as the improved diagnostic options, and the future of Farm Frites and frozen chips seems guaranteed.
An extra layer of efficiency at Farm Frites thanks to Heveco and Siemens
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