Kiln Loader Strippers
As part of a phased project over several years Au Automation were commissioned to integrate Kiln Loader/Strippers into the main control system and automate the operation replacing the local panel and pendant pushbutton operation at two of Diageo's largest malting sites.
Loading is the process of filling the kiln with malt in preparation for the kilning process. Kilns would be loaded with 30 - 60 tonnes of green malt in 1.5 to 2.5 hours. Stripping, which takes around 1 to 2.5 hours depending on the loaded weight, is the process of emptying or unloading the kiln once the kilning process is complete.
The scope covers eleven Kilns in total with three different loader designs. The first design is fixed at a central point in a circular kiln and has rotational and vertical movement. The second design is a crossbeam which moves horizontally and vertically within a rectangular kiln. The third type is fixed at a central point which, in addition to rotational and vertical movement, is extendable and retractable as it needs to reach the edges of a rectangular kiln.
Firstly the positional feedbacks and control signals for the loader are connected into the main control system. Then user editable profiles to automatically control the loader/stripper action are set up via the centralised SCADA and stored locally in the PLC. Finally, the loader and profiles are commissioned and fine tuned to ensure efficient operation and a consistent level of green malt in the kiln.