CASE STUDIES

Medical Packaging

LT Software recently provided an upgrade to a Medical Product Sealing line.  This upgrade addressed the Leak Testing of blister packs before they were sealed with a foil backing.  The existing system required 8 seconds to perform the pressure testing and used two very large and difficult to calibrate external leak detection units.
LT Software developed a solution using modern PLCs (Rockwell CompactLogix) coupled with high speed analog input modules and high resolution pressure transmitters.
The result was a very repeatable pressure testing system that only required 6 seconds to perform each test cycle.  The reduction of 2 seconds from the testing cycle provided a 25% increase in throughput and paid for itself in 2 months due to increased throughput.

Chocolate Molding

LT Software recently provided an upgrade to a Chocolate Molding line.  This upgrade addressed the Depositing of Chocolate into molds.  The existing system was only capable of depositing 14 molds per minute and would only operate problem free for a few hours.

LT Software developed a solution using modern PLCs (Rockwell CompactLogix) coupled with Kinetix Servo control to provide an increase in production that allowed the depositing of 20 Molds per minute.  The system now operates without any issues.

The result was a very repeatable depositing system that allows for fine adjustments to product weight and provided a 42% increase in throughput.  The increase in production throughput of 42% paid for the system upgrade in only 3 weeks.

Composite Press System

LT Software recently provided an upgrade to a dual 9 platen Composite Press system.  This upgrade addressed the temperature and pressure control of a molding process.  The existing system was full of bugs and the components were so outdated that they were no longer available.

LT Software developed a solution using modern PLCs (Siemens S7-1500) coupled with the LT Software Object environment to provide an increase in reliability and production that totally eliminated downtime due to failed runs and temperature and pressure control out of specification.

The result was a very repeatable Press system that allows for the continuous production of very repeatable product and provided a 100% increase in throughput due to constant Up Time.  The increase in production throughput of 100% paid for the system upgrade in less than 1 month.

Chocolate Industry Experience

We understand the chocolate industry challenges like tempering and recipe / flavoring control as well as controlling fat content.  From mixing, refining and conching through molding, packaging and inventory control, we have increased throughput by upgrading and optimizing Operator Interfaces and PLC systems.  Additionally our upstream integration of Chocolate Liquor Delivery Systems allows for better production flow and speed.

Other chocolate applications improvements include streamlining PLC programs and machine modifications to:

  • Increase production 25%
  • Provide clear rung by rung documentation
  • Translations from German and Flemish to English

Corrugated Auto Splicing Systems

The key to high speed corrugators is to never stop the process.  This requires high speed tracking of the number of rotations of the liner and corrugated rolls to be able to determine the roll diameters so that the next roll can be spliced in line automatically before the existing roll is used

LTSS has worked with high speed corrugators to upgrade antiquated control systems that were no longer supportable.  Upgrade of high speed pulse and counter operations with encoders and modern PLCs allows us to provide higher speed response to the splice event and allows for faster operation of the corrugators.

Transportation Industry

One of LTSS’s largest installations for both automation and communications is in the Light Rail industry.  Among many applications, a metro rail system requiring redundant front end PLCs connected to a UNIX based GUI (SCADA) system was just the beginning.  From there we created code for 114 PLCs communicating over an in-house LTSS designed custom remote telemetry communications protocol to achieve the communication levels required for the application.

One of our finest accomplishment is the communication integration of commands, data, alarms and the acknowledgements that the specification demanded, 36 simultaneous data streams through a custom high speed TCP/IP Ethernet network.  Large projects with many custom automation specifications are the type of projects LTSS is always ready for.

Semiconductor Industry

Wafer transport and production is a unique process that requires on the fly data collection at all levels of the plant hierarchy.  Adaptations of best route, positioning and communication accuracy are the requirements for success.  Some of the applications we have worked on include:

  • PC based automation application design and creation (C++, VB)
  • Motion control with Adept, Delta Tau and Animatics plus program creation
  • Ethernet to robot system throughput improvements
  • Ethernet to remote graphic system to improve resolution and update time
  • Vision (DVT, Cognex, Acuity …)

Due to the high cost of wafers we have simulated many of these projects prior to installation to insure virtually fault free software.

Pulp and Paper Industry

igh-speed web control is the name of the game for paper production.  PLC execution speed and closed loop drive control can now achieve the timing required to eliminate the production problems caused by a slow process (i.e. web tension, un-synchronized roller motion, etc.).  LTSS has worked with paper machines, wrap lines, re-wrap lines and chip handling processes in plant wide upgrades.

Upgrade of serial and Ethernet communications along with translation of European documentation and rewrite of difficult to understand Ladder Logic OEM Software has become a very important issue for our customers – who now are no longer held captive by the OEM or their complex software.

Beverage and Brewing Industry

The coordination of many OEMs machinery can be a challenge for the end user.  LTSS has helped many customers with different vendor’s equipment for seamless integration of a production line or for an entire plant wide control system.  Production tracking from the cellar control to recipe management and temperature control are just some of the important factors required for a successful brewing process.

LTSS has worked with several Distributed Control Systems (DCS) in these industries for batching and recipe management using x-term stations with remote I/O.  DCS technology provides many advantages including large amounts of data to be handled and easy access to plant wide data at many locations throughout the plant.

LTSS has implemented and upgraded the Siemens Braumat control system in many breweries across the country.  From Brewhouse Control to complete Brewery Automation LTSS is your best choice for the modernization and automation of Brewery control.

Multi-Platen Laminate Presses

ressure and temperature control are the key components in producing repeatable Laminate products.  From controlling the temperature of Hot Oil or Electric Heaters properly implemented and tuned PID loops are crucial to control success and product repeatability.

We also have extensive experience with Vacuum Laminating presses at many customers who produce widely varying products that all require the same common control components.  LTSS has mastered recipe based machine control across many HMI / SCADA platform that will provide you with the best solution for your press application.