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How PZ Cussons has automated and optimized production
To measure and automate most of the stages of creating recipes, mixing, processing and packaging, hygiene products manufacturer PZ Cussons has revamped its system for process control. Result: an optimization of its production performance, while meeting strict quality standards.

The British company PZ Cussons manufactures a wide variety of hygiene products and cleaning products: soaps, gels, shampoos, hair care cosmetics, detergents ... The process of manufacturing its products seems very simple: the factory receives raw materials, adds precise amounts of fragrances and additives with a list of recipes, then mixed and conditioned according to the production volumes required. In fact, this process requires extreme precision measurement and control for the lots conform to strict quality standards of society.

The former site of PZ Cussons has grown fairly erratic over the years, he was unable to produce sufficient volumes to achieve economies of scale necessary to remain competitive. Many areas where they could save money and eliminate unnecessary costs have been identified. Moreover, it was found too many human interventions at all stages of production, resulting in undesirable changes in income. The company acknowledged that only a modern plant would enable it to achieve its economic goals, knew she could make significant savings by improving its production operations.
A solution based entirely on ISA S-88

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To celebrate the renewal and modernization of its supply chain in the United Kingdom, PZ Cussons has chosen to use Rockwell Automation and Endress + Hauser's partner. The solution implemented is entirely based on ISA S-88 and uses an instrumentation network. Based on the Rockwell Automation integrated architecture, it has a common application environment oversimplifies the installation and migration. The process control system in place, PlantPAx is complemented by measuring instruments and fieldbus developed, designed and commissioned by Endress + Hauser. According to Andy Ellams, Head of Process Development at PZ Cussons: "We had a very clear vision of what we wanted: a distributed control system coupled to a set of servers integrated into our overall IT infrastructure."

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The overall control of the line by more than one PAC (Programmable Automation Controller) Allen-Bradley ControlLogix. These machines are at the heart of the control of control centers and are connected to FactoryTalk Batch and provide data to FactoryTalk Historian. The tool allows AssetCentre FactoryTalk asset management of the entire plant. The field instrumentation can be configured and maintained from a central point using the features FDT / DTM (Field Device Tool / Device Type Manager) network of ground FieldCare Endress + Hauser. This also facilitates the monitoring and analysis of communication traffic at the central level. This completes the seamless integration of the control system to the field device, allowing the validation of the variables measured and consistent maintenance of equipment.

The complete installation is covered by a maintenance contract and strategic support contract that supports all the problems encountered in the main system.

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Pilot testing and process simplification

With the former approach, all revenues were frozen in the code of PLC (Programmable Logic Controller). It was not easy to test new recipes and new mixes without a major rewrite exercise. Rockwell Automation technology has allowed PZ Cussons to test in pilot and small scale new recipes before launching mass production. The company was also able to effectively simplify some processes that previously required to appeal to specialized operators, with many years of training. With consequent reduction in output variability as each operator, although experienced, was his personal way to proceed on the machines ... Today, thanks to the scalability and portability of the software, any operator can turn any line. Operators become much more versatile, occur only in areas where their intervention is really necessary. Manpower assigned to one of the areas has been reduced from 16 people working in 4x8 to one person, inspecting the site once a day. Some of the positions eliminated were redeployed elsewhere in the plant.
Lots of successful first time

By measuring and automating most steps of creating recipes, mixing, processing and packaging, the solution installed at PZ Cussons has had a considerable impact. It has ensured the production volumes required. Moreover, thanks to the seamless integration of field equipment and accuracy of data collected, it could achieve the quality targets set. The savings were such that society is determined not to move production outside the United Kingdom. Ellams concludes: "Lots successful the first time are the norm today. Their quality is very high today, without special effort on our part. It happens sometimes weeks without any production problem occurs. In Overall, the factory knows less downtime, lots are more accurate and reduced processing time, which in turn allows us to save energy and get faster on the marketplace. "

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