Food – HBM Flow Wrapper – Premier Foods, Stoke- 2025

P22 Legs 1 & 2 HBM Flow wrappers at Premier Foods, Stoke-On-Trent

UCS Automation successfully completed two control system upgrades on the P22 HBM Flow Wrappers at Premier Foods in Stoke. The project modernised the flow wrapper’s control architecture, improved long-term supportability and provided a robust platform for future enhancements.

The upgrade involved the complete replacement of the backplate within the wrapper control panel. UCS Automation delivered a future-ready Allen-Bradley CompactLogix Safety PLC solution, incorporating the latest Kinetix 5500 servo drives with integrated safety over Ethernet. Existing servo motors were replaced with Allen-Bradley VPL servo motors and Wittenstein gearboxes, while inverter speed control was upgraded using Allen-Bradley PowerFlex 525 drives. The safety system was also modernised using Allen-Bradley safety I/O, with all safety switches replaced by Pilz units. The existing operator interface was replaced with a 10-inch Allen-Bradley PanelView Plus 7 HMI, installed in the same location as the previous unit. All drives, safety devices and the HMI were connected to the PLC via an Ethernet network, creating a fully integrated and scalable control solution.

Customer benefits

• Reduced obsolescence risk by replacing ageing control equipment with a modern Allen-Bradley CompactLogix Safety PLC platform.
• Improved reliability and maintainability through the use of current servo drives, inverters, safety I/O and networked control devices.
• Enhanced machine safety through the integration of updated safety hardware, safety over Ethernet and replacement Pilz safety switches.
• Improved operator experience with a modern 10-inch PanelView Plus 7 HMI, providing clearer control, status information and diagnostics.
• Greater visibility of the machine control system through Ethernet connectivity between the PLC, drives, safety devices and HMI.
• A scalable, future-ready platform that supports future flow wrapper upgrades, easier troubleshooting and long-term engineering support.

HBM Wrapper Upgrade photos:

To summarise each upgrade consisted of the following elements:

• Site survey to ascertain a detailed specification,
• Electrical design,
• PLC / HMI Software design,
• Manufacture of a new wrapper control panel backplate,
• Disconnection and complete removal of the existing wrapper control panel backplate,
• Disconnection and removal of the existing servo motors & gearboxes,
• Disconnection and removal of all guard / gate switches,
• Mechanical installation of the new servo motors & associated gearboxes,
• Installation of new guard switches,
• Installation of new dual channel Emergency stop stations,
• Installation of new servo cables,
• Reconnection of existing cables to new wrapper backplate,
• Electrical testing of the system,
• Software / production commissioning on site.