Project Overview

Proseq was engaged at short notice to provide specialist process engineering and automation services for a fully automated Clean-in-Place (CIP) skid.

With a demanding delivery schedule, the project required rapid development of the functional design, PLC and HMI software, integration of control hardware and comprehensive factory testing.

Drawing on more than 30 years of combined experience developing automated CIP systems for leading beverage and dairy manufacturers across Australia and New Zealand, Proseq applied proven CIP control philosophies to deliver a sophisticated automation solution.

The Challenge

The project involved considerably more than conventional PLC and HMI programming.

Working within an existing mechanical skid design, Proseq identified several process, electrical and integration challenges requiring additional engineering to achieve the required functionality.

Key challenges included:

• Accommodating the existing drain line arrangement while achieving appropriate conductivity and temperature validation.

• Developing CIP sequences around a heat exchanger positioned on the return rather than supply side.

• Identifying equipment protection requirements associated with heat exchanger operation.

• Addressing PLC hardware limitations without compromising system functionality.

• Resolving electrical wiring, pneumatic valve and control hardware issues during commissioning.

• Completing integration and FAT within a compressed timeframe.

These challenges required practical process knowledge, flexibility and close coordination to maintain project progress.

The Solution

Proseq delivered a comprehensive automation and process engineering solution tailored to the skid's mechanical configuration and operational requirements.

Our scope included:

Process Engineering & Functional Design

• Development of detailed functional descriptions and CIP operating sequences.

• Restructuring CIP sequences to support conductivity and temperature validation.

• Development of a reusable Master Sequence control framework.

• Review of process interlocks and equipment protection requirements.

PLC & HMI Development

• Siemens TIA Portal software development.

• Integration of the Siemens S7-1200 G2 PLC platform.

• HMI development and operator interface functionality.

• Software simulation, testing and integration.

Electrical & Mechanical Integration

• Troubleshooting and rectification of Siemens VSD STO wiring.

• Correction of pneumatic valve connections and solenoid bank configuration.

• Modification of valve operation to address water hammer.

• Wiring and configuration of IO-Link masters.

• Integration and wiring of the CIP return pump.

Commissioning & Factory Acceptance Testing

• Hardware configuration and functional verification.

• PLC and HMI integration testing.

• Troubleshooting of electrical, pneumatic and process equipment.

• Commissioning against the completed skid.

• Factory Acceptance Testing prior to dispatch.

Despite the tight timeframe and additional engineering requirements, the Proseq team worked extended hours to complete the project and prepare the system for delivery.

Results

The completed project delivered a fully automated CIP skid, successfully commissioned and factory tested at Proseq's workshop.

Key outcomes included:

• Completion of the automation system within a demanding project schedule.

• Development of CIP control sequences incorporating process validation requirements.

• Successful integration of Siemens PLC, HMI, drives and IO-Link hardware.

• Resolution of multiple mechanical, electrical and pneumatic integration issues.

• Development of reusable automation functionality for future applications.

• Completion of FAT and preparation of the skid for site installation.

Proseq's Value

This project highlights the value of combining specialist process engineering knowledge with practical automation and commissioning experience.

Rather than simply programming equipment, Proseq worked through the wider process and integration challenges to deliver a complete, functional automation solution.

Our ability to respond at short notice, adapt to changing project requirements and provide hands-on engineering support was instrumental in getting the project completed.

At Proseq, we don't just automate equipment. We understand the process behind it.

From functional design and Siemens PLC development through to system integration, troubleshooting and commissioning, Proseq provides the expertise manufacturers need to deliver reliable, efficient and fully integrated process automation solutions.

Project Summary

Industry: Food & Beverage
Application: Automated Clean-in-Place (CIP) System
Technology: Siemens S7-1200 G2, TIA Portal, HMI, IO-Link
Services: Process Engineering, PLC Programming, System Integration, Commissioning & FAT
Outcome: A fully automated CIP skid, engineered, integrated and factory tested under demanding project timelines.