Simplify installation. Accelerate commissioning. Gain richer diagnostics. Streamline Dairy Plant Commissioning with IO-Link Technology At a new $30 million dairy processing plant delivered by Pacific Process, ifm’s process instrumentation and IO-Link solutions helped simplify installation, accelerate commissioning and provide advanced device diagnostics and operational visibility. Process instrumentation IO-Link infrastructure Operational visibility PACIFIC PROCESS PROJECT AT A GLANCE $30m dairy processing plant 400+ process valves in plant 100+ process instruments 0800 803 444 +64 9 579 6991 sales.nz@ifm.com www.ifm.com/nz ifm electronic ltd has helped simplify installation and commissioning, and improve long-term plant performance at a new $30 million dairy processing plant delivered by Auckland-based engineering and project management firm Pacific Process for a large multinational dairy company. Specialising in food, beverage and dairy projects, Pacific Process employs around 50 engineers from diverse disciplines. The new facility included more than 400 process valves and over 100 process instruments, including flow, temperature, level and conductivity transmitters. Pacific Process selected ifm to supply the process instrumentation and IO-Link infrastructure for the project. The digital architecture simplified the control system, reduced installation complexity and delivered comprehensive device diagnostics and operational visibility. “Pacific Process needed instrumentation capable of supporting a large-scale dairy project while making installation and commissioning as simple as possible,” says Mark Jones, Managing Director of ifm electronic ltd in Auckland. “Our extensive range of process instruments and IO-Link solutions provided the flexibility and performance required to achieve that outcome.” Rather than relying on traditional analogue I/O technology, IO-Link uses standardised three-wire cabling to create a digital connection between instruments, sensors and the control system. This reduces wiring complexity, lowers installation costs and eliminates many of the signal quality issues associated with analogue transmission. “The real advantage of IO-Link is that it delivers far more than a process value,” says Jones. “It creates a two-way communication pathway that allows engineers to remotely configure devices, monitor health status and access valuable diagnostic information directly through the PLC.” At the dairy plant delivered by Pacific Process, IO-Link masters were installed throughout the processing skids, providing efficient connectivity to the central PLC, while enabling seamless integration of instruments across valve manifolds, tanks and process equipment. This significantly reduced wiring complexity, commissioning time and configuration errors. Devices can be replaced quickly using IO-Link's automatic parameter download feature, reducing downtime and simplifying future maintenance. For end users, the benefits extend well beyond commissioning. Advanced diagnostics and analytics from IO-Link-enabled instruments provide continuous visibility of sensor status, process conditions and device health. Maintenance teams can identify developing issues before they cause unplanned downtime, while plant operators gain access to richer process data that supports optimisation, energy efficiency and product quality improvements. The detailed diagnostic information also helps maintenance teams resolve faults faster and implement more predictive maintenance strategies, reducing operating costs across the life of the plant. ifm supported Pacific Process throughout the project, assisting with instrument selection, quotations, installation requirements and configuration of process connections. According to Daniel Smith, general manager of Pacific Process, the benefits were immediately apparent. “Having equipment available from stock when you need it is a huge advantage on a project of this size. The plug-and-play nature of the IO-Link devices allows equipment to be installed, connected and commissioned quickly. The simplicity of the system and the level of diagnostic information available through IO-Link have been extremely impressive.” The project highlights the broader capabilities of ifm, whose portfolio includes process instrumentation, pressure, temperature, flow and level sensors, condition monitoring, industrial communications, safety technology and Industry 4.0 solutions. As a family-owned company with a global presence, ifm combines the flexibility of a family business with the quality and professionalism of an international technology group. Its focus is on delivering automation and digitalisation solutions that improve efficiency, reduce resource consumption and support more sustainable industrial operations. “For us, quality is about much more than the product itself,” says Jones. “It is about understanding customer applications, responding quickly and delivering solutions that create lasting value throughout the life of a project.”
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