Overview
At In2Food’s juice production facility, a lack of standardisation across pasteuriser lines was creating daily operational challenges. Each machine had its own control system, wiring layout, and interface logic. This made it difficult to troubleshoot faults, apply consistent settings, or train operators effectively.
The inconsistent control setup was also affecting product quality. Temperature deviations in the pasteurisation process led to failed batches, rework, and product waste. With tight delivery schedules and strict food safety standards, the plant couldn’t afford unreliable production or unplanned downtime.
The engineering team needed a control solution that would stabilise the process, simplify maintenance, and allow them to take ownership of day-to-day support. Working with ElectroMechanica (EM) and system integrator Garnet Engineering, the plant moved to a unified Delta automation platform that replaced legacy panels, resolved control issues, and created a SCADA-ready foundation for plant-wide visibility and future upgrades.
The Challenge
Challenge 1
Equipment inconsistencies and production waste:
Each pasteuriser in the plant had been built or modified using different components, with no standard logic, interface, or wiring approach. Operators had to adjust to different controls from one unit to the next, and process parameters varied from batch to batch. Temperature control was especially unstable, with PID loops unable to hold to the required tolerances. This led to recurring product losses, with some failed batches requiring hundreds of litres to be dumped and reprocessed.
The lack of consistency also made it difficult to apply process improvements across the line. Settings that worked on one machine didn’t transfer to the next, limiting the engineering team’s ability to drive efficiency or enforce quality standards.
Challenge 2
Support gaps and lack of diagnostic visibility:
The site was running a mix of legacy equipment from different vendors, much of it unsupported locally. Replacement parts were hard to source, and documentation was often incomplete or outdated. With multiple communication protocols in use, the system couldn’t be monitored centrally or integrated easily with new equipment.
When faults occurred, identifying the cause often required manual checks or third-party intervention. This delayed recovery, extended downtime, and increased reliance on external support. Without access to consistent diagnostics or system-level oversight, the team spent more time reacting to failures than improving performance.
The Solution
From the outset, it was clear that retrofitting individual components wouldn’t solve the systemic challenges In2Food was facing. The control environment needed to be completely rebuilt — not just to stabilise the current pasteuriser setup, but to create a platform the team could maintain, scale, and standardise across future lines.
Fit-for-purpose specification and panel rebuild
A Delta AS300 PLC (AS332P-A) was selected to manage the system logic. It offers the program size and processing speed needed to maintain accurate PID loop control and manage multiple devices across the line.
Temperature control was addressed using two Delta options. DT3 stand-alone controllers were used in areas where localised PID control was sufficient. DTM Ethernet-based units were integrated directly with the AS300 PLC to enable tighter, centralised loop control. Both options support accurate, stable control within food-grade pasteurisation tolerances.
Delta CP2000 VFDs with Ethernet cards were used for motor control, selected for their reliability and seamless integration with the PLC. These replaced legacy drives that offered limited visibility and inconsistent performance.
The rest of the system was built for consistent communication and reliable operation. EM specified Delta Gigabit Ethernet switches for high-speed communication, Lyte II 24V power supplies for stable voltage, and IP65 stainless steel enclosures (RGS304) for environmental protection. Finder 46 Series plug-in relays were used across all panels to ensure switching consistency.
Training for in-house support
EM conducted training sessions and workshops to ensure that Garnet Engineering staff could support and maintain the system independently. Garnet Engineering handled the panel build and code development, while EM provided product advice and troubleshooting support.
SCADA-ready from day one
The upgraded system was built with Ethernet communication throughout, laying the groundwork for centralised control and plant-wide visibility. As a first step, VTScada Light was implemented to monitor key process data and validate the communication structure. This trial gave the engineering team a clear view of system performance and identified opportunities to standardise control across additional equipment.
Based on the success of the pilot, a full SCADA rollout is planned. The goal is to bring pasteurisation, utilities, and future production lines into a single monitoring and control environment. With VTScada, the team will be able to access real-time data, analyse trends, generate batch reports, and respond faster to faults, all from a single interface. It’s a scalable solution that supports both compliance and operational efficiency, while giving the plant team more control without adding complexity.
Implementation and results
The upgrade process spanned six months, including system design, procurement, panel build, and training. Factory acceptance testing was conducted in advance, which allowed the final switchover to happen with minimal disruption. The production line was only offline for three days during changeover.
Immediate results
- More stable temperature control and improved batch quality
- Quicker fault resolution
- No unplanned downtime post go-live
- Internal team can manage and maintain the system
Built for expansion
With the Delta platform now standardised across the line, In2Food can scale and integrate new production lines with ease. The architecture is ready for full SCADA integration and reporting, allowing for improved traceability and tighter quality control. As product volumes grow and certification demands increase, the foundation is already in place to support future automation.
Tech Specs
| Equipment | Function/Benefit |
|---|---|
| Delta AS300 PLC (AS332P-A) | Handles large logic programs with speed and reliability |
| Delta DOP-115MX HMI | 15” interface for real-time control and operator clarity |
| Delta CP2000 VFD with Ethernet/td> | Durable motor control with built-in diagnostics |
| Delta DT3 and DTM controllers | Precision PID control (stand-alone and integrated options) |
| Delta Lyte II DRL-24V240W1EN | Robust 24VDC power supply |
| Delta Gigabit switches | High-speed industrial Ethernet communication |
| EM RGS304 IP65 enclosures | Stainless steel protection for panel equipment |
| Finder 46 Series plug-in relays | Reliable switching and signal isolation |
| VTScada Light | Pilot SCADA system with full rollout planned |