PLC control panel design food processing plant.
Case study: electrical and PLC control panel design for a Sydney-based food processing line — including I/O schedules, schematic drawings, ladder diagrams and panel-builder shop drawings to AS/NZS 3000, AS 61439 and HACCP food-grade requirements.
Project overview
ASTCAD designed the electrical and PLC control panels for a new food processing line at a Sydney facility. The system controls weighing, pasteurising, filling and packaging stations with Allen-Bradley PLCs over EtherNet/IP, integrated into the plant’s existing SCADA.
The challenge
Food-grade hygiene requirements drove panel material specification (304 stainless steel, IP66) and remote-mounted operator interfaces. The integration into existing SCADA required mapping over 800 I/O points without disruption to adjacent operating lines.
Our approach
- I/O schedule development with PLC tag mapping
- Panel design in food-grade stainless steel, IP66
- Schematic and ladder logic drawings
- EtherNet/IP network design and topology drawings
- HACCP-compliant cable management and wash-down provisions
Deliverables
- Electrical schematics (62 drawings)
- PLC I/O list (838 points)
- Panel-builder shop drawings
- Network topology and IP address schedule
- Site installation drawings and cable schedule
Outcome
The line was commissioned with no electrical defects on punch list. The PLC integration into existing SCADA was completed during a single overnight shutdown window. The line has been operating without unplanned electrical downtime since commissioning.