In the competitive world of soy processing, saving money and improving operations are top priorities. A leading soy processing plant teamed up with Interstates to use advanced technology to better control its Disolventizer Toaster (DT). The client needed to reduce steam usage while enhancing temperature control for improved product quality. We approached them with a solution called Model Predictive Control (MPC). In just 9 months, under half the time it was estimated, the client surpassed their ROI.
Reduced steam consumption by one pound per bushel
Saved $162,000 annually in steam utilization
Decreased DT high temperature set point by 6.8%
Had an ROI in 9 months
MPC is like the “brain” of modern industrial processes, only it has superior multitasking capabilities. It uses mathematical models to predict the future behavior of a system based on current and past data. While traditional control systems focus on the current state of a single variable, MPC looks at multiple variables simultaneously and makes real-time adjustments.
High steam consumption: Steam waste leads to operational inefficiency and increased costs.
Temperature Variability: Inconsistent temperature controls which could result in product quality issues.
Set Point Issues: A higher-than-necessary temperature set point for end-product quality led to higher energy usage and costs.
Taking an MPC approach improved steam efficiency and DT temperature stability, resulting in cost savings and better quality. Once the project was complete, the client reduced steam consumption by one pound per bushel and saw a significant reduction in temperature variability. This enhanced the quality and consistency of their project.
The client is delighted with the success of this project and is now considering the possibility of using this technology in other areas of their operation to further strengthen their competitive advantage in the market. By partnering with Interstates, they could take advantage of their industrial, professional services expertise and experience in implementing Rockwell Pavilion8 MPC. This resulted in significant cost savings, improved operational efficiency, and enhanced product quality at their site. Given the project’s cost, Interstates estimated an ROI of 19 months. However, with the $162,000 annual savings, they had an ROI of just 9 months! The client can also expect additional savings from the improved temperature control and optimized set point.
You can rely on Interstates to bring your industrial facility to the next level. Work with us and optimize your plant with updated technology, faster turnaround times, and maximized efficiency. Let’s schedule a conversation so we can learn more about the ins and outs of your vision.