When processors modernize end-of-line operations, attention often focuses on new equipment. The bigger opportunity for Ken's Foods was in simplifying the controls architecture supporting the line.
As production demands increased, the company known for its salad dressings, sauces, and marinades faced several operational constraints. Legacy equipment, limited production visibility, and conveyor layouts that restricted material flow reduced efficiency in packaging and palletizing. At the same time, maintenance technicians had to leave the production floor to troubleshoot equipment through remote control cabinets, adding time to routine service tasks.
Ken's Foods implemented an on-machine architecture built around Rockwell Automation PowerFlex 350 variable frequency drives (VFDs) mounted directly on production equipment to fix the issues. The design reduced wiring requirements, simplified maintenance, and improved visibility into line performance.
Bringing controls to the equipment
Instead of routing motors and field devices back to centralized control panels, the new architecture places drives where the work is performed. With the PowerFlex 350 VFDs mounted on conveyors, Ken's Foods shortened cable runs. Additionally, there was a reduction in the engineering effort, while much of the traditional control cabinet infrastructure was eliminated. The system also streamlined installation and commissioning by requiring minimal configuration.
The change also improved operational awareness. Maintenance and production teams now have remote access to real-time drive data, including current, voltage, and speed, allowing them to identify developing issues more quickly and improve end-of-line performance.
Simplified maintenance
Moving the drives onto the equipment changed how maintenance is performed. For example, technicians can now troubleshoot and replace drives directly at the machine instead of having to go to remote electrical cabinets. Local disconnects, test points, and quick-connect power and input/output (I/O) connections simplify lockout/tagout procedures while allowing individual sections of the conveyor system to be isolated without shutting down larger portions of the line, which means less downtime during maintenance and faster recovery when issues occur.
Lowering installation costs
Another benefit to this architectural change is financial. "We estimate an overall cost savings of 17% compared to designing, building centralized panels and wiring directly to local motor disconnects, I/O points and motors," says Kyle Richard, Vice President of Business Development for Elm Electrical, an electrical partner of Ken's Foods. He notes that the on-machine VFDs also support a scalable safety system across a 130-drive palletizing line through a network-based architecture that reduces wiring and panel costs while allowing electronic stops to be placed where needed.
Building a standard for future projects
The results were significant enough that Ken's Foods adopted the architecture as the standard for future pallet-conveying systems.
"This approach helps us operate more efficiently as demand grows," says Tony Stolo, Project Engineer at Ken's Foods. "It takes up less space, installs faster and is easier to maintain. It also gives us flexibility to expand or reconfigure as our operations evolve."
As food manufacturers evaluating automation investments, it’s important to note that performance improvements don’t always mean adding more equipment. Sometimes, redesigning the controls architecture is all that’s needed to have a more scalable platform for future growth.
