BakeMark
Control System Boosts Bakery Ingredients Output by Over 50%
BAKEMARK
BakeMark is a leading international provider of
a wide range of bakery ingredients and frozen
bakery products to bakers and chefs across
the world. Its ingredients and frozen bakery
products are used by professional bakers and
chefs in many different bakery businesses from
Industrial Bakeries and Supermarket Instore
Bakeries to Artisan Bakers, Bake Off Stations
and chefs in hotels, restaurants and canteens.
THE CHALLENGE
At its factory in Manchester, England,
BakeMark was looking for a plant-wide control
system to replace its existing system, and
to expand production of its bread improver
ingredients – predominantly cake mixes, from
17.5kt to 27kt per annum. With the whole
factory being totally dependent on the control
system, it was crucial that the new system had
proven reliability.
THE SOLUTION
BakeMark commissioned Advanced Technical
Software (ATS) to run the project, who in
turn chose to install a new automation and
monitoring system using Mitsubishi PLCs and
CitectSCADA software which offers in-built
dual redundancy.
The system covers all materials handling,
storage, weighing, batching and blending,
and tracing of over 2000 different ingredients,
and can track over a million individual items
throughout the factory.
“Although most SCADA packages include
some form of product batching and control,
the very exact requirements of this plant
precluded their use. As an approved systems
integrator for a number of leading SCADA
systems, our choice was entirely objective”,
said Geoffrey Graves, MD for ATS and Project
Manager.
“CitectSCADA offered us the tightly integrated
easy networking we required, with powerful
facilities for generating complex and scaleable
graphics. Most importantly, its distributed
architecture proved perfect for our strategy of
dividing the plant control operation into two
distinct areas.”
As part of its strategy, ATS developed
two bespoke application packages; ‘Plant
Manager’ and ‘Line Manager’, which sit on the
CitectSCADA platform.
Plant Manager handles all material imports,
the ingredients preparation area and mixer
additions. It also provides administration
facilities, to handle recipe set-up, materials
tracking and reporting. Each production line
THE CHALLENGE
To create a reliable, plant-
wide control system to replace
BakeMark’s existing system,
and to expand production of
its bread improver ingredients
– predominantly cake mixes, from
17.5kt to 27kt per annum.
THE SOLUTION
Project Managers, Advanced
Technical Software (ATS) installed
a new automation and monitoring
system using Mitsubishi PLCs and
CitectSCADA software which
offers in-built dual redundancy.
CONCLUSION
The system covers all materials
handling, storage, weighing,
batching and blending, and tracing
of over 2000 different ingredients,
and can track over a million
individual items throughout the
factory.
The CitectSCADA/ Mitsubishi
system is reliable, flexible and
easy to use, and helps BakeMark
expand its production by providing
transparency across the plant, and
enabling process improvements. As
a result, BakeMark has been able
to increase its ingredients output
by in excess of 50%.
CaseStudy
 is also supported by its own PC running Line
Manager. These Line Manager PCs allow
production scheduling on a line basis and
also display all plant status information,
mimics, production and plant alarms together
with sophisticated maintenance and set-up
facilities. Each production line is dedicated to
a particular mixer; however, any Line Manager
PC can control all production lines dependant
on a user’s authorisation.
The inherent flexibility of the Line Manager
system provides the production manager at
BakeMark with the ability to predetermine
the work to be carried out over a forthcoming
period or shift.
The system offers the capability of storing up
to thirty runs for each mixer, with each run
given a projected start time, so that notice can
be given of which pallet and/or rigid containers
need to be prepared to meet production
requirements.
All data files for Plant Manager and Line
Manager are stored on the CitectSCADA server
in a database format, providing extensive file
security and backup facilities for all areas of
production and plant information from a single
secure location.
In addition to high levels of plant control
and production flexibility, the system we
have designed and commissioned provides
BakeMark with high levels of transparency.
Contact Citect’s Authorized users are able to request a number
experienced food & of reports, all of which are generated using
beverage specialists
industry standard Crystal Reports. These
allow full traceability of all materials and
to find out how we their location. For materials already used
can help you optimize in production the reports allow backwards
production efficiencies tracing from an individual product batch code.
and meet compliance The system includes very detailed plant
regulations. alarm and diagnostics allowing even an
inexperienced operator to quickly pinpoint any
www.citect.com/Food plant malfunction or fault condition.
Normal advanced alarm facilities are included
but these are supplemented by an on-screen
status monitoring and diagnostics panel for
each plant item showing its current status and
maintenance information.
CONCLUSION
The system covers all materials handling,
storage, weighing, batching and blending,
and tracing of over 2000 different ingredients,
and can track over a million individual items
throughout the factory.
The CitectSCADA/ Mitsubishi system is
reliable, flexible and easy to use, and helps
BakeMark expand its production by providing
transparency across the plant, and enabling
process improvements.
As a result, BakeMark has been able to
increase its ingredients output by in excess of
50%.
SUBMITTED BY
Paul Hurst, Regional Manager, Citect UK with assistance from
Geoffrey Graves, MD, ATS.
“CitectSCADA offered us
the tightly integrated easy
networking we required,
with powerful facilities for
generating complex and
scaleable graphics. Most
importantly, its distributed
architecture proved perfect
for our strategy of dividing
the plant control operation
into two distinct areas” -
Geoffrey Graves, MD for ATS and
Project Manager

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