Case Study: Increasing Output by 15% with a TSXRKS8 and VW3A1113 Upgrade

Executive Summary: A bottling plant increased line efficiency through a targeted control system modernization

In today's competitive manufacturing landscape, even small improvements in operational efficiency can translate into significant competitive advantages. This case study examines how a mid-sized beverage bottling facility achieved remarkable performance gains through a strategic upgrade of their control systems. The plant, which had been operating with increasingly outdated equipment, managed to increase their production line output by an impressive 15% following a carefully planned modernization initiative. The cornerstone of this transformation was the implementation of two key components: the TSXRKS8 programmable logic controller and VW3A1113 variable frequency drives. These technological upgrades, combined with the installation of the WH5-2FF 1X00416H01 circuit protection system, created a synergistic effect that exceeded initial expectations. What makes this achievement particularly noteworthy is that it was accomplished without a complete line overhaul, demonstrating how targeted technological investments can yield substantial returns. The plant management reported not only increased production volumes but also improved product quality, reduced energy consumption, and enhanced overall equipment reliability. This comprehensive approach to modernization serves as an excellent blueprint for other manufacturing facilities considering similar upgrades to their aging control systems.

The Problem: The existing relay-based system was slow, inflexible, and caused high mechanical wear on motors

The bottling plant's challenges began with an aging control system that had served the facility for over two decades. The relay-based architecture, while reliable in its time, had become a significant bottleneck in the plant's operations. Line changeovers between different bottle sizes and product types required manual adjustments to numerous physical relays, a process that typically took production staff 45-60 minutes to complete. This downtime significantly impacted overall equipment effectiveness and limited the plant's ability to respond quickly to changing production demands. More concerning was the mechanical stress imposed on motors throughout the system. The abrupt starting and stopping characteristic of relay-controlled motors created tremendous inertial forces, leading to premature wear on motor bearings, couplings, and gearboxes. Maintenance records revealed that motor failures occurred approximately every three months, with associated repair costs averaging $5,000 per incident including both parts and labor. The lack of speed control also meant that conveyor belts operated at fixed velocities regardless of production requirements, resulting in unnecessary energy consumption during slower production periods. Production managers noted that line speeds had gradually decreased over the years as operators deliberately ran the equipment slower to reduce the frequency of jam-ups and mechanical failures. The cumulative impact of these issues was a production line operating well below its theoretical capacity, with escalating maintenance costs and diminishing reliability.

The Solution: Replacing old relays with a TSXRKS8 for smarter control and installing VW3A1113 drives on conveyor motors for soft-start and speed optimization

The engineering team developed a comprehensive solution that addressed the root causes of the production limitations while minimizing disruption to ongoing operations. The centerpiece of this modernization was the TSXRKS8 programmable logic controller, which replaced the labyrinth of electromechanical relays that had previously governed the line's logic operations. This advanced controller brought sophisticated programming capabilities that enabled more complex and responsive control sequences. Unlike the rigid relay system, the TSXRKS8 could store multiple production recipes, allowing operators to switch between different product configurations with a single command from the human-machine interface. This reduced changeover time from nearly an hour to under five minutes. Complementing the PLC upgrade, the team installed VW3A1113 variable frequency drives on all critical conveyor motors. These drives introduced soft-start functionality that gradually ramped motor speed up and down, eliminating the damaging mechanical shocks that had plagued the old system. The VW3A1113 units also enabled precise speed control, allowing operators to fine-tune conveyor velocities to match optimal production rates for different products. To ensure complete electrical protection for the upgraded system, the engineers specified the WH5-2FF 1X00416H01 circuit breaker configuration. This robust protection system provided coordinated protection against overloads, short circuits, and other electrical faults, safeguarding both the new control equipment and the motors from electrical damage. The integration of these three components created a holistic solution that addressed control flexibility, mechanical preservation, and electrical safety in a single coordinated package.

The Implementation: Phased installation with minimal downtime, followed by thorough testing

The implementation strategy was carefully crafted to minimize production disruption while ensuring a thorough and reliable system integration. The project team divided the installation into three distinct phases, each scheduled during planned maintenance windows to avoid interfering with normal production schedules. Phase one focused on the physical installation of the VW3A1113 drives and the WH5-2FF 1X00416H01 protection system while the existing relay controls remained operational. This approach allowed the electrical team to mount and wire the new components without rushing, ensuring proper mechanical installation and electrical connections. During phase two, the team executed the critical switchover from the old relay system to the new TSXRKS8 controller over a weekend shutdown period. This intensive 48-hour window required meticulous planning, with pre-written control logic thoroughly validated on a test bench before implementation. The programming team developed and simulated the control sequences extensively beforehand, dramatically reducing commissioning time. Phase three consisted of comprehensive system testing and operator training. The engineering team conducted rigorous performance validation, running the line at various speeds and with different product types to verify system stability and responsiveness. Particular attention was paid to the interaction between the TSXRKS8 controller and the VW3A1113 drives, ensuring that acceleration and deceleration profiles were optimally tuned for both mechanical preservation and production efficiency. Operators and maintenance technicians received hands-on training covering both normal operation and troubleshooting procedures, empowering them to fully leverage the new system's capabilities.

The Results: A 15% increase in line speed, a 30% reduction in motor maintenance, and a full ROI achieved in under 12 months

The measurable outcomes of the control system upgrade exceeded the plant's most optimistic projections. Most notably, the production line achieved a sustained 15% increase in operating speed, directly translating to higher output without additional capital investment in machinery. This improvement stemmed from multiple factors: the reduced changeover time afforded by the TSXRKS8's recipe management, the ability to run at higher speeds confidently thanks to the VW3A1113's soft-start capabilities, and the elimination of previously frequent jam-ups that had required line stoppages. The mechanical benefits proved equally impressive, with motor maintenance costs decreasing by 30% in the first year of operation. The gentle acceleration profiles provided by the VW3A1113 drives significantly reduced stress on motor components and mechanical linkages, extending equipment life and reliability. The robust protection offered by the WH5-2FF 1X00416H01 system prevented two potential electrical faults from escalating into equipment damage incidents, further contributing to maintenance reduction. From a financial perspective, the project delivered a complete return on investment in just 10.5 months, far quicker than the anticipated 18-month payback period. This accelerated ROI resulted from the combination of increased production revenue, reduced maintenance expenses, and lower energy consumption achieved through optimized motor operation. The success of this project has inspired the plant management to consider similar targeted upgrades for other production lines, demonstrating how strategic technology investments can breathe new life into existing manufacturing assets.