ABC Process Automation LLP

ABC Process Automation is at the forefront of advanced automation solutions in India.

We deliver solutions that are specifically designed for the Dairy, Food & Beverage Industry.
With a deep domain knowledge of the industry & wide exposure to the cutting-edge
technologies, ABC Process Automation is fully geared to deliver products & solutions that
shall meet the needs of the Dairy, Food & Beverage Industry.

Our products and services include Advanced Process Control, MES, Plant and Process
automation, Drive solutions, and Electrical switch boards that are engineered in-house.
Backed by a team of highly experienced, multi-disciplined engineering, design and
application talent; ABC Process Automation helps clients achieve their business goals by
helping them improve time to market, greater efficiencies, improved & consistent Quality.

ABC is a specialized end-to-end solution provider company engaged in design, engineering,

manufacturing and installation of Electrical, Instrumentation, Automation and Information
solutions & provides solutions, support & services throughout the Product/ Solution life
cycle. As turnkey solution provider we help customers write the future of industrial
digitalization and realize enterprise value

Digital Transformation isn't only about driving innovation across assets and operational
lifecycles. It's also about adapting how people work to improve profitability of production
operations, maximise return on capital investments and achieve the lowest total cost of
ownership. Digital technologies of today can be enabled to keep real time connect between
the customer and its consumer as also the vendor and the customer

With ABC as your Digital Transformation partner, you can take advantage of the speed, agility,
and efficiency of modern technologies such as cloud, IIoT, artificial intelligence and
augmented reality, through our services and expertise. When the enterprise wants to go
further by turning data insights into the direct action that "closes the loop" and generates
customer value in the physical world, ABC has the right solutions to offer. Our unified,
cross-industry digital offerings — extending offerings from standalone field devices to the
edge to cloud — with devices, systems, solutions & services enable our customers to know
more, do more, do better, together.

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 Our Vision, Mission & Core Values
ABC Process Automation is committed to enhance customer satisfaction
through on time completion of projects at competitive price and of best
in class quality. We are committed to provide cost-effective, cutting-edge
solutions to our end customers with quality engineering practices and
highly skilled professional approach and teamwork. We strive for continual
improvement in the effectiveness of quality management system.
Vision
ABC Process Automation envisages being partner of choice for Dairy, Food &
Beverage & Allied Industry for Electrical, Instrumentation, Automation and
Information Solutions by continuously enhancing the stakeholder’s value to
the extent that it becomes a ‘Delight’ & ensures sustainable & profitable
growth year over year.

Mission

Customer Driven:
Provide response to the customer with sense of urgency & speed.
Continuously look for ways to make it easier to do business with ABC Process.
Seek Feedback & Continuous improvement.

Innovation & Communication :

Core Value Communicate & be receptive to new ideas, innovation, better way of doing things
and compliance. Simple & clear in the communication.

People & Process Oriented Approach:

Invest time & money in developing quality infrastructure & processes for
sustainable growth. To consistently grow & nurture human capital.

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 The Dairy Industry
Backed up by deep in-depth processing knowledge and experience in Dairy Processes and
Product manufacturing ABC Automation has completed a large number of projects ranging
from minor upgrades and extensions to major greenfield and brownfield projects with
thousands of items.

The projects done by us cover complete turnkey dairy installations with centralized
automation including milk reception, processing, product manufacturing facilities for
market milk, ghee, fermented milk products like butter milk, Lassi, curd, Yogurts, cheese,
Paneer and indigenous sweetmeats. We have successfully done integration with third party
control systems and PLC’s presenting integrated one shop solution to our customers

ABC Automation masters all disciplines within the above activities including complex
control algorithms e.g. fats and protein standardization, whether based on in-line or batch
standardization principles.

ABC Process has developed a standard software library for controlling and monitoring
dairy processes. The library handles all elements of the automation supply order
horizontally and vertically. The library yields full traceability from the weighing-in/reception
of the raw materials to the delivery of the finished product to the warehouse, food safety
and improved productivity. Furthermore, data from the time the order is placed in the
ERP system until the activation of the individual functions in the production software are
handled with full traceability and reporting generated as process orders are completed.

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 Products, Solutions & Services
At ABC Process Automation, we pride ourselves on providing a variety of Product, Solutions
& Services to our clients to the highest standards and ensuring customer satisfaction from
concept to production.

ABC Automation is industrial automation specialist providing a comprehensive service in

Process Equipment Modules, Green field projects, upgrades and expansion and assists in
maintenance services .

ABC Process Solution specializes in Equipment Manufacturing, Process Engineering and

Project Execution in Dairy and Food Beverage Sector. We have an experience of having
executed turnkey automated Dairy, Food and Beverage Plant covering Milk Bulking,
Processing, Packaging, Product manufacturing Plants for Butter, Fermented Milk Products,
Cheeses and Paneer , Ice Cream and speciality Products like Chocolate, RUTF etc. Our
solutions include Utility generation and Distribution and also Effluent Treatment Plants
Our another associate Alfa Genesis transforms the Customer requirement into Process
and Equipment modules and make them best fit in the devised End to End solution
Together with Our Associates, ABC Process Solutions Limited and Alfa Genesis Limited,
we provide a complete End to End solutions to our customers covering Plant and Process
Design, Processing Equipment, Modules and Systems, Supporting facilities on Utility
Equipment and ETP with appropriated and customized automation

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 Food & Beverage Industry
ABC Process Automation has completed many projects in other segments of the food
industry such as Infant Food, Noodle Line, Vending Mix, Chocolate line, Beverages, Egron,
Extruder etc. Our projects have also included connection / automation in Utility generation
and distribution, effluent treatment plants as well

The projects are implemented in close collaboration with either OEMs supplying the
processing equipment or directly to the end user.
The company has also complied to and worked with Nestle Standards (NesTech Standards)
for Control Systems & SCADA for various applications

Fully automatic processing of recipes with barcode scanning of raw material admixtures
and automated adjustments is a naturally integrated part of solutions delivered by ABC
Process to customers.

Typically, ABC Process’s software library and standard solutions are applied to these
projects and fully integrated from ERP to factory floor control.

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 DCS/PLC/PAC Based Automation Solutions
By staying abreast of the latest advances in the automation industry we are able to bring to
your plant the best possible solutions. We approach every project with a strong emphasis
on a cost effectiveness balanced with a low cost of ownership.

We have experienced team of engineers conversant with different vendors programming

standards like Rockwell Automation, AVEVA, ABB, Siemens

iCAM engineers have domain expertise in industry verticals and are proficient in detailed
design, engineering & software development of DCS/PLC/PAC based automation Systems
and can undertake application development in ladder, SFC, Structure Text, Step, FBD etc.

PLC / DCS Code

The PLC code is the heart of the Industrial Automation project and there are typically a
number of steps.

Process Engineering Design.

Site Standards to which the code is written.
Designing and writing the PLC / DCS code.
Testing the code with the client's representative.
Testing the PLC's / DCS’s inputs and outputs.
On-site commissioning

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 Visualization & Historian Components
Touch Screens - Factory Floor
As part of the PLC / DCS installation there are usually a number of Touch Screens that are
linked via network directly to the PLCs. The Touch Screens are configured with many HMI
pages which allow operation of the plant directly from the factory floor.

SCADA HMI - Factory Floor

The control rooms will typically have a number of computers running state of the art
SCADA-HMI software. The SCADA software gives the operators a detailed view of the plant
via many HMI pages and allow changes and alarms to be easily dealt with.

Data Historian
The modern plant is required to keep production records. To do this a Data Historian is
installed on a Server which logs all of the essential data for the plant accessing the PLCs via
IO-Servers across the network.

Software Development
Software development has become an important component for many industrial plants,
providing managers and operators with meaningful information derived from the enormous
amounts of data now available. Proven modern Microsoft development tools are used to
create reliable easy to maintain applications which are deployed on to the automation
servers on site. The types of software applications range from public websites to background
programs, but all work with real time data in one way or another.

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 Support Services
Off site and On site Training modules on operation and Maintenance

Scheduled maintenance support services

These are scheduled call-out services provided on man-day basis .

Annual Maintenance Contracts (AMC)

These are annual customer support services agreements wherein preventive (scheduled)
maintenance and emergency call out services are bundled together.

Under this agreement scheduled maintenance site visits by ABC engineers are performed
to access & monitor the health of assets under agreement. Routine health and diagnostic
check-ups of application and product are performed to ascertain the health status and
prevent future failures . Any minor modifications required are performed and all application
backups taken and versioned . All reports and backups are handed over to customer.

In case of any breakdown / emergency immediate support is mobilised both remote and
on-site respectively as shall be required. All calls are attended to with 4 hours and site
mobilisation of required is done with 48 hrs.

Breakdown / Emergency maintenance support services

These are emergency call out services provided under AMC only on priority as per agreed
SLA. Any other breakdown services support is provided on availability basis . A typical
contract envisages scheduled quarterly visit and 2 emergency visits annually.

Remote / online support services

This support provides for cost effective and timely support option. This support is offered
under AMC as well A-la carte. Under this both scheduled as well as breakdown services
are offered . Under this agreement unlimited email and voice support is provided to
customer 24/7 – 365 days or 9/5 5days a week based on agreed SLA.

Parts Management services/ Spares Support

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 Application Modules
ABC Process Automation has developed a number of advanced Modules to support our
hi-tech automation solutions. These modules are based on Industry 4.0 and, together with
our competences, software standards, and expert knowledge, forms the digital toolbox
ensuring the best solutions for our customers.

MES (Manufacturing Execution System) Module

Analytics Module
E-Document Module
OEE (Overall Equipment Effectiveness) Module
AR (Augmented Reality) Module

MES Module
Production and Inventory Operations Management
Digitally managing the business rules and capturing information about the “Who, What,
When, Where, Why and How Much” in batch and hybrid production processes.
Manage and monitor work order execution,
Enforce products build to specification and document all manufacturing execution detail
and material flow in real time on the shop floor. Streamline order flow and production
execution.

Performance Management
Overall Equipment Effectiveness (OEE) KPI monitoring.
Categorise unplanned downtime vs. product changeover, idle time, or other planned events.
Dynamic performance target adjustments based on different products,
Real-time indication of schedule adherence and actual line performance.

Quality Operations Management

Execute quality sample plans with complete functionality for both automated and manual
data collection.
Alignment with work order execution events.
SPC visualisation for fast moving goods manufacturing.

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 Analytics Module
The ABC Process data analysis module is an analysis tool for optimizing production processes.
By analysing and focusing on production processes, companies can achieve great savings
on, time and resources.

Easy and fast access to data

Fast overview of data
Optimising tool – reduces waste and time
Highly flexible report service
Compared with golden batches to increase
efficiency and analyse data
Customisable points of interest
Document your processes

The application will create reports, providing an intuitive graphical dashboard with indication
of deviations, warnings, and critical alarms, all guiding the staff to trim and adjust the
processes in order to optimize on effectiveness, quality, and cost, and at the same time
minimising waste, advantageous to environment.

E-Document Module
The E-Document Module is a smart documentation
system, ensuring that all documentation concerning
the plant is stored electronically in a secure and
appropriate manner. Also, user access to
documentation has been made simple and intuitive.
The documentation is stored on a database server
and is accessed via a tablet by scanning QR codes in
the physical installation. Documentation such as
maintenance manuals, operating manuals, and instruction videos are uploaded and stored on
the server in a S88 database structure. The database is created and maintained by the user in
the configuration software which comes with the Document Module.
Documents are easily inserted in the database using drag-and-drop functionality.

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 OEE Module
The OEE Module (Overall Equipment Effectiveness) is a unique software tool for optimising
the efficiency of your plant, from a single unit/machine to an entire processing line or factory.

The OEE Module can be easily integrated on

top of existing units/lines and is a strong tool
or e.g. identifying: OEE values and displays
on dashboards Top ten reasons for stoppage
(focus areas) Here-and-now status on the
line/production order User-defined reports
per batch/shift/24-hour period User interface
enabled via a web-based HTML5 dashboard. Users can build customised
dashboards with the KPI data relevant to the individual user. Configurative OEE dashboard
Plant model structured according to the S88 model. Data analysis for plant optimisation
Integrated production planning

AR Module
The AR (Augmented Reality) Module is a powerful
supplement to the traditional information available
via SCADA stations in the control room
Augmented Advisor puts real-time information at
your fingertips, whenever and wherever it is needed.
The custom application improves operational
efficiency with augmented reality — enabling
operators to superimpose the current data and
virtual objects onto a cabinet, machine, or plant & giving production managers, laboratory
staff, and others immediate access to information on plant status, tank content, critical process
values, etc.

Holding a tablet or smartphone in front of the plant equipment, a virtual information layer
on the screen will give the user immediate access to selected key process data. As an
integrated part of the solution the system can be configured to include critical alarms and
measurements.
The equipment manufacturer can further equip access to spares, maintenance and trouble
shooting information through QR Code

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