Batching Facility Control System

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Industry: Food & Beverage
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Location: Melbourne
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Department: Automation
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Services Provided: Control System Design, MCC & Panel Construction, Industrial Networking, PLC Programming, SCADA, Process Control, Databases, Reporting

BRE Services delivered one of its most extensive automation-led projects to date—a full batching plant control system upgrade for a major Victorian dairy facility. The project encompassed the design and manufacture of a new MCC and a comprehensive control system to manage all aspects of the batching process.

The system covered tanker unloading, storage silos for milk, cream, and sugar, product transfer lines and valve paths, batch tanks, recipe controls, homogeniser and pasteuriser integration, CIP sequences, and product transfer to existing filling lines. It also included cleanliness status monitoring and interlocking for enhanced safety and hygiene.

BRE’s scope spanned the entire lifecycle: from initial design and hardware procurement to panel construction, site installation, programming, and commissioning. The solution featured a 1500 I/O count control system, seven remote I/O cabinets, VSD and DOL motor control, functional safety systems, and PID control for flow and heating profiles.

Built to ISA-88 standards, the PLC control system was paired with a custom Ignition SCADA interface, including a recipe database and editor, batch and CIP reporting, and production analytics. The result is a robust, scalable platform that enhances operational efficiency and product consistency.

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Result That Power Real Progress

Our client’s don’t just talk about great service – they experience it every day.

BRE Services developed and implemented a safety control system for one of our dangerous animal enclosures. Their innovative approach integrated seamlessly with our existing procedures, adding an additional layer of protection for our staff and visitors. Their engineering expertise gave us confidence in a critical area, and their post-project support has been exceptional.

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Stuart Cross

Zoos Victoria

Krones Pacific has enjoyed a strong, mutually beneficial, working relationship with BRE over the past 15 years.

This strong working relationship coupled with BRE’s ability to understand and deliver on expectations has led to the successful completion of many Krones projects throughout Australia.
BRE’s quality of workmanship, professionalism and reliability have positioned them as a key partner for Krones Pacific.

Krones Pacific looks forward to continuing to work with BRE on many more successful projects in the future.

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Richard Gahagan

Krones Pacific

I’ve been consistently impressed with the service provided by BRE Services from Boral. Their response times across all our sites are incredibly fast, ensuring minimal downtime. The team is always proactive and efficient, and the follow-up work is top notch ensuring everything is running smoothly long after the initial service. BRE’s dedication to quality and reliability has made them an invaluable partner for us. Highly recommended!

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Daniel Durham

Boral

BRE has been a trusted partner of Vanderlande over 5 years delivering quality electrical installation services on various logistics automation projects. The BRE team at all levels of the business uphold high level of professionalism, quality standards and effectiveness in managing the best outcome for their clients. Their relationship-based approach towards clients is a critical factor of the successful partnership between Vanderlande and BRE.

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Daniel Benjamin

Vanderlande

I have worked with BRE for nigh on 16 years as a contract service provider, emergency break downs when we needed immediate assistance and small & large capital projects. The scope of work has covered contract electrical/control service, electrical and power design, layouts, MES and Batch Control systems, and many areas of compliance for new and old facilities. BRE have always responded quickly providing the right assistance. Of course, all of this work has been provided at the right commercial price. In the past 16 years the industry has changed. More and more automation, the emergence of the digital footprint and recently the use of AI. BRE have always invested in the future and can be relied on to have a product, advice or service to meet your needs.

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John Buckley

Pact Group

BRE has proven themselves to be an exceptional partner, particularly when it comes to delivering under pressure. When our project deliverables shifted the BRE team were there to support.

BRE has consistently demonstrated exceptional value as an automation partner, particularly through their comprehensive knowledge of a broad range of PLC systems and industrial networking.

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Mark Nield

Erilyan

BRE Services has been supporting Alto Mulgrave and Moorabbin sites, and I have always found they are always available—no matter if it’s a minor issue or a complex factory challenge. Their reliability and advanced expertise in handling intricate electrical systems have kept our production running smoothly. I trust them implicitly and highly recommend their services.

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Gavin Krygger

Pact Manufacturing

BRE played a key role in the successful delivery of the new Pact-operated state-of-the-art Circular Plastics Australia recycling facility in Laverton North, VIC. Their attention to detail in the electrical installation of the two production lines showcased their experience and commitment to quality.

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Elcio Lizak

Pact Group

BRE Services has been crucial to KNAPP’s success as a Value Chain Tech Partner in Australia.

Their expert electricians and dedicated management team have consistently delivered outstanding results.

The transparency and mutual respect in our collaboration make this partnership truly exceptional.

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Laurenz Pinter

KNAPP Australia

Throughout my career as a maintenance and engineering specialist, BRE have been my key support agent for all electrical, safety and automation solutions.

Whether it is a short-term shift cover role, large scale automation project, a safety improvement assignment or optimising a process with software implementation they have always delivered on expectations.

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James Murphy

Freedom Foods

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