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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