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CCSL Automates Production and Increases Capacity for RS Assemblies with SmartWire DT
Location:
Oxfordshire, UK
The Challenge:
RS Assemblies was experiencing rising demand for their high fibre horse feeds and needed to rapidly scale up production. Any solution would need to be installed over a single weekend to minimize disruption to their operations. Additionally, as an animal feed provider, RS Assemblies needed certification that required integrating third party software to control the moisture content.
A conventional control system would require over 8km of cabling and take far too long to install and commission. RS Assemblies required a rapid yet robust automation solution.
“We have used Eaton before for various upgrades, but this was a significant milestone for our business, and it was vital to get it right. SmartWire DT is easy to install and commission, and this system enabled us to meet a very tight deadline without any problems. It also gives us great feedback for easier fault-finding to help minimize downtime.”
Rodney Hughes, Managing Director, RSAssemblies
The CCSL Solution:
Drawing on our extensive experience with SmartWire DT, CCSL proposed a decentralized control architecture using 9 local control panels, reducing cabling to just 3.5km. Offsite testing enabled us to fully configure the system and reduce commissioning to just 9 hours after installation.
Integrating 232 outputs, 536 inputs and 40 load cells, we utilized SmartWire DT I/O modules as well as safety relays and electronic motor starters. Seamless integration with the existing variable frequency drives and third party control software completed the automation picture.
Rapid Deployment and 4X Production Increase:
Working closely with RS Assemblies team and contractors, CCSL executed the project over one weekend as planned. The system commissioned smoothly and the plant reopened on schedule the following week without issues.
Production increased from 8 to 35 tonnes per shift, a 4X improvement. Our customer also cited easier expansion, diagnostics and fault finding with SmartWire DT as key benefits over conventional control.
At CCSL, we leverage Eaton’s latest technologies like SmartWire DT to deliver automation solutions that help manufacturers optimize processes, reduce downtime, and maximize productivity. Our expertise in project execution enables rapid benefit realization on aggressive timelines.
