GANI ENGINEERING — WORK PACKAGE

PLC and safety migration for a bottling line

Controls and safety migration of a running bottling line for a regional beverage producer, executed inside planned shutdown windows.

PROGRAM PROFILE

Delivery geography: Türkiye
Variants in scope: 2 filler lines
Program duration: 6 months, executed in two shutdowns
Responsibility level: Work package
Standards applied: IEC 60204-1 · IEC 61131-3 · EN ISO 13849-1

WHAT IT DOES

What the delivered system actually does.

A bottling line that has run for fifteen years usually still works. What has stopped working is the supply chain behind its controls: the PLC generation is out of production, the safety concept predates the current standards, and a single failed module can idle the line for a week while a used part is found.

This programme replaced the controls and the safety system on a running line. The machines, the conveyors and the process stayed; the PLC, the safety architecture and the operator interface were renewed, and the line came back producing the same product to the same recipe.

It was done inside planned shutdown windows, in sections, with a defined way back at each step. That is the whole point of the job: a beverage producer cannot stop selling while its line is modernised, so the migration has to fit into the weekends the plant already schedules.

THE CHALLENGE

The line ran on a discontinued PLC family with no spares path and an outdated safety concept. The producer could not accept extended downtime: filling continued in season, so every step had to fit weekend shutdowns with a guaranteed way back.

STARTING CONDITION

A twenty-year-old line with fragmented documentation, a mix of hardwired safety and legacy controls, and no current electrical drawings.

CUSTOMER PROVIDED