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
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The line ran on a discontinued PLC family with no spares path and an outdated safety concept.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 CONDITIONA twenty-year-old line with fragmented documentation, a mix of hardwired safety and legacy controls, and no current electrical drawings.
CUSTOMER PROVIDED
- Access to the line for survey during planned stops
- Remaining original documentation and modification history
- Production calendar with agreed shutdown windows
- List of known faults and operator workarounds
GANI OWNED
- On-site survey and re-documentation of the existing installation in EPLAN
- Migration concept split into reversible weekend packages
- New PLC and safety architecture with pre-built and pre-tested panels
- Stepwise changeover with rollback plan per window
- Commissioning, operator briefing and updated documentation
OUTCOME
What the program delivers.
- Migration completed inside the planned shutdown windows
- Line handed back to production after each window without carry-over work
- Current EPLAN documentation established as the new baseline
- Follow-on support agreement for the migrated installation
