Overview customer success stories

Ait revolutionizes the automation of floretting processes

Ait solutions for the food industry

Ait enables their clients to transform their food manufacturing processes, significantly by increasing performance and minimizing production costs

Thanks to our collaboration with Eaton in developing and commissioning machines for the agri-food sector (Silex, Polux, Matrix and Mixta), we have helped our clients to transform their food manufacturing processes, significantly increasing performance and minimizing production costs

Ricardo Comín, Director of R&D at Ait

Background

Founded in 1997, Ait manufactures machinery and offers solutions for the food industry Based in Tudela (Ribera Navarra)—a region highly specialized in agriculture and the related industry—Ait is centered around preserves, frozen products and fresh-cut fruit and vegetables. Ait focuses on providing solutions for the food industry by offering machinery designed to process post-harvest agricultural products using its own technology and a highly experienced research and development (R&D) area.

The firm's client base includes companies that process food for large supermarkets, as well as those within the agricultural sector itself, including Green Giant, Bonduelle and Congelados de Navarra. Both sectors demand low prices and high performance when it comes to manufacturing processes. Until recently the machinery the company had been producing was too small to meet the sector's production needs, and it lacked modules that are now essential for efficient, remote management.

Ait therefore turned to Eaton in 2008 for help with expanding the technology of its leading broccoli-cutting and floretting machinery, due to Eaton's experience in the machine-automation sector and its state-of-the-art equipment adapted to the IIoT (industrial internet of things). The aim is to use this technology so that production can be automated, processed and adapted as required at any time.

Challenge

Due to the nature of Ait clients' activities, achieving high-speed production processes and outstanding product quality is crucial. Therefore, the company's main objective was to automate the broccoli-cutting process—otherwise known as floretting—to reduce labor costs and increase production, enabling its clients to achieve maximum profitability.

The company also needed a solution that offered connectivity—allowing different components to communicate with each other and data to be obtained remotely—and that was equipped with a simple, intuitive interface.

Finally, AIT needed a versatile and adaptable solution that could also be used for processing other products, such as cauliflower and cabbage.

The patented system makes the SILEX broccoli floretting machine the only one of its kind to create an automatically customized cut for each head of broccoli.

Solution

Eaton and Ait have collaborated to develop the Silex machine, which is available in two different models. The most powerful model—theSilex 2 line—is a high-speed Mixta machine that operates two lines simultaneously, allowing cutting to be individually programmed for each line. This machine is fully type-tested for use with food, and its components can be washed and sanitized. Both Silex models can be managed via a touch screen and are able to separate the stalk from the florets by depositing them in different places.

Silex machines are equipped with Eaton's most advanced technology. Firstly, they feature the SmartWire-DT intelligent wiring system, which allows you to replace point-to-point control circuit wiring with a single cable, integrating power supply and communication in a faster, easier way with virtually no risk of error. In addition, SmartWire-DT provides a high volume of system information without having to add additional devices, providing real-time data about power, connection and errors that can be used for predictive diagnostics

AIT-BROCOLI-COLIFLOR._Z7X7146 doble_XV300.jpg

The MIXTA floretting and decoring machine by AIT retains the intelligent cutting of single-product versions. This exclusive system eliminates the need for preliminary sorting by size and increases yields and efficiency in the cutting process.

Eaton's technology is also utilized within the Silex machine's cutting-edge control panel featuring the XV152 touch panel, which, in combination with SmartWire-DT, enables the implementation of control, visualization and data management tasks with state-of-the-art networking options. The control panel also benefits from the XV300 touch panel, based on the operator interface of a smartphone or tablet, which makes it easy to use thanks to its capacitive touch technology and ensures high system performance. Furthermore, the XN300 I/O system offers great flexibility, since the ultra-compact system allows for tailor-made system solutions to be created. The rapid backplane communications in the CANopen system environment also enable response times of less than 1 ms.

The I/O system also saves space inside the control cabinet. The XN300 design allows up to 20 channels to be integrated using push-in technology and provides a status display, despite the front panel only measuring 12.5 x 102 mm. To help plan the XV300 device, Eaton offers Galileo version 10, an intuitive visualization software that supports a wide range of communication protocols, ensuring its compatibility with most commercially available controllers.

The PLC (programmable logic controller) programming is based on CODESYS and international standard IEC 61131.Eaton offers version 2 or 3 of XSoft CODESYS, allowing clients to protect their existing software solutions and develop new designs in line with the latest standards.

In terms of variable frequency drives, the Silex machine is equipped with Eaton's PowerXL DA1, a device specially designed for demanding applications that depend on speed and torque. The integrated function block editor also means that the variable frequency drive can be adjusted for each client, ensuring maximum flexibility. The machine also features the PowerXL DC1, which is noted for its compact size and user-friendly interface and the PowerXL DE1. Both are specially designed for use in standard applications such as fans, pumps and conveyors.

Finally, the machine is equipped with Eaton's RMQ Titan modular pilot devices, which stand out thanks to their ergonomic design, flexibility, versatility and, above all, robustness — with IP67 and IP69K degrees of protection.

Results

Developing and commissioning the Silex machine has enabled Ait's clients to transform their food manufacturing processes, significantly increasing performance and minimizing production costs, reaching 200 units per minute, while also reducing labor costs.

Furthermore, this machine has undeniably contributed to the international expansion of the company. Ait is now able to operate in Europe—where it already had a strong presence—as well as in the US and Canada (America); Australia and New Zealand (Oceania); China, Turkey and Uzbekistan (Asia); among others.

"Thanks to our collaboration with Eaton in developing and commissioning machines for the agri-food sector (Silex, Polux, Matrix and Mixta), we have helped our clients to transform their food manufacturing processes, significantly increasing performance and minimizing production costs," says Ricardo Comín, Director of R&D at Ait.

"Our collaboration with AIT through Sumelec—one of our key partners in the area—demonstrates how technology and innovation can help to optimize processes in all kinds of sectors and achieve excellent business results," explains José Ignacio Ruiz, Sales Manager of the machine-manufacturing sector at Eaton.

Ait continues to depend on Eaton's technology to develop a constantly evolving machine, adapting it to the growing needs of the company and its clients.