Industrial Oven Control Systems for a Can Manufacturing OEM
Sector:
Packaging, OEM & Special Purpose Machinery
Type:
New Build - Control System, Software
Platform:
Allen Bradley
Certification:
CE / UKCA
Summary
DelaControl designed and built two fully integrated control systems for an OEM specialising in can manufacturing line equipment — one for a Pin Oven and one for an Internal Bake Oven. Each system was built, software-loaded, and factory acceptance tested at DelaControl's Bristol facility before delivery.
Challenge
A specialist OEM required control systems for two distinct industrial oven machines destined for a can manufacturing production line: a Pin Oven and an Internal Bake Oven (IBO). Both machines demanded a consistent, proven control architecture with variable-speed drive control across multiple fan and conveyor duties, an integrated safety system, and a full documentation package including a SISTEMA (ISO 13849-1) performance level assessment.
The customer required complete control panels including PLC, HMI, and all motor control equipment, along with junction boxes, emergency stop stations, local isolators, and position encoders. A thorough factory acceptance test (FAT) was needed prior to delivery to minimise on-site commissioning risk.
Solution
DelaControl designed and built a control panel for each oven, both based on the Allen Bradley GuardLogix 1756-L81ES safety PLC and a PanelView Plus 7 1000 HMI. The Pin Oven panel featured a drive suite covering zone recirculation fans (two at 37 kW via PowerFlex 753), exhaust and cooling fans, a pin stripper conveyor, a vacuum fan, and an air knife fan — spanning PowerFlex 525 and 755 drives across the range. The Internal Bake Oven panel was configured for three recirculation zones, two exhaust duties, cooler supply and exhaust, a belt conveyor, and nozzle jacks, all via PowerFlex 525 drives.
For each system, DelaControl produced a full electrical design pack in AutoCAD (schematics, general arrangement drawings, and cable schedules), along with a SISTEMA report to document the achieved ISO 13849-1 Performance Level rating of the safety functions. A Declaration of Conformity was issued to the Low Voltage Directive and EMC Directive, in accordance with BS EN 60204-1, BS EN 61439-1, and BS EN 61439-2. PLC and HMI software was adapted from proven donor code used on previous comparable oven projects, then loaded and commissioned within the panel prior to dispatch.
Prior to delivery, each panel underwent a structured factory acceptance test programme including I/O simulation using purpose-built test boxes, drive testing with connected motors, and a full functional run-through of the control system. The customer was invited to witness the FAT in person or via video conference.
Key Facts
• Two control systems delivered: one Pin Oven and one Internal Bake Oven (IBO)
• Allen Bradley GuardLogix 1756-L81ES safety PLC and PanelView Plus 7 1000 HMI on each panel
• Pin Oven drives: two 37 kW PowerFlex 753, plus PowerFlex 525 and 755 units covering exhaust, cooling, vacuum, and air knife duties
• IBO drives: up to 11 kW PowerFlex 525 units across three recirculation zones, two exhaust duties, cooler, belt conveyor, and nozzle jacks
• SISTEMA report (ISO 13849-1) produced for each system
• Full factory acceptance test including I/O simulation and drive testing carried out at DelaControl's Bristol facility
• Full electrical drawing pack produced in AutoCAD; delivered in DWG and PDF formats
• Declaration of Conformity issued to LVD and EMC Directive for each panel