In 2021 Maple Leaf Foods began construction of the largest, most technically advanced poultry processing
plant in the world. This $772 million – 660,000 square foot facility in London, Ontario was designed to
process 400,000 chickens per day. The engineers, OEMs, contractors and integrators came together to
seamlessly integrate 4,000 pieces of equipment on various control platforms with secure IT and OT
networks.

The client’s vision; “Our investment in industry-leading food safety, environmental and animal care
technologies will allow us to efficiently deliver a premium mix of value-add poultry products to meet
steadily growing consumer demand, while also strengthening Canada’s food system and advancing our
vision to be the most sustainable protein company on earth”

RidgeTech Automation was entrusted by their long-time client to architect, manage and implement the
control systems and integration philosophy that aligned with the client’s vision. Understanding the sheer
scale and complexity of the project, both the client and RidgeTech knew that a Rockwell Automation
solution was the answer to integrating such a vast number of process equipment components. RidgeTech
Automation, Rockwell Automation and the client worked with vendors to adopt a common controls
architecture using ControlLogix 5580, Compact Logix 5380 alongside PowerFlex VFD’s and Point IO with
safety and FactoryTalk View SE. 175 Rockwell PLCs and over 1500 VFDs were implemented while
maintaining a Pld safety performance level. Encompass partner hardware was utilized where specialized
and proprietary equipment didn’t allow for the standardized platform.

Once the build phase was complete, it was all-hands-on-deck for the commissioning phase throughout
2022. It was exciting to see progress as the automation equipment came online. Constant attention was
focused on safety, scheduling and forecasting throughput. One area of focus was the grading and
packaging area. This area of the plant uses complex equipment to process, sort and distribute the various
cuts of poultry and then sends them through a tiered network of highway conveyors. Accuracy of handling
the various cuts and getting them to the desired destination was an immense task considering the high
demand of output while minimizing any wasted product.

At RidgeTech, we decided to simulate this part of the process to understand all of the parameters effecting
the deliverable. There was a huge benefit in having PLC and HMI code written along with OEM CAD and
product data. We had all of the resources we needed to create a digital twin environment. We leveraged
Rockwell’s immense portfolio and started planning our solution with Emulate 3D. Emulate 3D has
fantastic tools that allow for interoperability with PLCs, HMIs, robots and other third-party equipment. In
our case, we had several PLCs and HMIs that control the area due to the IO count and complexity. Having
a global overview of the entire layout also allowed for intricate control of product SKUs and traffic flow. In
some circumstances, we could forecast trouble areas where jam-ups might occur and identify lanes that
were underutilized. The system came together in a digital world without the added cost of part trials,
mock-ups and product waste. On one hand, the simulation proved the intent of the automated process
but there was a need to get to the next step and investigate continuous improvement and feasibility of
added value to the existing process. Machine learning technology was applied to the simulation with the
intent of enhancing product flow and reducing operating costs. A vast array of data samples were
collected and the value-add enhancements were implemented into the systems digital twin to ensure
accuracy was greater than 99%. The continuous improvement study took place while production was
running which made this a seamless experience for the end-user.

This is a true testament to new technology and real-life experience benefiting each other to improve
process. We are honored to be able to support and strengthen the “most sustainable protein company on
earth”.