In food and beverage manufacturing, extended production shutdowns are rarely an option. During the automation modernization of Valio’s R1 dairy plant in Riihimäki, a fast and successful switchover was achieved through careful planning, close collaboration and the use of a digital twin developed for process simulation.
Valio’s R1 facility in Riihimäki has been operating since 1968. Originally established as a yogurt production plant, the facility today receives milk from approximately 550 dairy farms and produces milk, cream and cultured buttermilk products. The site also hosts Valio’s Southern Finland distribution center.
In early autumn 2023, the plant completed a major dairy automation modernization project that had started in February 2022 and was delivered by Insta as a turnkey solution.
The existing Mitsubishi PLC-based automation system, which had reached the end of its lifecycle, was completely replaced and integrated into the plant’s Siemens Simatic PCS 7 process control environment. Distributed control cabinets, pneumatic valve systems and I/O connections were renewed, while process improvements expanded and optimized production capabilities. Optimized product changeovers help reduce the consumption of raw materials, energy and water while minimizing production losses and environmental impact.
According to Antti Laaksonen, Project Manager at Insta, commissioning was carried out by a team of approximately 20 specialists working in three shifts.
“We replaced the legacy PLCs with a new process control system, renewed the solenoid valve cabinets and their components, refurbished selected existing cabinets and delivered the new software platform. The project also included new control room displays and supervision of electrical installations.”
Automation plays a key role in safeguarding production reliability
Food manufacturers are expected to ensure reliable production and maintain operations even during exceptional circumstances. Automation plays a critical role in meeting these requirements.
“Because our facility cannot be shut down even for a single day, operational reliability is essential, and automation has a major impact on that. We also use automation to improve waste management and reduce losses,” explains Pekka Maalo, Technical Specialist at Valio.
According to Maalo, the objective was to replace as much of the old automation platform as possible while simplifying the overall system architecture.
“The previous system contained a considerable amount of unused code and legacy functionality accumulated over the years. The modernization gave us an opportunity to remove that burden. While much of the field equipment remains unchanged, moving this part of the operation onto a new platform represented a significant improvement.”
Fast switchover built on planning and collaboration
Manufacturing facilities are expected to achieve increasingly high utilization rates, leaving little room for lengthy production stoppages during modernization projects. System cutovers must therefore be completed as quickly as possible to avoid disruptions to production.Comprehensive planning and preparation formed the foundation of the project. Activities, responsibilities and schedules were defined in a detailed commissioning plan.
According to Laaksonen, the project was divided into several phases.
Preparation work included the installation of the automation system and mechanical preparations at the control cabinets before the actual switchover. During the shutdown period, the team completed cabinet replacements, cable connections and commissioning of fieldbus communications. This was followed by extensive testing of motors, process equipment and field devices, before final software testing and start-up.
Digital twin technology supports successful commissioning
Factory Acceptance Testing (FAT) utilized Siemens Simit simulation technology, enabling the creation of a digital model of the production environment and its processes.
The simulation environment allowed potential fault scenarios to be tested before commissioning and helped validate system behavior under different operating conditions.
Simulation models and digital twins are becoming increasingly common in industrial modernization projects. In addition to supporting faster commissioning, they can also be used for data analysis, operational decision-making and future investment planning.
Production interruption stayed below target
According to Laaksonen, the complete shutdown period for the project was estimated at just under three days, which is close to the practical maximum for a modernization project of this scale.
The project team ultimately exceeded expectations. Initial software systems were started significantly ahead of schedule, and the first pasteurizer was operational approximately eight hours earlier than planned. Milk receiving and product dispatch operations continued throughout the switchover without interruption.
“We were able to manage both incoming raw milk deliveries and outgoing shipments without interruption. Our warehouse and distribution organization prepared for potential delays, and while there were some minor delays during the following week, none of them affected customers. Together we successfully achieved our schedule targets,” says Maalo.
Haasteet ratkottiin sujuvalla yhteistyöllä
In addition to the R1 facility, Insta serves as an automation partner for Valio’s R2 snack production facility in Riihimäki as well as the company’s Joensuu production plant, supporting the ongoing digitalization of Valio’s manufacturing environment.
The R1 modernization project was based on a competitive tendering process conducted several years earlier, in which Insta was evaluated as the strongest overall supplier. As a certified Siemens Solution Partner, Insta combines extensive process industry expertise with advanced Siemens automation capabilities.
According to Pekka Maalo and Iiro Simola, Automation Technician at Valio, cooperation throughout the project was smooth and productive.Regular joint planning meetings and a shared commitment to solving challenges together played a key role in the project’s success.
“Some challenges arose from modifications that had been made to the old system over the years and were no longer fully documented,” Maalo notes.
“Insta is a highly capable supplier with extensive expertise. What is particularly important is that agreed actions are followed through. That reliability has been a major strength throughout the project,” conclude Maalo and Simola.
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Joonas Eirola
Profit Center Manager, Food & Chemistry Insta Automation firstname.lastname (at) insta.fi
