The development of Adelholzener Alpenquellen GmbH of Siegsdorf into one of the most modern mineral water companies began as early as 1929 with the construction of a bottling plant which was highly modern for its time. Nowadays, three bottling plants are used in the production of more than 35 different refreshment beverages. By continuously optimizing the production processes, it has been possible to cope with the increasing demand, which means filling up to 170 000 bottles every day. The increase in production capacity made it necessary to build a new storage and logistics center including an administration building. In addition to expanding the storage capacity, the plan was to create space for an improved forwarding logistical system at the same time. A forklift store for approx. 25 000 full goods pallets was set up on a site occupying 20 000 sq. meters. The entire building services control system and the conveyor systems were implemented in accordance with the company's philosophy, namely "A high-tech company conscious of its environment - We don't just talk about environmental protection - We are practicing it"

Decentralized substation
for the air-conditioning
and ventilation systems

Reduced Fire Load
The drastic reduction in the amount of cables containing PVC and the use of metal conduits and cable raceways has reduced the installed fire load by more than 50%. In absolute terms, this signifies a reduction from 70 000 kWh to approx. 35 000 kWh, without increasing the costs. Ever since the fire at Düsseldorf Airport, the topic of "low-fire load electrical installations" has become increasingly important. Thanks to the use of INTERBUS, only power cables and just a single bus cable have been laid instead of thick bundles of PVC-insulated cables.

In the subsequent transshipment area, brightness meters measure the intensity of the illumination and set the lighting to a defined nominal value in accordance with the available daylight. The additional costs this involves will be paid off in about two years thanks to a saving of approx. 300 000 kWh per annum. The loading of trucks in the transshipment area is monitored by video cameras. Only when loading is complete is the roller gate opened to allow the truck to leave the hall. This optimum control system of the roller gates makes it possible to regulate the air-conditioning and ventilation system in an efficient manner.
Information from the light sensors, from thermometers for the air-conditioning and humidity sensors for the ventilation is also recorded by INTERBUS in a decentralized arrangement. For this purpose, decentralized substations with ST components have been installed in the individual bays. A new, imposing administration building has been built onto the storage hall. Three PLCs in this building ensure that lighting and climate conditions are maintained at optimum levels in the northern and southern sections of the storage hall as well as the administration building.

Safe Transport
Two PLCs are used for the conveyor system from the production section into the new storage area. The full goods pallets arriving from the palletting system are transported to the forklift unloading stations using three chain conveyors in this process. The interface to INTERBUS is provided by an IBS S5 DCB/I-T module in this arrangement. The approximately 600 digital and analog inputs and outputs of the elements of the conveyor system are wired up on decentralized smart INTERBUS-ST stations. Rapid and reliable transportation of the full goods pallets is guaranteed at all times thanks to the incorporation of an INTERBUS-capable operating terminal. Barcode scanners have been integrated into the system in order to record the products and ensure they are transported to the correct location.

Excellent (Working) Climate
In addition to the I/O information relating to the lighting and roller gate control functions, both of the controllers for the storage hall also receive signals from the air conditioning and ventilation systems. All data required for a good climate, the correct level of atmospheric humidity and the right temperature are transferred to the master stations via INTERBUS. The third PLC controls the processes in the administration building. In the building, all I/O data lines, whether from the light switches in the offices, the anemometers or the light sensors for controlling the shutters, are connected in the individual storey distribution boards using ST components as well.

Three PLCs - Simply Connected
Status information concerning lighting and climate conditions is exchanged between the controllers in the entire building complex. This "networking" of the controllers was also achieved at a favorable cost using INTERBUS in this application.

Summary
Georg Heim, responsible for electrical engineering at Adelholzener Alpenquellen GmbH, summarizes the advantages of using INTERBUS in all the areas discussed above as follows: "We decided to use INTERBUS because of its high degree of flexibility and because the system is open to most suppliers of automation systems and field devices. Subsequent installation costs in case of changes are largely a thing of the past and there are interfaces available to higher-level systems. Once again, the bus system in our storage hall installation has produced significant cost savings."

Dipl.-Ing. Stefan Lorenz