When it comes to high quality chocolate, Our client is up there with the

best. Our client is a household name and is known for producing beautiful,
mouth-watering creations.
During the summer of 2009 a master chocolatier awarded Datastor Systems
Limited a contract to upgrade the centre boil manufacturing control sys-
tems. This project included enhanced software functionality and manage-
ment reporting together with upgrading the existing obsolete hardware.
Case Study
Facts
at a glance

Customer Profile
Our client is one of the best
loved and oldest names on
the high street. For almost a
century they have been pro-
ducing a delicious range of
chocolates that are almost
impossible to resist.

The Project Scope
The existing control system
was originally installed by
Datastor in 1992. Through-
out this time it has effective-
ly controlled the process for
producing the liquid cen-
tre's for a delicious range of
chocolates. During 2009
the decision was made to
upgrade the system to take
advantage of a range of
new functionality and en-
hancements.

The Solution
The key functionality pro-
vided by Datastor Systems
included;
Recipe control
Mixing and boiling
Clean in Process (CIP)
Data capture and analysis
Stock control
Error alerts
Process visualisation
Traceability
Label printing

The Benefits
The upgrade was completed
in March 2010 and
Thorntons are delighted
with the end result. The
system now gives our client
even greater control of their
operations and the benefit
of improved flexibility and
information management
reporting.
Centre Boil Control System
Upgrade
P A G E 2
WE ADD VALUE
TO OUR
CUSTOMERS
BUSINESS BY
INNOVATION
The Production Process
Project Overview
Strict Time Scales
Datastors PC Batch Control
Software was originally in-
stalled in 1992 to control
the batch production of the
chocolate centres. The sys-
tem also comprised of an
Intel Modbus based system
utilising Pamux I/O that was
nearing the end of its life
and needed replacing. This
also applied to their opera-
tor PCs which were replaced
with Rockwells Panel View
Plus Terminals. They also
wanted to extend the exist-
ing software functionality
and this could only realisti-
cally be achieved by up-
grading both the software
and hardware.



Datastors PC Batch Control
system provides automated
control of the centres pro-
duction process up to the
filling operation. This in-
cludes; recipe management,
hand weigh of ingredients,
product labelling
(traceability), mixing and
boil operations. The whole
process can be seen and
monitored by the operators
via Tilcon graphics. The sys-
tem alerts operators to error
conditions and also controls
the CIP process.. Real-time
data is captured and pro-
vides instant production
analysis.


A crucial requirement was to
keep production downtime
to a minimum. This was
achieved by careful detailed
planning utilising a weekend
shutdown to maximum ef-
fect. In all, it took Datastors
engineers 4 days to com-
plete the upgrade process
which included pre-upgrade
testing and simulation.


Example Tilcon graphics that
greatly improved process vis-
ualisation for the operators .
The whole process can now
be monitored with ease.




P A G E 3
Centre Boil Graphics
Refiner Graphics
Phone: 01260 277025
E-mail: sales@datastorsystems.com
Website: www.datastorsystems.com
74 Manchester Road
Congleton
Cheshire
CW12 2HT
Datastor Systems is a leading supplier of process control
and information management solutions for industry,
which are configured to satisfy individual customers re-
quirements.
Established in 1978 and based in Congleton, Cheshire
Datastor has delivered over 300 systems to customers in
20 countries throughout the world and provides the level
of service and support which competitive businesses
need as they are challenged by regulatory, legal, health
& safety and commercial changes.
Our Clients Include;
Carlsberg
Barry Callebaut
AB Agri
Thorntons
& Many More
Datastor Systems Limited
We Have The Missing Piece
INTEGRATED CONTROL SOLUTIONS
Our expertise covers the following applications;

Helping and advising clients to specify and design plant & process control
requirements
Bespoke batch control and automation systems including integration with
existing business systems (ERP).
PLC / SCADA based systems including panel build, upgrades, programming and
support.
Environmental monitoring solutions e.g. temperature, energy etc. We supply
solutions designed to continuously monitor the pulsed outputs from energy
meters which will typically be electricity meters gas, steam, water, compressed
air and other meters if desired.
Cost effective technical support packages for existing incumbent control systems
Data collection and associated reporting and analysis.
Vision systems for product inspection and verification
Plant performance monitoring e.g. Overall Equipment Effectiveness ( OEE).
Tank / silo monitoring of levels in bulk storage
Labelling systems
Weighing solutions
In- Line Moisture Monitoring and Control
Bar code systems
Motion Control and Robotics
Sales@datastorsystems.com
www.datastorsystems.com
Tel-01260 277025