“Automation is a key contributor to product consistency and increased efficiencies”

on March 15, 2017

ESE’s Director of Engineering, Kevin Nowack, was recently quoted in a Beverage Industry article. The article focuses on data collection and how to best keep operators “in the know.”

Data collection proves valuable in processing automation

High-pressure processing gains traction in beverage market

NBC’s public service announcements within the series title “The More You Know” have been informing TV viewers on a wide range of topics since its inception in 1989. As beverage-makers increasingly utilize alternative ingredients and high-pressure processing (HPP) technology, “the more they know” can help improve productivity and ultimately their bottom line.

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eseinc“Automation is a key contributor to product consistency and increased efficiencies”

John Tertin featured in “Food Engineering”

on March 10, 2017

ESE’s Director of MIS, John Tertin, was recently quoted in a Food Engineering article. The article discussed how the right tools can cut waste, curb giveaways, improve efficiency, decrease downtime and maximize product.

Advanced controls yield major process improvements

You think your dairy processing plant is efficient, but when you do the math, you can’t account for 7 million pounds of lost milk per year. That’s a loss of more than $1 million. In addition, your POTW is billing you more than $80,000 annually for exceeding the maximum permitted levels of fats, oils and greases (FOG) in your wastewater. What’s going on? Seems like money down the drain, doesn’t it?

Unfortunately, stories like this are not uncommon, especially when you don’t know what’s going on in your process. And, as Murphy’s Law’s first corollary states, “Left to themselves, things tend to go from bad to worse.” Most likely, without intervention, this dairy facility would have seen even worse numbers as time went on. Fortunately, this story has a happy ending. Vigilistics, Inc. (now part of SafetyChain Software) production management software was employed to get a handle on what was happening to the “spilt milk.”

The advanced controls software includes real-time data collection from the plant floor. To get started, engineers segmented the plant into key performance areas. Then, key performance metrics were established using the data collection engine for each key step. Up and running, the system revealed a measurable shrink, and the dairy was able to reduce the shrink from 2.5 percent to less than 1 percent the first year, translating to an annualized savings of $600,000. The dairy was able to stop the FOG from going to the POTW and realized an additional $80,000 savings the first year.

The Vigilistics system includes real-time variance reporting and collaboration, which highlight variations from the key performance metrics. Operators are alerted to problems before they expand to become significant issues. In addition, milk receiving and cream load out procedures were adjusted, and operators were retrained as needed to understand procedures. Production planning adjustments were made to avoid unnecessary product changeovers and minimize recycle time on the pasteurizer—the time to change from product to water and water to product was reduced to an acceptable level. Filler loss and overfills were reduced, and the production of unsalable product was reduced. Waste stream FOG levels were monitored and managed.

Advanced process control and suitable applications
While you might think of advanced process control (APC) as sophisticated model predictive control (MPC) systems, neural networks or advanced regulatory control (ARC), even data historians coupled with SPC (statistical process control) may actually be more “advanced” than what some processors are using.

“A production historian is a must-have for processors to improve process efficiency,” says John Tertin, director of manufacturing information systems, ESE Inc., a member of the Control System Integrators Association (CSIA). “While food processors are starting to adopt this technology, the number of major processors that haven’t yet is astounding.”

Read the full article here.

Don’t forget to check out the Sidebar section on “APC and ERP” at the bottom of the article.

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eseincJohn Tertin featured in “Food Engineering”

ESE becomes a SolarWinds Authorized Partner

on February 16, 2017

ESE recently became an official SolarWinds Authorized Partner. SolarWinds is a company that offers a suite of products that continuously monitors Ethernet Networks and data centers. It can monitor for network outages, bottlenecks, issues with individual network nodes (a PLC, drive, or PC). It can even monitor server resources like memory, processor utilization, and hard drive space.

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ESE included in Control Engineering article

on December 21, 2016

ESE and three other CSIA members commented on “How to Select a System Integrator” a Control Engineering article. The original article can be found here and the full text is below.

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Mordell Joins ESE as Project Manager

on December 12, 2016

MARSHFIELD, Wis. – ESE, Inc., a control system integration company that designs and develops plant automation systems for the food and beverage industry, recently hired Jim Mordell as a Project Manager.

Mordell has over 26 years of engineering experience in mechanical engineering analysis and design, technical management, project management and automation. He’s served in a variety of industries including: power generation, aircraft controls, turbo machinery OEM and aftermarket, packaging, food, paper and industrial automation. Mordell is a past Chapter President of the American Society of Mechanical Engineers (ASME).

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eseincMordell Joins ESE as Project Manager

ESE gains accreditation as a VMWare Professional Solution Partner

on November 29, 2016

VMW_09Q4_LGO_PARTNER_SOLUTION_PROVIDER_PROESE recently gained accreditation as a VMWare Professional Solution Partner. VMWare is a company that provides cloud computing and virtualization software and services. ESE has leveraged VMware technology for several years to provide robust, highly available systems using features within both Rockwell Automation and VMWare software

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eseincESE gains accreditation as a VMWare Professional Solution Partner

Director of Engineering, Kevin Nowack, quoted in Food Engineering article

on October 19, 2016

ESE’s Director of Engineering was recently quoted in Food Engineering. The article was titled, “Why investing in food safety helps everyone” and was in the October issue. Kevin’s quote is below and a link to the full article can be found here.

“We have experienced customers’ need for greater flexibility in the creation of cleaning programs so they can tailor the programs to effectively clean individual circuits,” says Kevin Nowack, director of engineering at ESE, Inc., a Control System Integrators Association member. “Plants are looking for greater visibility of the wash cycles completed and the circuits cleaned daily.”

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eseincDirector of Engineering, Kevin Nowack, quoted in Food Engineering article

Moeller Joins ESE as Inside Sales/Application Specialist

on September 27, 2016

MARSHFIELD, Wis. – ESE, Inc., a control system integration company providing design and development of plant automation systems for the food and beverage industry, recently hired Craig Moeller as an Inside Sales/Application Specialist.craig_moeller_website

Moeller’s eight years of experience as an electrical engineer and two years in business development, makes him well-suited for ESE customers. This experience ensures that he is able to serve customers and understands the industry.

ESE President and CEO Michael Richart stated, “Craig’s skills and experience in multiple areas of our business will help us as we develop turn-key solutions tailored to our clients, whether they have needs in process automation, information solutions, or product analyzers.”

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eseincMoeller Joins ESE as Inside Sales/Application Specialist

ESE celebrates 30th anniversary

on September 1, 2016

ESE is happy to have been serving clients for the past 30 years. What started out as a half-time venture in a garage has progressed into a full-fledged company that serves hundreds of clients in process automation, product analyzers and information solutions. Below is a brief history of our company.ese_employees

1981: The company was founded by Mark Weber under the name Electrical Systems as a small, part-time venture.

1986: Mark Weber turned Electrical Systems into a full-time business

The business started by making electrical panels for control systems. It soon grew and added a sales person and engineer to provide automation controls.

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eseincESE celebrates 30th anniversary

Pruden joins ESE: ESE, Inc., expands customer service to west coast

on August 11, 2016

MARSHFIELD, Wis. – ESE, Inc., a control system integration company providing design and development of plant automation systems for the food and beverage industry, has named Joanna Pruden as a Senior Account Executive.ESE_HeadShots_17_BW

By adding the Utah-based Pruden to its team, ESE takes another step in serving customers across the United States. She has more than 10 years of experience working in the process industry, working with leading food manufacturers to optimize plant operations. Additionally, Pruden has worked with leading manufacturers to design custom solutions for instrumentation and automation. Her material handling and instrumentation expertise will further strengthen ESE’s total plant solution capabilities.

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eseincPruden joins ESE: ESE, Inc., expands customer service to west coast