Intelligent Factory Transformation Project of a Food and Beverage Leading Enterprise - IPC-5120, IPC-7120 and FPM-1150
User Background
In the current fiercely competitive manufacturing industry, stable and efficient production processes have become the core competitiveness for enterprises to seize market heights. A leading enterprise in the food and beverage industry takes technology-driven as its strategic core and improves the automation level of production lines through intelligent transformation to solve the efficiency bottleneck and quality fluctuation problems in the traditional production mode. Relying on the technical accumulation in the field of industrial computers, KTB provides high-performance industrial computers such as IPC-5120, IPC-7120 and FPM-1150 for its workshop production lines to help realize production transformation.
Challenges Faced
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Environmental Compatibility Requirements: The food processing workshop has high humidity (85% RH), corrosion of acid-base cleaning solutions and pollution of flour/sugar dust. Traditional industrial computers show interface corrosion failures on average within 6 months.
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Production Continuity Pressure: The shutdown of the beverage filling line for 1 hour leads to a production capacity loss of 200,000 bottles. The industrial computer is required to support 7×24-hour fault-free operation, and the MTBF (Mean Time Between Failures) needs to reach more than 50,000 hours.
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Quality Traceability Needs: 3 million products need to realize full-link recording of production data every day, but the manual entry error rate is 8%, which cannot meet the requirements of the food safety management system.
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Multi-device Collaboration Dilemma: More than 20 types of equipment such as filling, labeling and packing come from different manufacturers, and the inconsistent protocols lead to a data intercommunication delay of more than 15 seconds.
Application Overview
KTB deploys products using a three-layer architecture of "edge control + central management + human-machine interaction".
KTB IPC-7120 Central Management Host
Installed in the workshop control room, it is equipped with an Intel Core processor, builds an industrial Ethernet through 8 Gigabit Ethernet ports, and uniformly manages all workshop equipment; it has a built-in MES system interface to automatically generate production reports, replacing manual entry.
KTB IPC-5120 Edge Control Unit
Deployed in key equipment such as filling lines and sterilization kettles, it is made of 1.0mm SGCC material with environmental protection and fingerprint resistance to withstand cleaning solution spraying; it connects sensors through 4 isolated RS485 channels to collect process parameters such as temperature and pressure in real time, with a data upload delay of <10ms.
FPM-1150 Human-Machine Interface
As a high-performance industrial monitor, FPM-1150 displays solid support for precise control of production lines. Equipped with a 15-inch high-resolution display, it features clear visualization and vivid colors, enabling operators to monitor production data and equipment status in real time. Rigorously tested, FPM-1150 demonstrates excellent stability and reliability, enabling long-term stable operation, effectively reducing failure rates, and enhancing production efficiency.
IPC - 5120 & IPC - 7120 & FPM - 1150
KTB Industrial Computers
Application Achievements
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Production Efficiency Breakthrough: The filling line speed is increased, and the daily production capacity of a single production line is enhanced; the model change and debugging time is shortened, saving man-hours.
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Quality Control Upgrade: The sterilization temperature control accuracy and product qualification rate are improved; 100% electronicization of full-link data traceability is achieved.
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Reliability Enhancement: The IPC-5120 operates continuously for 24 months without failure in high-humidity environments, reducing maintenance costs; the system fault warning detects potential issues in advance, minimizing unplanned shutdowns.
Cost Optimization: The manpower requirement for a single workshop is reduced, lowering annual labor costs; the energy consumption management module decreases the unit energy consumption of the production line.
Convenient Operation
Efficient & Stable
Data Collaboration
Fault Alert
24/7 Operation
Related Configurations
Ktb IPC-5120
- Desktop/wall-mounted chassis, front I/O interface layout, supporting quick maintenance; simplified airflow channel with special CPU fan, controlling the CPU temperature within 75℃ under high load operation.
- Anti-vibration drive bracket supports 1×5.25" device (such as optical drive) + 2×3.5" hard disks (SATA III interface), and optional RAID 1 data redundancy configuration.
- The front end supports 4 half-length PCI/PCIe expansion cards (such as motion control cards, data acquisition cards), adapting to the diversified functional requirements of production lines.
- Power/HDD status LED indicators display the operation status in real time, and the fault location time is shortened to within 30 seconds.
Ktb IPC-7120
- Desktop/wall-mounted design, adapting to Micro ATX/ATX motherboards, supporting the integration of larger size motherboards and more interfaces.
- Anti-vibration disk bracket supports 1×5.25" drive (external) + 2×3.5" hard disks (1 external and 1 internal), and can install mechanical hard disks and SSD hybrid storage.
- The front end supports 4-7 half-length card expansions (3 more expansion slots than IPC-5120), suitable for central control scenarios requiring high-density interfaces.
- The same LED indicator design as IPC-5120, with the added motherboard temperature warning function (threshold can be customized).
Industrial Display FPM-1150
- 15-inch TFT-LCD display, resolution 1024×768, brightness 300cd/m², supporting clear display in strong light environment of the workshop.
- Five-wire resistive touch screen (supporting glove operation) + external USB keyboard and mouse interface, compatible with different operation habits.