Mondelez Ukraine Confectionery Factory. Automation and Power Supply of Production Areas

Description

“Mondelez Ukraine” is part of Mondelēz International — an American multinational food manufacturing corporation. According to the official website of “Mondelez Ukraine”, it is the largest confectionery company in the world.

Until 2014, the company was known as “Kraft Foods Ukraine.” Today, the plant in Trostianets manufactures the following products: “Korona” and “Milka” chocolate, “Barni,” “Picnic,” BelVita cookies, OREO, Tuc, and others.

What was done

1. Modernization of the 10 kV transformer substation. S-Engineering completed the technical upgrade of the 10 kV transformer substation of the factory’s main production building. A new modern Siemens 8DJH SF6-insulated switchgear with microprocessor-based protection and automation devices was installed. This 10 kV substation supplies power to all technological processes of the factory’s main production building.

2. Replacement of old transformers with modern Siemens units. Earlier, in 2020, S-Engineering specialists replaced outdated oil transformers with new Siemens AG Geafol dry-type transformers that meet Ecodesign requirements – ecological norms 209/125/EC of the European Economic Area. The total capacity of the six new transformers used in the substation is 6000 kVA. The substation supplies electricity to the main production building and the administrative building of “Mondelez Ukraine.” All project works were carried out at an operating facility without disconnecting consumers from the power supply.

3. Modernization of the recipe station. The recipe station is responsible for preparing chocolate masses used in production of chocolate products.

The project included:

• development of project documentation;
• full renewal of the recipe station by replacing all technological equipment;
• development and integration of a modern automation system with extension of the existing SCADA;
• complete replacement of liquid-ingredient pipelines (3 floors, 3 station lines);
• modernization of vacuum pipelines for dosing dry components;
• dismantling and construction works, including creation of new openings for tanks;
• installation of technological equipment and electrical works for the dry-component storage and dosing system;
• aligning existing cable routes with hygienic requirements;
• commissioning works and personnel training.

A special feature of this project: S-Engineering performed non-core work as well — design of building and technological parts, dismantling, welding, equipment installation. When designing liquid-ingredient pipelines, the team used 3D engineering, which ensured optimal layout in a limited space. All activities were synchronized with scheduled production shutdowns, enabling strict deadline compliance.

4. 10 kV protection settings configuration using NEPLAN

Works included:

• modeling the factory’s electrical network (Trostianets);
• short-circuit current calculations;
• selectivity analysis for protection devices (protection coordination);
• arc flash energy calculation.

Arc flash calculations were performed according to IEEE 1584, which has no equivalent in Ukrainian regulations. This allowed S-Engineering to meet the international occupational safety requirements of the client.

5. Modernization of OREO cookie production process control. The project included installation and commissioning of Siemens Sinamics frequency converters, ensuring precise, stable and fault-free recipe-based cookie production.

6. Integration of a 2 MW autonomous power station. S-Engineering connected an autonomous 2 MW internal combustion power station to the plant’s electrical system. Additionally, the company supplied OBERON SE equipment (manufactured under S-Engineering’s technology), performed commissioning and developed the required software. The team also modernized automation systems on several production lines — from ingredient transport to final baking.

7. EPC contractor for a 1.5 MW cogeneration plant. S-Engineering acted as EPC contractor for the construction and commissioning of a 1.5 MW cogeneration unit and a 10 kV switchgear with OBERON SE cells. The project will improve uninterrupted power supply for one of the production workshops and allow integration of a gas-powered cogeneration unit that generates heat and electricity.

Results

• The use of modern power-supply equipment brings the operational safety and reliability level of the factory to a completely new standard. The equipment and project solutions comply with the strictest Ukrainian and European safety regulations, while automation and relay-protection solutions guarantee a high level of accident-free operation of the transformer substation.
  A high level of control over equipment operating parameters and electricity consumption will allow the enterprise to improve its energy-resource monitoring system.
• The modernized control system of the recipe station performs dosing of dry and liquid ingredients according to the recipe, and also allows preparing chocolate masses with the required ratio of components. As a result of the modernization, the explosion safety, productivity of the recipe station, and consequently the quality of chocolate-mass preparation have increased.
• In the project for configuring the 10 kV protection settings, our specialists set the protection parameters in such a way as to minimize the arc-flash event and increase the safety of operating personnel when working with electrical installations. The smaller the arc flash, the lower the required class of personal protective equipment (PPE) for the service personnel.
  After commissioning and the final recalculation of the arc flash, marking labels with the calculated data were placed on all three-phase switchboards/panels of the enterprise. Based on these labels, which indicate the arc-flash energy, the service personnel must wear the appropriate PPE.
• The use of SF6-insulated switchgear significantly reduced the space occupied by the equipment at the substation, which opens up opportunities for further development of the enterprise.