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JBS Pump System

Optimizing the multistage pump system

Responsible for pumping water from the reservoir to the high-pressure hoses, the multi-stage pump system is fundamental to the sanitation process of the slaughter area at the Ana Reck unit.

Greater control over resource usage

The motors constantly pumped water from the reservoir to the operating environment under continuous pressure, resulting in water waste, rapid deterioration of the motors, and risk of incidents.

The solution to reduce water consumption and investment in motor maintenance was the installation of a control system using the compact XP Series controllers as the centerpiece.

Data Collection

Real-time monitoring of operational variables through smart sensors, providing up-to-the-minute data

Diagnostics

An advanced alert and diagnostic system offering full oversight of every stage of the process

Energy Efficiency

Significant reduction in the frequency of motor replacements and lower water and energy consumption

Flexible development

Nexto System technology enables the development of customized programs for special use cases

Optimizing the multistage pump system

The solution integrates an IoT-Ready XP325 PLC, a 10” P2 HMI, Altus frequency inverters, and sensors placed at key points throughout the process. These devices monitor and alert the team to motor status (on/off), water pressure, and reservoir levels.

With this system in place, the motors now activate only when the cleaning hoses are in use, drastically reducing water and electricity consumption.

This optimization has also extended the lifespan of the motors, reducing the replacement rate from one motor per month to one motor every six months. These improvements have significantly cut operational costs, positively affecting the unit’s overall financial performance.

Independence and security with Altus technology

To ensure the team could fully leverage the capabilities of the Altus PLCs and other equipment used in the modernization, we provided tailored technical training to the maintenance staff at the client's headquarters.

Carlos Henrique Azambuja, JBS automation technician and developer of the process logic, emphasized the readiness of the Altus technical team in assisting with adjustments and noted how the training programs were pivotal to the project’s success. "A lot of what I know today came from Altus' online certification training," he says.

Jairo de Quadros, the unit’s maintenance and project coordinator, highlights that the independence offered by Altus’ technology platform is one of its key advantages. "The autonomy I get from using Altus PLCs is incredibly reassuring. It gives me confidence in our daily operations. I truly believe in and trust your (Altus) products," Jairo stated.