Control systems + automation
Efficiency and traceability in feed production As South Africa’s poultry industry continues to evolve in response to rising demand, cost pressures, and stringent quality requirements, producers are increasingly turning to advanced automation systems to optimise operations. At Sovereign Foods, one of the country’s leading poultry suppliers, a large-scale automation project has delivered significant gains in eiciency, traceability, and operational control. W orking in partnership with proudly South African industrial so£ware leader Adroit Technologies, Sovereign implemented the Mitsubishi Adroit Process Suite (MAPS) across a key feed production facility, easy to see where faults are, and operators can quickly understand what is happening in the plant.” This usability extends beyond operations into maintenance and troubleshooting. “It is not just about running the plant, it is also about maintaining it,” adds Hewitt. “The system makes fault-finding and troubleshooting very straightforward, which reduces downtime and helps us keep the plant running eiciently.”
creating a scalable, integrated system capable of supporting current operations and future expansion. Dominik Zabiegaj, MAPS Project Engineer, says, “The system is fully integrated, from materials and recipes through to batching and reporting. Everything is built into the platform, which means no separate systems or add-ons are needed.” Integrated SCADA and PLC layers “From a project perspective, one of the biggest advantages of the MAPS suite is the reduction in engineering time,” says Bradley Campbell, National Sales Manager. “Because the SCADA and PLC layers are integrated, the engineering eort is, in eect, halved, complexity is reduced, and the quality of the system is improved. That translates directly into cost savings for the customer, along with the benefit of strong local support.” Starting in 2019, the project was implemented in phases, allowing Sovereign to align the system rollout with broader operational goals and capital planning. By the time Senior Production Manager Neil Hewitt joined the business in late 2020, the system had been installed but was not yet fully operational. “I came on board to manage the mechanical and electrical aspects of the project,” Hewitt explains. “I was involved in the commissioning phase and understanding how the system interacts with the plant. From there, it was about refining the system to ensure it works optimally from an operator and maintenance perspective.” Reduced engineering complexity The integrated SCADA and PLC functionality on the MAPS platform in a single environment significantly reduces
Processing live operational data One of the most powerful aspects of the MAPS system is its ability to capture and process live operational data. This provides Sovereign with deeper insight into performance, energy usage, and production eiciency. “The system allows us to gather a significant amount of live data that we can use to continually improve our processes,” says Hewitt. “We can extract it into reports, track eiciencies, and monitor electricity usage. We have only scratched the surface of what is possible.” This data-driven approach enables more informed decision-making and supports continuous improvement across the operation. Traceability supports quality control In a highly regulated industry like animal feed production, traceability is critical. The MAPS system provides full visibility across the production process, from raw material intake to final product delivery. “Traceability is one of the most important aspects for us,” Hewitt adds. “We can track materials from the point they enter the plant, through batching and processing, to the final product delivered to farms.” This level of detail supports quality control and risk management. “If there ever is an issue, we can trace exactly what was used, where it came from and where it went, within minutes. A further benefit is that if something is out of specification, the system will stop the process immediately. That allows us to address issues in real time, rather than a£er the fact.” Operational consistency Technically, the MAPS platform delivers a high degree of integration and standardisation, simplifying initial deployment and future modifications. This standardisation also benefits long-term maintenance and scalability. “By standardising on MAPS, any contractor can come into the plant and quickly understand the system,” Zabiegaj highlights. “It makes fault- finding easier and ensures consistency across the operation.” Additionally, the system architecture enables expansion without significant re-engineering. “It is based on a client-server model, so if the plant grows, the user can simply upgrade licences and add more I/Os or PLCs. There is no need to redesign the system,” says Zabiegaj. Sovereign designed the system with future expansion in mind, ensuring additional capacity and functionality could be added with minimal disruption. “We took a phased approach and built in the capability for expansion from the start,” says Hewitt. “That means we can add new equipment and functionality without major changes to the infrastructure.” This flexibility has already been demonstrated, with additional plant capacity introduced in 2023. “It is
Bradley Campbell, Adroit Technologies.
Neil Hewitt, Sovereign Foods.
engineering complexity. It also meets a further key requirement for Sovereign – ensuring that the system is intuitive and accessible for operators at all levels. According to Hewitt,
this has been one of the standout successes of the project. “For the end- user, the system is far more user-friendly than others I have worked with,” he says. “The graphics are clear, it is
Integrated automation enhances visibility and control across poultry operations.
6 Electricity + Control JUNE 2026
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