How Axtel Industries created a fully automated ingredient management system by leveraging ControlLogix® processor and PlantPAx® system.

Axtel Industries has more than 30 years of experience in offering customised solutions for the food processing industry. The company’s design, engineering and manufacturing capabilities are focused towards delivering solutions that maximise profitability, ensure sustainability and improve reliability. Axtel is a specialist in engineering process systems for the food industry. The company is recognised for its expertise in Turnkey Systems, Product Development and Customer Service. Axtel’s advanced manufacturing facility, located on Vadodara – Halol highway, Gujarat, India, is suitably equipped to build robust and aesthetically designed machines.

Challenge: Need for higher level of accuracy, efficiency and safety in production

The field of process automation is constantly evolving, and as an original equipment manufacturer (OEM), it was crucial for Axtel to stay up to date with the latest technologies. To enhance productivity in a more efficient, safer, and sustainable way, the processes and technologies in their chocolate molding lines had to be updated constantly.

The traditional process automation technology used by Axtel had limited capabilities, where different stock-keeping units (SKUs) were required – from a single chocolate molding line, including solid bars, shells with inclusions, one-shot molding and ribbons. The complex chocolate molding processes, which involve fillings and book molding for multiple SKUs on a single molding line, require high levels of accuracy, precision, and efficiency.

In spice processing, Axtel had a need for enhanced reporting capability as the evolving market dynamics demanded better compliance, operational efficiency, quality control, and safety.

Solution: Develop fully automated chocolate molding line and spice processors

Axtel turned to Rockwell Automation to make their chocolate molding lines fully automated. This collaboration aimed to meet market demand and product innovation; boost productivity, accuracy, efficiency; and to deliver greater safety and sustainable growth for the company.

Starting in 2009, Axtel used Rockwell Automation’s Kinetix® 6500 multi-axis servos drive to develop a fully automated chocolate molding line, entirely in-house. This helped Axtel with increasing precision and accuracy of the processing line.

For operational excellence, in 2024, Axtel leveraged Rockwell Automation’s Integrated Architecture® consisting GuardLink® 2.0 and Kinetix® 5700 servo drives system to enhance safety and efficiency of its molding line.

In 2019, Axtel created a fully automated ingredient management system by leveraging ControlLogix® processor and PlantPAx® system to enhance efficiency and precision in spice blending solutions.

Result: Becoming a global leader in chocolate molding

The innovative solution built using Kinetix® 5700 servo drives and Category 3 safety solutions from Rockwell Automation has made Axtel's chocolate molding lines a leading choice in the global market.

In spice processing, managing multiple ingredients, including small and micro, while ensuring data integrity has significantly supported the manufacturing process for spice processors. This automation has improved precision and efficiency, leading to enhanced quality and consistency in the final product.

Overall, in its manufacturing solutions, Axtel has reached the PLd Safety Performance Level. This accomplishment has made Axtel-manufactured machines and process plants safer and more sustainable.

The innovation in automation has further led to improvements in their troubleshooting and maintenance processes, enhancing the aesthetics of the production line using a common controller, and simplifying the wiring. Additionally, it enables remote troubleshooting through EIP connectivity.