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Automation for Beverage Can Plants

TDL has worked on the control systems of beverage can lines at Crown's Dong Nai and Da Nang plants since 2017: the cupper and body makers at the front end, the conveyors and line control between them, end-of-line packaging and the compressed air supply. The projects below are grouped by line stage.

By line stage

• Cupper

  The cupper on can line 1 at Dong Nai upgraded from PLC-5 to ControlLogix 5570 with a PanelView Plus 7 HMI, PowerFlex 755 and PowerFlex 525 drives, a resolver-based cam module and a Guardmaster safety relay.

  Project references

  • 2023Crown Dong Nai – Cupper Line 1 PLC-5 to ControlLogix Upgrade

• Body makers

  Body maker control moved from PLC-5 to CompactLogix at Dong Nai, and from DeviceNet to ControlLogix 5580 on EtherNet/IP at Da Nang, installed and started up inside the line 1 shutdown.

  Project references

  • 2026Crown Da Nang – Body Maker Control Upgrade to ControlLogix 5580
  • 2017Crown Dong Nai – Body Maker PLC-5 to CompactLogix Upgrade

• Front end conveyors and line control

  Front end swap of Can Line 3 and Can Line 4: motor power and sensor wiring moved between the two line control systems, a panel extension, PowerFlex 525 drives for the cup conveyors and Ethernet links from six body makers, with the PLC programs of both lines changed and tested.

  Project references

  • 2026Crown Dong Nai – Can Line 3 and Can Line 4 Front End Swap

• End of line

  A new strapper integrated with the existing packaging conveyor: I/O configuration, integration programming, commissioning and operator training.

  Project references

  • 2024Crown Dong Nai – New Strapper Machine Integration

• Compressed air

  A control cabinet with two 90 kW variable-frequency drives for two air compressor motors at Da Nang, with PLC and HMI monitoring in the plant control system.

  Project references

  • 2025Crown Da Nang – VFD Control Cabinet for Two Compressors

Related services

• PLC & Control System Migration

  Allen-Bradley PLC-5, SLC 500 and MicroLogix, GE Fanuc, Siemens S5 and HIMA systems upgraded to ControlLogix and CompactLogix; ControlNet and DeviceNet to EtherNet/IP; older HMI/SCADA (RSView32, Citect, PanelView) to FactoryTalk View and PanelView Plus 7. Drive upgrades: DC drives to PowerFlex DC, legacy servo drives to Kinetix. Site survey, code conversion, FAT/SAT and planned cut-over, onshore and on offshore platforms.

• Control Panel Engineering

  Control and marshalling panels: design, schematics, fabrication, wiring and factory acceptance testing before shipment. Ex-rated enclosures for hazardous areas.

• Breakdown Support & Lifecycle Services

  Line down? TDL troubleshoots on site or remotely, fixes programs and supplies replacement Allen-Bradley parts to get production running again. Also commissioning, preventive maintenance, PLC backup and version control (FactoryTalk AssetCentre), vibration monitoring and training on Rockwell Automation and AVEVA software.

Project references

• 2026 – Crown Da Nang – Body Maker Control Upgrade to ControlLogix 5580ControlLogix 5580 · DeviceNet to EtherNet/IP · PowerFlex 755 / 525 · PanelView Plus 7
• 2026 – Crown Dong Nai – Can Line 3 and Can Line 4 Front End SwapCan Line 3 ↔ Can Line 4 front end swap · motors and sensors re-routed · PowerFlex 525 · PLC changes on both lines
• 2025 – Crown Da Nang – VFD Control Cabinet for Two CompressorsTwo 90 kW VFDs · control cabinet design · PLC and HMI · integration with plant control
• 2024 – Crown Dong Nai – New Strapper Machine IntegrationNew strapper integrated with the existing conveyor · commissioning and training
• 2023 – Crown Dong Nai – Cupper Line 1 PLC-5 to ControlLogix UpgradePLC-5 → ControlLogix · PanelView Plus 7 · PowerFlex 755
• 2017 – Crown Dong Nai – Body Maker PLC-5 to CompactLogix UpgradePLC-5 → CompactLogix · PanelView · AC drives · central SCADA interface