Case Study 3

PRJ21-0114 - Dammarie Aluminium Waste Treatment



What were we asked to do?

We were asked to developer new software for the Aluminium Waste Treatment, this was a new part of plant aimed to combat waste. The purpose of this plant was to recover trapped metal to re-melt and recover the salts used in the process. This would mean the waste product becomes a useful feedstock for other industries and – crucially – leaving zero waste for landfill.
The plant where the site is used contains salt slag that was contaminating a local water course. The salt slag is now taken from the ground, where it is fed into the pre-treatment plant.

What did we use?


  • Studio5000 on a Rockwell CompactLogix L30ER.
  • FactoryTalk Machine Edition on a PanelView Plus 7 (x3).
  • 10 x Remote LCP's communicating via Ethernet.
  • Ewon COSY131.
  • Ethernet Comms to existing Micrologix 1400.

Although the process covered a number of areas, and required several Rockwell PanelView Plus units, each of the process tasks were relatively isolated, meaning the CompactLogix was more than capable of undertaking the task.

The LV panel was supplied and installed by others.
All electrical and mechanical commissioning were carried out by others.

How did it go?

As with any JV project, the software underwent Internal Factory Acceptance Test (IFAT) and Quality Factory Acceptance Test (QFAT) prior to inviting the customer to witness the system.

Unfortunately this is when Ryan caught Covid-19 and had to isolate. Eager to maintain momentum on the project and not miss thea arranged CFAT date, Ryan persevered and carried out the CFAT albeit remotely. With the PLC setup on the bench, Ryan shared his screen over Microsoft Teams and walked the customer through every stage of the process, resulting in a brilliant 9/10 feedback on his form, the only comment being the lack of JV lunch due to covid-19.

We will get you that kebab next time Gareth!


The commissioning was carried out at Dammarie, in France, just over 500 miles from the JV Office. Ryan spent about 4 weeks in France supporting the project to completion.

With his time on site, our engineer found some changes were required compared to the initial design and worked hand in hand with the engineers on site and our customer, to translate their requirements into software.

Even after the 4 weeks on site, small modifications were required but this possibility was forseen, given that the process was new. Therefore we utilised a Ewon Cosy for remote access, when powered on site JV Controls were able to dial into the site and monitor the PLC and/or make modifications to the software as required by the customer, this was massively beneficial as new changes were required on site.

Who from JV was involved?

Team Image

Ryan Humphreys

Control Systems Engineer

Who did we work with?

A special thanks to:
Gareth Bedford.