Project Summaries and Case Studies

Every project has a unique set of challenges and objectives, including scope, budget, time frame, regulatory requirements and more. MAVERICK addresses each concern in developing custom solutions that meet each customer’s needs.

Publishing Projects

• Major Newspaper Integrates Packaging Facility
  To integrate a newly built 117,000-square-foot Sunday edition packaging facility, a major Midwestern newspaper publisher* sought a complete software control solution. The solution required a seamless interface with warehouse management, palletizing, collator control and polywrapping systems.
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• Major Newspaper Rolls Out Integrated Inserter Control Systems
  A large southeastern newspaper’s* OEM-supplied control systems were not capable of integrating with downstream equipment and Pre-Print Planning System (PPS). Additionally, the restrictions of the control systems kept the client from generating the production statistics required for accountability to advertisers.
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• Major Newspaper Modernizes Press Roll Handling Systems
  The client required a more integrated and data-driven solution. The desired specifications included a system with control over all equipment — from the laydown area to reel stands - in order to target specific paper types and manufacturers to specific reel stands.
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• Material Handling SCADA System for Newspaper with Seven Inserters, Four Collators
  As part of a conversion from a proprietary control system, MAVERICK handled the data acquisition and control for seven inserters, four collators and the associated downstream equipment. The project required installation and integration of 10 PLC 5/80 systems and 102 PLC 5/04 systems using Ethernet and DH+, an Oracle data interface, serial interfaces, C++ interface programs and an individual Wonderware HMI operator interface for all 11 machines.
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• Material Handling SCADA System for Newspaper with Three Collators
  For this greenfield facility, MAVERICK handled the data acquisition and control for three collators and the associated downstream equipment. The project required installation and integration of three SoftLogix PLC systems, three ControlLogix systems and 60 PLC 5/04 systems using Ethernet, ControlNet, MS SQL, serial interfaces and a Wonderware HMI, which communicates directly with the SoftLogix PLC via standard OPC drivers.
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• Material Handling SCADA System for Newspaper with Three Collators
  For this greenfield facility, MAVERICK handled the data acquisition and control for three collators and the associated downstream equipment. The project required installation and integration of one SoftLogix PLC, one ControlLogix system and 20 PLC 5/04 systems using Ethernet, ControlNet, MS SQL, serial interfaces and a Wonderware HMI, which communicates directly with the SoftLogix PLC via standard OPC drivers.
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• Material Handling SCADA Retrofit for Newspaper with 10 Inserters
  To enable a conversion from a proprietary control system, MAVERICK handled the data acquisition and control for 10 inserters and the associated downstream equipment. The project required installation and integration of 10 Allen-Bradley ControlLogix 5550 PLC systems using Ethernet and DH+, MS SQL data interface, serial interfaces and a VB HMI.
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• Material Handling SCADA Retrofit for Newspaper with Four Inserters
  To enable a conversion from a proprietary control system, MAVERICK handled the data acquisition and control for four inserters and the associated downstream equipment. The project required the installation and integration of three Allen-Bradley SoftLogix PLCs and three ControlLogix PLCs using Ethernet, DeviceNet, ControlNet, MS SQL, serial interfaces and a VB HMI.
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