In the eight years Todd Burkhart has worked as a maintenance technician on large food processing equipment at Sandridge Food Corp. in Medina, he’s seen a revolution. During that time, the machinery he’s worked on has transitioned from relay-based systems to computer-based programmed logic controllers.
So when Sandridge Food joined a consortium of food processing companies in partnership with The Ohio State University Agricultural Technical Institute in Wooster to offer cost-effective technical and industrial training, Burkhart jumped at the opportunity to learn how to use PLC systems.
Winner: The Ohio State University Agricultural Technical Institute
Project: Expansion of the Regional Food Processing Training Consortium
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“It’s where our industry is going,” says Burkhart of programmed logic controllers. “We pay through the teeth for programmers to make modifications on the different components. It would be a big advantage for us to change things in-house on the fly.”
At Sandridge, a refrigerated prepared food company, the machine that Burkhart uses to fill the 16-ounce container of macaroni and potato salads used to be controlled by 25 relays with wires running out to every switch. Now the same function is completed with a 6-inch programmed logic controller, making the machine more efficient and easy to clean.
Sandridge had nine of its 400 employees take the first-level PLC training course, including Burkhart, who has since moved on to a more advanced PLC course.
“I’ve learned the parts of a PLC and some of the options in programming,” he says. “This will take it to the next step.”
The OSU Agricultural Technical Institute developed the consortium about a year ago when a number of local food-processing companies in Wayne and Medina counties expressed that continuing education for their workforce was imperative in their changing industry. A significant percent of the skilled workforce is nearing retirement, says Kim Sayers, director of business training and educational services for OSU Agricultural Technical Institute.
“Many of these companies are in the midst of technology upgrades,” Sayers says. “There are new technologies being used in the manufacturing process.”
By pooling several companies together for training, they can save money versus specializing training for each individual company, she says.
It also addressed the need to have workers on the floor at all times. A member of the consortium can send just a few employees at a time so there is always a crew to man the machines. So far, Frito-Lay in Wooster, Gerber Poultry in Kidron, J.M. Smucker Co. and Smith Dairy in Orrville, and Sandridge Food Corp. in Medina are involved. The program is open to other food-processing companies outside the current coverage area as well, Sayers says.
To participate in the consortium, a member pays only for the training it uses, and there are no membership fees.
The consortium is partially funded by an $117,000 Ohio Skills Bank Workforce Innovation Solutions Grant received by the OSU Agricultural Technical Institute. It’s being used for startup costs and to offset the cost of training for the companies.
“We look at it as using it as our launching point,” Sayers says of the grant, which runs out in June.
Since the program’s inception, more than 250 employees have been trained in a variety of areas including applied mathematics, PLCs, on-the-job communication, welding, industrial motors and motor controls. Basic hydraulic training has also recently been added.
“Not many people have a lot of PLC experience,” says Jeff Kremer, maintenance manager at Sandridge Food. “We are becoming more of a PLC-driven environment. These classes make our employees more valuable.” — Sarah Filus