Rockwell Automation Empowers Tate & Lyle’s Sustainable Citrus Fiber Production in Brazil
Tate & Lyle recently inaugurated a state-of-the-art manufacturing facility in Matão, São Paulo, to produce NUTRAVA® Citrus Fiber. This innovative ingredient utilizes orange peels to meet the growing global demand for clean-label food products. To ensure peak operational efficiency, Tate & Lyle collaborated with Rockwell Automation to implement a comprehensive industrial automation framework. This partnership highlights a significant step in Tate & Lyle's expansion following its strategic acquisition of CP Kelco in late 2024.
Integrated Control Systems Drive Operational Precision
The Matão plant relies on a sophisticated DCS (Distributed Control System) approach to manage complex chemical dosing and raw material handling. Rockwell Automation provided a complete suite of hardware and software designed for seamless integration. Specifically, the installation includes high-performance PLC (Programmable Logic Controller) units and remote I/O modules. These components allow engineers to monitor critical production variables in real-time. As a result, the facility achieves the high level of precision necessary for specialty food ingredient manufacturing.
Power Distribution and MCC Infrastructure
Reliable power management remains the backbone of any factory automation project. Rockwell Automation’s Power Systems unit delivered essential medium- and low-voltage switchgear alongside CENTERLINE® 2500 Motor Control Centers (MCCs). These systems ensure stable energy distribution across the production line. Furthermore, the inclusion of dedicated transformers protects sensitive electronic equipment from power fluctuations. This robust electrical infrastructure minimizes unplanned downtime and extends the lifespan of the plant's mechanical assets.
Lifecycle Services and Virtualization for Industry 4.0
Beyond hardware, the project emphasizes digital transformation through advanced virtualization infrastructure. Rockwell’s Lifecycle Services team managed the Factory Acceptance Testing (FAT) and provided comprehensive operator training. This digital-first approach allows Tate & Lyle to run simulations and manage data more effectively. Moreover, the Industry 4.0-ready design facilitates future scalability. Consequently, the plant can easily transition from its initial 3,700-ton capacity to a projected 10,000 tons per year without overhauling the core control systems.
Expert Insight: The Value of Centralized Automation
In my view, this collaboration represents a benchmark for modern sustainable manufacturing. By converting citrus waste into high-value functional ingredients, Tate & Lyle addresses both environmental and commercial goals. However, the complexity of processing organic raw materials requires a highly responsive automation software environment. Rockwell’s ability to provide a "single pane of glass" view via a centralized control room is crucial. This integration reduces human error and optimizes energy consumption, which is vital for maintaining a "green" supply chain.
Future-Proofing Through Scalable Technology
The Matão facility serves as a blueprint for how industrial automation supports global sustainability targets. As food producers face stricter regulations regarding clean labels, the ability to scale production rapidly becomes a competitive advantage. The modular nature of Rockwell’s PLC and MCC solutions means Tate & Lyle can expand operations with minimal disruption. In addition, the partnership proves that investing in high-end automation early in a project’s lifecycle yields significant long-term ROI through reduced waste and improved resource management.
