We create plant simulations for batching processes to test all recipes and phases before implementing the system. This approach reduces commissioning time and mitigates potential troubleshooting delays. The simulation replicates the behaviour of all plant devices, such as valves, motors, digital or analogue sensors, and processes like transfers, additions, heating, and cooling. With this simulation, users can test the system's operation, induce unexpected situations, and observe the system's responses.
Yes, the batching and automation methods are widely applicable to the preparation of other liquid materials. The same approaches can be adapted to the manufacturing of liquid emulsions, suspensions, gels, and slurries, used in several industries, mostly chemical, pharmaceutical, and plastics. Such products include inks, like those used in additive manufacturing of fuel cells, paints and coatings, machine lubricants, ceramics and polymers for casting or moulding, and gel medication. Each product has a different process and a distinct set of steps, but automation knowledge of dosing, mixing, milling, and measuring is necessary in creating the production process of all of them.
The ISA-88 (IEC 61512) batching standard is a globally recognized framework for batch process control. This standard, also known as S88, provides a consistent model for designing, operating, and managing batch processes. It helps ensure repeatability, scalability, and quality across various applications.
Using the ISA-88 standard, we can break down the washcoat preparation process into smaller, manageable steps or "phases." Each phase represents a specific action or set of actions needed to complete a part of the process, such as filling a tank, mixing, heating, or dosing. By structuring the process this way, we can precisely control and monitor each stage, ensuring that the final product meets exact specifications.
Yes, we perform both on-site and remote commissioning, depending on the needs of the project. Since we use an in-depth plant simulation during the testing phase, commissioning times are appropriately shorter, taking from one to eight weeks based on the process and client needs. To reduce administrative and travel overhead, as well as our environmental footprint, parts of the commissioning can be done remotely. Even with most of our automation technology team connected remotely, some technicians and electricians are still needed on site.
Yes, our system is designed to be highly versatile and can integrate seamlessly with a wide variety of controllers and control equipment. We understand that each plant has unique requirements and existing setups, so we do not mandate specific equipment. Instead, we tailor our solutions to work with the customer's existing infrastructure and preferred vendors.
We are experienced and certified in working with leading equipment from Rockwell Automation (Allen-Bradley, FactoryTalk View, FactoryTalk Batch, PlantPAx), Siemens (SIMATIC, WinCC, PCS7), and AVEVA (Batch Management, System Platform, InTouch HMI). We develop for and integrate solutions using this equipment, as well as offer vertical and horizontal integration with other systems, such as warehouse and recipe solutions, if that is beneficial for the solution outcomes.
