Chemical Production Processes

Automated software and hardware solutions for the synthesis of resin, nanomaterials, preparation and addition of reactants, neutralization, pH regulation, peptization, pigmentation, crystallization, and production of PVA glue.

Wide spectrum of
solutions for any material

Flexibility is our greatest asset, allowing us to handle a diverse range of projects from small, custom-made systems to large-scale distributed control systems (DCS) with the same amount of adaptability. We specialize in the ISA-88 (IEC 61512) standard, ensuring our solutions are reliable and industry-compliant with improvements we developed for it over the years. This allows us to meet various customer needs with precision and efficiency. This adaptability ensures we can deliver optimal solutions for any scale or complexity of the project.

Reliability and safety
in any environment

Our solutions perform reliably in challenging environments, from harsh industrial settings to explosion-prone zones. We carefully evaluate process requirements to develop solutions that meet stringent safety and operational standards. By ensuring compliance with standards and optimizing for robustness, we guarantee both our automation systems and the materials can withstand the conditions they were created for. This ensures the chemicals produced maintain their efficacy and reliability across diverse conditions, providing consistent results in various applications.

End-to-end solutions
with broad support

Our solutions, tailored to each process, encompass process analyses, requirement focused solution design, and the development of sophisticated machinery, automation and intelligence systems, including laboratory equipment, AGVs, code scanners, label printers, smart devices, and more. We offer vertically and horizontally integrated end-to-end systems which work seamlessly with hardware and software from industry leading suppliers. This breadth allows us to also integrate existing equipment from the customer’s preferred vendors.

Automating a wide range
of processes

Our process automation solutions are designed to cater to a wide variety of chemical processes, ensuring precision, consistency, and efficiency throughout production. Using PLC and Batch system control, we automate essential steps such as dosing, mixing, temperature control, and transfer. For processes like resin synthesis, nanomaterial production, reactant preparation, and pH regulation, our systems maintain the desired quality and consistency by closely tracking and adjusting parameters.

Through integrated MES, Batch and SCADA/HMI systems, we provide operators with real-time monitoring and control capabilities. This includes overseeing tank states, agitator speeds, and valve statuses, allowing for quick identification and resolution of issues. Operators can easily transition between sites thanks to our unified interface across facilities.

Precision in material management and quality assurance is critical, particularly in complex chemical processes. Our dosing algorithms minimize material wastage and ensure precise traceability, adhering to the ISA-88 batching standard. Safety interlocks and isolation protocols are in place to prevent interference and ensure safe operation, allowing batch issues to be resolved without affecting overall production.

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End-to-end project management
and control

Our solutions are tailor-made for the batch processing of chemicals, specific to every customer and every recipe. We handle every aspect of the automation from start to finish, ensuring precise control and integration throughout the entire process. We begin with a complete FEED study and continue by preparing IO schedules, electrical drawings, functional design specifications (FDS), and developing PLC code, MES, batch management applications, and SCADA systems.

While we develop the system, we take great care of the product we’re working with, so that as little of the expensive materials are wasted testing. To that end, we prepare a digital simulation of the entire plant where we can perform all testing and operator training before any material is spent in production. After commissioning and testing, we offer a robust support system with engineers as our first line of support to provide expert guidance and rapid problem resolution.

Specialized Chemical Production Automation

Synthesis of
Resin

We optimize polymerization processes for resin synthesis, including epoxy, polyester, and phenolic resins. By controlling temperature, pressure, and reaction time, we ensure consistent polymer formation. Our systems can also manage the addition of curing agents and hardeners where applicable. Real-time monitoring and feedback loops adjust parameters to maintain product quality and efficiency.

Synthesis of Nanomaterials

Our expertise in nanomaterial synthesis involves maintaining stringent control over reaction environments to produce uniform nanoparticles. We utilize techniques like chemical vapor deposition (CVD), sol-gel processing, and precipitation. Advanced analytical tools are integrated to monitor particle size and distribution, ensuring precise control over the nanomaterial properties.

Preparation and Addition of Reactants

We automate the precise preparation and addition of reactants, utilizing automated feeders, pumps, and mixing systems to ensure accurate dosing and homogenous mixing. Our systems manage resource allocation and sequencing to prevent cross-contamination and ensure reproducibility. Real-time monitoring of flow rates and concentrations ensures optimal reaction conditions.

Neutralization and pH Regulation

We implement automated pH sensors and dosing systems to maintain optimal pH levels during chemical processes. Real-time monitoring and feedback loops ensure precise pH control, which is critical for reaction efficiency and product quality. This is particularly important in processes such as fermentation, where pH can significantly impact yield.

Production of
PVA Glue

We automate the production of PVA glue by managing the polymerization of vinyl acetate and the subsequent emulsification process. Precise control over reaction conditions, such as temperature and mixing speed, ensures consistent polymer characteristics. Continuous monitoring of parameters like viscosity and adhesion properties guarantees that the final product meets stringent quality standards.

Peptization, Pigmentation, and Crystallization

In peptization, we control the addition of peptizing agents to disperse precipitates into stable colloids in the production of materials like catalysts and coatings. For pigmentation, high-shear mixers and automated dosing systems uniformly distribute pigments. During crystallization, precise temperature control ensures consistent crystal size and shape, important for product stability in pharmaceuticals and fine chemicals.

Related Solutions

Batch Automation

Automate ISA-88 batch manufacturing processes with resource allocation, recipe management, and real-time monitoring. Used in the production of washcoats for catalytic clean air solutions, inks, and ionomers for additive manufacturing, as well as paints, glues, broths, titania, and resins.

Ink Preparation

Precise addition, dispersion, and heat treatment of inks for additive manufacturing, integrated into the production environment. Custom-designed vacuum and pump systems, tank inertization, and constant material tracking are just some of the improvements we made to this ISA-88 compliant process.

Washcoat Preparation

Catalytic washcoat preparation features precise dosing and phase control, real-time monitoring, and material traceability focuses on consistent individual batch quality. The ISA-88 compliant and improved process can be vertically and horizontally integrated into the wider production environment.

Precision Coating

Fully automated, highly accurate precision coating of liquids and powders for a uniform, high-quality protective or reactive coating on any kind of substrate, suitable for washcoats, catalysts, and inks in the automotive, chemical, and fuel cell industries.

Data Historian

Specialized software system designed to acquire, store, process, and display real-time data from industrial equipment and processes, providing a centralized repository for time-stamped production data, machine performance metrics, and environmental conditions.

Frequently Asked Questions

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.
We use and specialize in AVEVA Batch Management, Rockwell Automation PlantPAx Batch, and Siemens PCS7 with SIMATIC BATCH. Each of these software solutions offers robust capabilities for complex batch processes, including recipe management, real-time monitoring, and regulatory compliance. Our expertise in these platforms ensures precise control, scalability, and seamless integration with the respective hardware and software ecosystems.
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.
The same batching and automation 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 for additive manufacturing, for example for fuel cells, washcoats for catalytic clean air solutions, 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 chemical processes is necessary in creating the production process of all of them.
Yes, INEA can connect to existing recipe management and warehouse systems when automating any chemical production facility. Our expertise in system integration allows us to seamlessly interface with your current infrastructure, ensuring a smooth and efficient transition. By leveraging our advanced software and hardware integration capabilities, we can synchronize data and processes between the batch management solution and your existing systems, enhancing overall operational efficiency and providing a unified, cohesive solution.

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