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Washcoat Preparation

for diesel particulate filters, catalytic converters, and other clean air technologies.

Constant quality
assurance

Our system monitors, historizes, and analyses key parameters including flow, temperature, and viscosity. The integrated SCADA/HMI system offers a real-time overview and control of the entire process, allowing the operators to react quickly. If a problem is detected in a batch, it can be contained and resolved more effectively, minimizing the impact on overall production. If possible, the process continues with no need to spend time and material on restarting the entire batch.

Dosing and phase
control

Years of experience and development have led us to using our own phase logic, which adheres to the ISA-88 industrial batching standard while adding layers of flexibility, optimisation, and transparency. Leveraging all available measurements, we execute each stage of washcoat preparation exactly to specification and as close as possible to the defined recipe. Tanks and dosers are calibrated and cleaned periodically, recovering as much material from each flush.

Exact material
traceability

Material costs in washcoat preparation can be very high due to precious metals like platinum, palladium, and rhodium. Materials used to produce a batch are traced and their usage saved, historized, and available for analysis with detailed reports. Even at flow rates of over 10 tons per hour, we achieve deviations of < 1 % from the recipe. Inflight material and residue in tanks are accounted for before the final product output, wasting as little material as possible.

End-to-end solutions
with broad support

Our solutions, tailored to each process, encompass process analyses, custom design, and development of machinery, automation and intelligence systems, including laboratory equipment, AGVs, code scanners, label printers, and smart devices. We offer vertically and horizontally integrated end-to-end systems which work seamlessly with hardware and software from industry leading suppliers, such as Rockwell Automation, Siemens, and AVEVA.
Helios
IKA
Johnson Matthey
PPG

End-to-end project management
and control

Our washcoat preparation automation solutions provide tailor-made automation of the batching process, 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. Our expertise encompasses preparing IO schedules, electrical drawings, functional design specifications (FDS), and developing PLC code, 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.

 

Wc Agv 1

Wc Dosing 1 Zaslon

Advanced automation
and monitoring

We use PLC control to automate all parts of the process: dosing, mixing, milling, measuring, temperature control and final transfer to transportation or coating. As materials are added to the suspension or slurry, we keep close track of all relevant parameters to assure proper consistency and homogeneity, adjusting the speed of agitators as needed. Each component is controlled and monitored through an integrated SCADA/HMI system. This control system monitors key parameters such as flow, temperature, and viscosity, ensuring optimal batch quality and process efficiency.

The user interfaces offer a real-time overview and control of the entire process. Operators can monitor the state of tanks, the fullness, pressure, RPM of agitators, and the status of various pipes and valves. Each station can be equipped with its own HMI, allowing localized control while maintaining overall process integration. This ensures any issues can be quickly identified and addressed, maintaining high productivity and quality standards. Across sites, we strive to provide a unified user experience, so that operators from one facility can quickly be transferred to another and instantly be familiar with the interface.

 

Precision in material management
and quality assurance

Precise material addition and dosing are critical for batch quality, especially when dealing with expensive precious metals like platinum, palladium, and rhodium. Our proprietary phase logic and dosing algorithms ensure minimal material wastage, with a low margin for error even at flow rates of several kilograms per second. This precision extends to traceability, with detailed reports on material usage and batch history. Regular calibration and cleaning of tanks and dosers recover as much material as possible from each flush, further reducing waste.

Adhering to the ISA-88 batching standard, our system ensures that each batch is prepared to exact specifications. Safety interlocks and isolation protocols are in place to prevent interference and ensure safe operation. If a batch issue arises, operators can isolate and resolve it without affecting overall production, minimizing waste and downtime.

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Zoho Support Kanban Zaslon

Comprehensive support
and training

We provide extensive operator training and first-line support directly from the engineers who developed the system. This ensures that expert assistance is always available. Detailed manuals and reports support ongoing operation and maintenance, while our simulation-based testing approach minimizes material waste during training and commissioning.

Our competitive advantage lies in our deep familiarity with these processes and years of experience in implementing them. We have developed our own algorithms and phase logic for controlling these processes. We are well-versed in a wide variety of controllers and control equipment, so we can offer advice and improvements to the customer during the design phase of the project. Our solutions are all-encompassing and comprehensive, including HMI and SCADA solutions on all major platforms.

Sustainability and cost
efficiency

Our solutions focus on sustainability through precise material conservation and efficient batch management. The precise dosing and phase control algorithms ensure that as little material as possible is wasted. This efficiency not only supports cost savings but also aligns with environmental goals.

Managing production in batches makes it easier to trace and isolate any quality issues that may arise. Our system monitors key parameters, allowing for quick reaction to any problems. If a problem is detected in a batch, it can be contained and resolved more effectively, minimizing the impact on overall production. The process enters a controlled pause state while maintaining critical activities, such as agitator operation, in already mixed slurries and suspensions. Once the problem is resolved, the process can continue adjusted from that point onwards, saving material in the case of minor anomalies.

Safety Screen Zaslon

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.

SCADA Solutions

Unified industrial software platform offers real-time management, visualization, analytics, and control across thousands of mobile touchpoints. Essential for industrial control and monitoring, it enables efficient operation, real-time oversight, and detailed analysis of complex, dispersed processes.

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.

Chemical Processes

Comprehensive, automated, and ISA-88 compliant 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.

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

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.

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