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    Digitalization in Emerging Process Industries Specialty Chemicals, Pharma, Food & Beverages, Consumer Packages Goods

    Digitalization refers to enabling or improving processes by leveraging digital technologies and making digitized data available when needed, where needed based on the context. Digitalization in Process Industries is achieved through Process Automation, cellular technology, artificial intelligence. Digitalization increases productivity, safety and efficiency while reducing costs.  Digitalization improves existing processes but doesn’t change or transform them.  With the present pandemic social distancing has become the new norm in the industry and hence every industry is in the process of digitization, as it minimizes the interaction between the plant personnel, increases the plant efficiency/productivity without compromising the safety.

     

    Digital Transformation is business transformation enabled by digitalization.  For example, shift from a manually locally operated process to software driven remotely monitored and controlled process. It involves IT/OT convergence. So, a production plan based on sales forecasting from ERP is fed to the Automation system, which does the production planning and execution at the plant level and feeds the production data back to ERP enabling raw material procurement and warehouse information, integrating the supply chain for greater efficiency and response. All information can be made available in portable handheld device being carried by field operator, thus minimizing coordination problems between the field and control room. With the advent in technology, the plant down time gets drastically reduced using Preventive/Proactive maintenance, as the plant personnel get greater insights to the various equipment’s and its efficiency.

     

    While every industry is striving to transform their businesses through Digitalization, let’s see in which way the process is different for the “Emerging” process industries like F&B. Pharma, Specialty Chemicals and CPG.  Let me explain why I am calling them “Emerging”.

    The process industry can be broadly divided into three categories. Industries like Refining, Petrochemical, Power, Oil & Gas are large continuous processes. DCS were developed to cater to the automation needs of these industries. The systems have evolved over last 50 years with developments in technology. But primarily their focus areas of application have been large continuous process industries. A lot of standards, practices, literature, case studies in these industries are available. It is also worthwhile to note that highly experienced professionals related to these industries are available. These industries have high CAPEX and OPEX.

     

    At the other end, industries like machinery, metal fabrication, electronics, electrical, automotive are discreet processes. PLCs were developed for automation of these processes. PLC’s with  HMI/SCADA as human interface play a dominant role in their automation.

     

    Between these two are the “Emerging” industries such as F&B, Pharma, Specialty Chemicals, CPG. They are called “Emerging” because their growth is exploding and their demand for Digitalization is overtaking other process industries. They had manually operated plants with no automation 20-25 years back. In last 20 years, many of them have grown into enterprises with multiple manufacturing locations and nationwide or global supply chains. With increase in the size of plants, complexity of processes, pressure from regulatory authorities, need to improve consistency in quality and productivity, these industries are heavily investing in automation. In last 5 years, the focus has turned to digitalization to reap the benefits of automation to make the organizations more agile.

     

    Unfortunately, the automation systems available in the market and expertise to implement them have never looked seriously at these industries. DCS Systems though took advantage at these emerging industries initially, as additional business potential, the prohibitive cost of DCS systems became the bottleneck for many industries. Many features in the DCS such as HART, Foundation Fieldbus, Asset Management, Conformal coating, Hot Standby, Proprietary I/O buses and networks, Advanced control templates, SOE etc. make the DCS expensive without adding much value to the emerging process industry applications. The system delivery is through the manufacturers. It increases the dependability on them, and the life cycle costs. The cost of integration with third party systems, customization, upgradation due to obsolescence is usually high.

     

    Similarly, PLC/ SCADA which were developed for the discreet manufacturing and supervision are open systems and flexible, but do not have templates for the standard operations and required too much customization, and the performance depended on the skills and effort of the application software developer. Lack of standardization make the systems difficult to maintain, particularly with the turnover of engineers that we see today.

     

    The available DCS and PLC/ SCADA systems were employed to cater to the growing demand from the “Emerging” segments. In many cases they have been failures or met with only partial success. It was because of two reasons, first being unsuitability of the systems for the emerging industry applications and second limited domain knowledge and expertise about the applications by the consultants and the executioners.

     

    Let’s try to analyze the requirements of Automation in Emerging Process Industries:

     

    1. Most of these industries have batch processes. Multiple products are manufactured with the same equipment. Due to continuous development, product formulations are frequently changed. The product recipes are confidential and are required to be closely guarded. They need good ISA S88 based Batch Management systems with flexible recipe management and batch-based reporting.
    2. It should have templates for common operations such as motors through intelligent MCC and VFDs, pneumatic and motorized on-off valves, raw material charging, different schemes for batch reactor temperature control, sequential control etc.
    3. It should have segment specific template libraries.
    4. The system must be with open architecture and flexible. The IT hardware – Workstations and Servers, operating systems and networking should be compatible with standard IT infrastructure without use of any proprietary components.
    5. Easy and cost-effective integration with third party automation systems on common ethernet protocols and OPC.
    6. Easy and cost-effective integration with intelligent MCC components, VFDs, Energy Management Systems, field instruments such as flowmeters, weighing systems on Ethernet and OPC.
    7. Easy connectivity with Batch, MES, ERP and IoT systems.
    8. The systems should have cyber security features integral with the system.
    9. Allow design and implementation by system integrators having the requisite domain knowledge and expertise in automation in these segments.
    10. Allows easy integration with mobile and wireless technologies.

     

    Some automation manufacturers recognized this gap and developed New Generation DCS designed specifically for the emerging industries. They retain good features of the conventional DCS such as single database, tight integration and powerful diagnostics as well as the good features of the PLC/ SCADA systems such as flexibility, ease of use and openness. They provide the features listed above and make them ideal for use in the emerging process industries.

     

     

    New Generation DCS and Open Automation Framework

    Though the DCS vendors are taking advantage of the technology developments, still some amount of proprietary architecture with constraints regarding allowing third party software applications. Thus, depriving the end user to reap the full benefits of digitalization.   They depend on the organic developments within their own organizations to adopt advanced concepts in digitalization such as analytics, artificial intelligence, machine learning, object orientation, service-oriented architectures etc.   Due to such limitations of the systems, software applications written for one system cannot run on another system. End users are unable to improve their production processes and profitability at reasonable cost and have to heavily depend on the supplier of the systems they use.

     

    The New Generation DCS operate from an open, as against a proprietary industrial framework. They are open to work with best in class third party digitalization vendors and thus create a competitive advantage for the end user very quickly. It allows the systems to take full benefits of the Industry 4.0 and the Industrial Internet of Things (IIoT).

     

    Artificial intelligence and Machine Learning algorithms can greatly improve the quality of operational processes. Prediction of equipment failures before they happen can reduce unplanned downtime. Real-time optimization of products based on raw-material spot prices and real-time optimization of production can be used to maximize the throughput. Industry analysts estimate that the new more flexible production techniques could boost manufacturer productivity by as much as 30%.

     

    End-user organizations such as “Open Process Automation Forum” (OPAF) and “User Association of Automation Technology” (NAMUR) are advocating for changes to the existing proprietary automation system paradigm. To realize full benefits of the Open Automation Framework, the New Generation Automation Systems are adopting IEC 61499 standard. IEC 61499 defines a high-level system design language for distributed information and control systems. The standard allows encapsulation of functionality, graphical component-based design, event driven execution and distribution of automation applications for execution across a broad range of automation & control devices, as well as edge computing devices. Instead of remote I/O stations, smaller and modular localized controllers for individual units are recommended. For maintenance of such systems, it will allow replacement of individual controllers without shutting down the main automation system.

     

    The scope of Digitalization extends much beyond the DCS selected for the core process. A typical process plant in the emerging segments consists of various specialized process equipment and utility equipment supplied by their OEM along with their own automation systems. For successful Digitalization, it is necessary to integrate these automation systems with the main DCS.

     

    Conventional DCS manufacturers show some reluctance to these market demands as compared with the new generation DCS. This job should be entrusted to an experienced Automation Solution Provider having Alliance with a Global New Generation Automation System manufacturer. This will ensure that the chosen automation system is based on the latest technology, will be reliable, will be upgraded from time to time with developments in technology and supported by them. It will also help you in selecting the best-in-class sensors, transmitters, valves and other instrumentation required for the Digitalization project.

    Following are some tips for getting the most out of your Digitalization project:
    1. At the concept stage, your planning must include the entire scope of Digitalization, starting with raw material tanks, process equipment, intermediate and finished products tanks, utilities, filling machines, robotics, OEM equipment, Intelligent MCC, Energy Management systems, Batch, MES, ERP Integration. If there are budget constraints, implementation could be done in a phased manner.
    2. Needless to say, that the core automation system should be a new Generation DCS. The sizing of the DCS should be done keeping in mind the third-party systems to be connected – number of devices and the data to be handled. All communication with third party systems should be on Ethernet. The DCS should have adequate I/O scanning capacity with at least 50% spare.
    3. A plantwide Fibre optic Ethernet ring works out to be cost-effective, reliable and fast. For the process I/O you may consider remote I/O stations on Ethernet; RIO stations with about 100 I/O each distributed throughout the plant.
    4. Intelligent MCC and VFDs must be on Ethernet for fast and efficient motor operation.
    5. Intelligent field instruments such as load-cell based weighing systems, mass flow meters etc. should be connected to the DCS on Ethernet.
    6. A separate Energy monitoring system connecting the energy meters and intelligent breakers is recommended. The energy data required for energy reporting should be exported to the DCS through OPC. This will reduce the load on the DCS for scanning large number of energy meters.
    7. The Automation System (DCS) package should include the Intelligent MCC, VFD and Energy monitoring system and the automation vendor should be responsible for the integration and successful implementation.
    8. ISA S88 based batch management system, MES and integration with ERP should be considered in the road map. You will need them to transform your business. When smart phones were introduced, many people felt that they did not need them. Five years down the line, you cannot live without them.
    9. Many processes have exothermic reactions and can turn into a catastrophe if not adequately safeguarded. In recent years, there have been many such incidents. There is a rising trend to use the Safety PLC systems based on IEC-61508 as Emergency shutdown systems over and above the normal automation systems. For hazardous processes, safety PLC systems that can be easily integrated with the DCS should be considered.
    10. The emerging industries usually do not have experienced automation professionals in their project teams. The decisions are taken by the Project Managers who are not having automation background. They find it convenient and safe to offload the automation package to one of the large Automation system manufacturers. The automation package consists of many items and services beyond the scope of a single automation vendor. Success of the projects depends on successful integration of various components and services. Therefore, only system integrators having requisite domain expertise as well as system integration expertise should be considered for execution. This practice is followed in the advanced countries like USA and Europe.
    11. End products of Pharma, F&B and CPG are for direct human consumption and hence subject to strict regulatory compliances. Features such as User management, Audit Trails, compliance with 21CFR11 etc. help in meeting the regulatory requirements and should be available in the selected system.
    12. The selected system must have advanced cyber security features integral with the system. The firewall and other security features must be a part of the system architecture.

    An Example

    Following is an example of an Automation system consisting of many features mentioned above. It was implemented in 2019 for a large Decorative Paint manufacturing plant in India. The system architecture is shown below. The machines shown in the architecture are actual number of machines used. Such large systems are virtualized these days.

     

    The system consists of the New Generation DCS “EcoStruxure Process Expert” from Schneider Electric with 2 no. Operation Servers, 1 no. Engineering Server, 8 nos. Operating Stations, 2 sets of M-580 Hot Standby Process Automation Controllers. 55 nos. remote I/O stations, 8 nos. Intelligent MCC panels with 150 Tesys T intelligent relays and 43 Altivar VFDs are connected on an Ethernet ring network. Third party PLCs for OEM systems – Zeppelin Pneumatic Conveying system, Oliver Y Battle Mixers, Ystral Mixers, Devree Bulk Filling Machines, Cadetronics Retail Filling Machines, ABB Robots, Godrej Z Conveyor and ASRS system, have been integrated with the DCS on with Modbus TCP/IP, Ethernet I/P and Profinet. Schneider Electric Multifunction meters in Electrical panels have been connected to “Power Monitoring Expert” (PME) software for Energy management. Relevant energy data has been provided in the DCS and Batch through OPC DA. About 75 nos. Load-cell based weighing systems and 60 nos. mass flowmeters have been connected to the system through Ethernet I/P and Profinet respectively. The system has approx. 15,000 I/O. Archiving of critical data and customized reports have been provided through the Historian. Wonderware InBatch has been used to provide advanced ISA S88 based Batch Management. The system has on-line interface with the customer’s SAP system. Process orders are received from the SAP, scheduled in the InBatch, and executed in the DCS as per the recipes. On-line batch and process data is transferred to the SAP phase by phase. At the end of a batch comprehensive batch reports are automatically generated. The system will be shortly upgraded with MES to improve its analytical capabilities. A 64” display is provided in the control room to show the dashboards with critical operating parameters. 

    Conclusion

    Automation requirements of the emerging process industries are different from the continuous and discreet process industries. They need new generation DCS to meet their automation requirements. The basic automation system or the DCS is only a part of the total scope of Digitalization. Integration with the third-party automation systems for process and utility equipment, intelligent MCC, Energy monitoring system, intelligent field instruments, Batch management, MES, ERP must be taken into consideration at the design stage. The job of design and implementation must be entrusted with an experienced Automation Solution Provider and not the automation system manufacturer. Digitalization is not an option it is the survival strategy.

    By: Supertech | Date: June 16, 2021
    Read More
     

    Digitalization in Emerging Process Industries Specialty Chemicals, Pharma, Food & Beverages, Consumer Packages Goods

    Mr. CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    Digitalization refers to enabling or improving processes by leveraging digital technologies and making digitized data available when needed, where needed based on the context. Digitalization in Process Industries is achieved through Process Automation, cellular technology, artificial intelligence. Digitalization increases productivity, safety and efficiency while reducing costs.  Digitalization improves existing processes but doesn’t change or transform them.  With the present pandemic social distancing has become the new norm in the industry and hence every industry is in the process of digitization, as it minimizes the interaction between the plant personnel, increases the plant efficiency/productivity without compromising the safety.

     

    Digital Transformation is business transformation enabled by digitalization.  For example, shift from a manually locally operated process to software driven remotely monitored and controlled process. It involves IT/OT convergence. So, a production plan based on sales forecasting from ERP is fed to the Automation system, which does the production planning and execution at the plant level and feeds the production data back to ERP enabling raw material procurement and warehouse information, integrating the supply chain for greater efficiency and response. All information can be made available in portable handheld device being carried by field operator, thus minimizing coordination problems between the field and control room. With the advent in technology, the plant down time gets drastically reduced using Preventive/Proactive maintenance, as the plant personnel get greater insights to the various equipment’s and its efficiency.

     

    While every industry is striving to transform their businesses through Digitalization, let’s see in which way the process is different for the “Emerging” process industries like F&B. Pharma, Specialty Chemicals and CPG.  Let me explain why I am calling them “Emerging”.

    The process industry can be broadly divided into three categories. Industries like Refining, Petrochemical, Power, Oil & Gas are large continuous processes. DCS were developed to cater to the automation needs of these industries. The systems have evolved over last 50 years with developments in technology. But primarily their focus areas of application have been large continuous process industries. A lot of standards, practices, literature, case studies in these industries are available. It is also worthwhile to note that highly experienced professionals related to these industries are available. These industries have high CAPEX and OPEX.

     

    At the other end, industries like machinery, metal fabrication, electronics, electrical, automotive are discreet processes. PLCs were developed for automation of these processes. PLC’s with  HMI/SCADA as human interface play a dominant role in their automation.

     

    Between these two are the “Emerging” industries such as F&B, Pharma, Specialty Chemicals, CPG. They are called “Emerging” because their growth is exploding and their demand for Digitalization is overtaking other process industries. They had manually operated plants with no automation 20-25 years back. In last 20 years, many of them have grown into enterprises with multiple manufacturing locations and nationwide or global supply chains. With increase in the size of plants, complexity of processes, pressure from regulatory authorities, need to improve consistency in quality and productivity, these industries are heavily investing in automation. In last 5 years, the focus has turned to digitalization to reap the benefits of automation to make the organizations more agile.

     

    Unfortunately, the automation systems available in the market and expertise to implement them have never looked seriously at these industries. DCS Systems though took advantage at these emerging industries initially, as additional business potential, the prohibitive cost of DCS systems became the bottleneck for many industries. Many features in the DCS such as HART, Foundation Fieldbus, Asset Management, Conformal coating, Hot Standby, Proprietary I/O buses and networks, Advanced control templates, SOE etc. make the DCS expensive without adding much value to the emerging process industry applications. The system delivery is through the manufacturers. It increases the dependability on them, and the life cycle costs. The cost of integration with third party systems, customization, upgradation due to obsolescence is usually high.

     

    Similarly, PLC/ SCADA which were developed for the discreet manufacturing and supervision are open systems and flexible, but do not have templates for the standard operations and required too much customization, and the performance depended on the skills and effort of the application software developer. Lack of standardization make the systems difficult to maintain, particularly with the turnover of engineers that we see today.

     

    The available DCS and PLC/ SCADA systems were employed to cater to the growing demand from the “Emerging” segments. In many cases they have been failures or met with only partial success. It was because of two reasons, first being unsuitability of the systems for the emerging industry applications and second limited domain knowledge and expertise about the applications by the consultants and the executioners.

     

    Let’s try to analyze the requirements of Automation in Emerging Process Industries:

     

    1. Most of these industries have batch processes. Multiple products are manufactured with the same equipment. Due to continuous development, product formulations are frequently changed. The product recipes are confidential and are required to be closely guarded. They need good ISA S88 based Batch Management systems with flexible recipe management and batch-based reporting.
    2. It should have templates for common operations such as motors through intelligent MCC and VFDs, pneumatic and motorized on-off valves, raw material charging, different schemes for batch reactor temperature control, sequential control etc.
    3. It should have segment specific template libraries.
    4. The system must be with open architecture and flexible. The IT hardware – Workstations and Servers, operating systems and networking should be compatible with standard IT infrastructure without use of any proprietary components.
    5. Easy and cost-effective integration with third party automation systems on common ethernet protocols and OPC.
    6. Easy and cost-effective integration with intelligent MCC components, VFDs, Energy Management Systems, field instruments such as flowmeters, weighing systems on Ethernet and OPC.
    7. Easy connectivity with Batch, MES, ERP and IoT systems.
    8. The systems should have cyber security features integral with the system.
    9. Allow design and implementation by system integrators having the requisite domain knowledge and expertise in automation in these segments.
    10. Allows easy integration with mobile and wireless technologies.

     

    Some automation manufacturers recognized this gap and developed New Generation DCS designed specifically for the emerging industries. They retain good features of the conventional DCS such as single database, tight integration and powerful diagnostics as well as the good features of the PLC/ SCADA systems such as flexibility, ease of use and openness. They provide the features listed above and make them ideal for use in the emerging process industries.

     

     

    New Generation DCS and Open Automation Framework

    Though the DCS vendors are taking advantage of the technology developments, still some amount of proprietary architecture with constraints regarding allowing third party software applications. Thus, depriving the end user to reap the full benefits of digitalization.   They depend on the organic developments within their own organizations to adopt advanced concepts in digitalization such as analytics, artificial intelligence, machine learning, object orientation, service-oriented architectures etc.   Due to such limitations of the systems, software applications written for one system cannot run on another system. End users are unable to improve their production processes and profitability at reasonable cost and have to heavily depend on the supplier of the systems they use.

     

    The New Generation DCS operate from an open, as against a proprietary industrial framework. They are open to work with best in class third party digitalization vendors and thus create a competitive advantage for the end user very quickly. It allows the systems to take full benefits of the Industry 4.0 and the Industrial Internet of Things (IIoT).

     

    Artificial intelligence and Machine Learning algorithms can greatly improve the quality of operational processes. Prediction of equipment failures before they happen can reduce unplanned downtime. Real-time optimization of products based on raw-material spot prices and real-time optimization of production can be used to maximize the throughput. Industry analysts estimate that the new more flexible production techniques could boost manufacturer productivity by as much as 30%.

     

    End-user organizations such as “Open Process Automation Forum” (OPAF) and “User Association of Automation Technology” (NAMUR) are advocating for changes to the existing proprietary automation system paradigm. To realize full benefits of the Open Automation Framework, the New Generation Automation Systems are adopting IEC 61499 standard. IEC 61499 defines a high-level system design language for distributed information and control systems. The standard allows encapsulation of functionality, graphical component-based design, event driven execution and distribution of automation applications for execution across a broad range of automation & control devices, as well as edge computing devices. Instead of remote I/O stations, smaller and modular localized controllers for individual units are recommended. For maintenance of such systems, it will allow replacement of individual controllers without shutting down the main automation system.

     

    The scope of Digitalization extends much beyond the DCS selected for the core process. A typical process plant in the emerging segments consists of various specialized process equipment and utility equipment supplied by their OEM along with their own automation systems. For successful Digitalization, it is necessary to integrate these automation systems with the main DCS.

     

    Conventional DCS manufacturers show some reluctance to these market demands as compared with the new generation DCS. This job should be entrusted to an experienced Automation Solution Provider having Alliance with a Global New Generation Automation System manufacturer. This will ensure that the chosen automation system is based on the latest technology, will be reliable, will be upgraded from time to time with developments in technology and supported by them. It will also help you in selecting the best-in-class sensors, transmitters, valves and other instrumentation required for the Digitalization project.

    Following are some tips for getting the most out of your Digitalization project:
    1. At the concept stage, your planning must include the entire scope of Digitalization, starting with raw material tanks, process equipment, intermediate and finished products tanks, utilities, filling machines, robotics, OEM equipment, Intelligent MCC, Energy Management systems, Batch, MES, ERP Integration. If there are budget constraints, implementation could be done in a phased manner.
    2. Needless to say, that the core automation system should be a new Generation DCS. The sizing of the DCS should be done keeping in mind the third-party systems to be connected – number of devices and the data to be handled. All communication with third party systems should be on Ethernet. The DCS should have adequate I/O scanning capacity with at least 50% spare.
    3. A plantwide Fibre optic Ethernet ring works out to be cost-effective, reliable and fast. For the process I/O you may consider remote I/O stations on Ethernet; RIO stations with about 100 I/O each distributed throughout the plant.
    4. Intelligent MCC and VFDs must be on Ethernet for fast and efficient motor operation.
    5. Intelligent field instruments such as load-cell based weighing systems, mass flow meters etc. should be connected to the DCS on Ethernet.
    6. A separate Energy monitoring system connecting the energy meters and intelligent breakers is recommended. The energy data required for energy reporting should be exported to the DCS through OPC. This will reduce the load on the DCS for scanning large number of energy meters.
    7. The Automation System (DCS) package should include the Intelligent MCC, VFD and Energy monitoring system and the automation vendor should be responsible for the integration and successful implementation.
    8. ISA S88 based batch management system, MES and integration with ERP should be considered in the road map. You will need them to transform your business. When smart phones were introduced, many people felt that they did not need them. Five years down the line, you cannot live without them.
    9. Many processes have exothermic reactions and can turn into a catastrophe if not adequately safeguarded. In recent years, there have been many such incidents. There is a rising trend to use the Safety PLC systems based on IEC-61508 as Emergency shutdown systems over and above the normal automation systems. For hazardous processes, safety PLC systems that can be easily integrated with the DCS should be considered.
    10. The emerging industries usually do not have experienced automation professionals in their project teams. The decisions are taken by the Project Managers who are not having automation background. They find it convenient and safe to offload the automation package to one of the large Automation system manufacturers. The automation package consists of many items and services beyond the scope of a single automation vendor. Success of the projects depends on successful integration of various components and services. Therefore, only system integrators having requisite domain expertise as well as system integration expertise should be considered for execution. This practice is followed in the advanced countries like USA and Europe.
    11. End products of Pharma, F&B and CPG are for direct human consumption and hence subject to strict regulatory compliances. Features such as User management, Audit Trails, compliance with 21CFR11 etc. help in meeting the regulatory requirements and should be available in the selected system.
    12. The selected system must have advanced cyber security features integral with the system. The firewall and other security features must be a part of the system architecture.

    An Example

    Following is an example of an Automation system consisting of many features mentioned above. It was implemented in 2019 for a large Decorative Paint manufacturing plant in India. The system architecture is shown below. The machines shown in the architecture are actual number of machines used. Such large systems are virtualized these days.

     

    The system consists of the New Generation DCS “EcoStruxure Process Expert” from Schneider Electric with 2 no. Operation Servers, 1 no. Engineering Server, 8 nos. Operating Stations, 2 sets of M-580 Hot Standby Process Automation Controllers. 55 nos. remote I/O stations, 8 nos. Intelligent MCC panels with 150 Tesys T intelligent relays and 43 Altivar VFDs are connected on an Ethernet ring network. Third party PLCs for OEM systems – Zeppelin Pneumatic Conveying system, Oliver Y Battle Mixers, Ystral Mixers, Devree Bulk Filling Machines, Cadetronics Retail Filling Machines, ABB Robots, Godrej Z Conveyor and ASRS system, have been integrated with the DCS on with Modbus TCP/IP, Ethernet I/P and Profinet. Schneider Electric Multifunction meters in Electrical panels have been connected to “Power Monitoring Expert” (PME) software for Energy management. Relevant energy data has been provided in the DCS and Batch through OPC DA. About 75 nos. Load-cell based weighing systems and 60 nos. mass flowmeters have been connected to the system through Ethernet I/P and Profinet respectively. The system has approx. 15,000 I/O. Archiving of critical data and customized reports have been provided through the Historian. Wonderware InBatch has been used to provide advanced ISA S88 based Batch Management. The system has on-line interface with the customer’s SAP system. Process orders are received from the SAP, scheduled in the InBatch, and executed in the DCS as per the recipes. On-line batch and process data is transferred to the SAP phase by phase. At the end of a batch comprehensive batch reports are automatically generated. The system will be shortly upgraded with MES to improve its analytical capabilities. A 64” display is provided in the control room to show the dashboards with critical operating parameters. 

    Conclusion

    Automation requirements of the emerging process industries are different from the continuous and discreet process industries. They need new generation DCS to meet their automation requirements. The basic automation system or the DCS is only a part of the total scope of Digitalization. Integration with the third-party automation systems for process and utility equipment, intelligent MCC, Energy monitoring system, intelligent field instruments, Batch management, MES, ERP must be taken into consideration at the design stage. The job of design and implementation must be entrusted with an experienced Automation Solution Provider and not the automation system manufacturer. Digitalization is not an option it is the survival strategy.

    By: Supertech | Date: June 16, 2021
    Read More

    Advice for Integrating New Digital Solutions with Existing Manufacturing Execution Systems (MES)

    Over the years, generations of manufacturing technologies have provided the tools for individual workers to profitably convert raw materials into the affordable, quality goods that consumers wish to purchase. As plant owners seek to improve speed of operations, to lower production costs, and to minimize errors, a dilemma always presents itself: When is the right time to bear the expense of displacing the existing technology install base? The questions around technology decisions become especially acute when competitive and marketplace pressures mount and when new technology breakthroughs occur, such as the recent Industry 4.0 wave of digital solutions.

    We at Supertech, an automation systems integrator and certified Schneider Electric Alliance Partner and EcoXpert, are often asked by our clients to evaluate the validity of new technology investment decisions, particularly in the area of Manufacturing Execution System (MES).

    Why MES is Critical to Process Operations

    When we provide our evaluations, we are cognizant of our clients’ MES investments over time. Since the 1970’s, process manufacturing stakeholders have used MES to achieve efficiency and productivity goals. Over that period, MES has evolved as an important link between planning systems (such as ERP) and control systems (such as sensors, PLCs, and HMIs). Today, most MES’s serve as work-order-driven, work-in-progress tracking systems that manage and monitor production events and reporting activities. MES manages and records the events in processes and logistics as they occur, providing an information source that is current and accurate in near real time.

     

     

    Most of the processes within the Consumer Packaged Goods (CPG), Pharmaceutical, Food & Beverage (F&B), and Specialty Chemicals industries are batch processes.  MES helps compare batch cycle times, parameters, and variables across batches, and then produces trend reports that summarize the batch data. In this way, the operations benefit from batch process consistency, reduced variability, and improved overall quality.

    The International Society of Automation (ISA) has defined standards for the structuring of MES and its integration in a larger company-wide IT architecture independent of a particular solution vendor. ISA S95 “Enterprise-Control System Integration,” for example, defines a layer model that addresses integration aspects pertaining to ERP, MES, and production control levels. ISA S88 “General and Site Recipe Models and Representation,” on the other hand, defines a process state model for the batch industry.

    It has taken years to establish such standards. We have observed that the organizations who have deployed MES over that time have benefitted in multiple ways. In general, they have experienced:

    • 30 percent gains in quality improvement and equipment uptime,
    • 20 percent gains in Overall Equipment Effectiveness (OEE) and in manufacturing cost reduction, and
    • 10 percent increased productivity on average.

    Options for Integrating Digital Solutions with MES

    Yet, given this evolution and these impressive benefits, businesses still must look ahead and achieve further improvements in order to remain competitive. Over the last few years, trends like Industry 4.0-inspired smart manufacturing have been supported with new technologies such as cloud computing, the proliferation of industrial internet of things (IIoT) devices, digital twins, and artificial intelligence (AI) to name a few. These tools are helping manufacturers to overcome supply chain, production, and distribution complexity obstacles by linking core processes into a unified digital environment.

    Given this wave of emerging technologies, there has been much discussion as to whether MES is still relevant. When clients ask us these questions, we propose these options:

    • Pure Digital Approach — If the scope of digital transformation is limited to just one or two functions, such as data collection and dashboarding, then IIoT devices and analysis software can suffice.  Devices such as smart sensors can be used to collect data from disparate automation systems across the enterprise. This has the benefit of turning siloed data into corporate-wide actionable information that can be analyzed by cloud services for the purposes of benchmarking and process optimization.
    • Supplementing MES with Digital — If a plant is characterized by complex workflows, interoperability, a need for standardization, or an environment that is highly regulated, then MES systems will still provide core benefits above and beyond what some of the Industry 4.0 tools can deliver. Since MES offerings have evolved by industry sector, and the knowledge and best practices of customers has been built into these offerings, those existing benefits should be maintained. The operational process knowledge infused into MES solutions will be difficult to replicate through new digital solutions.

    Digitization technologies will, of course, continue to evolve and mature. However, it is unlikely that they will fully replace MES any time soon. For those who have already invested in MES systems, digital solutions will be a net productivity enabler and a complement, rather than a substitute, to MES. It is likely that both solution sets will collaborate in the future and expedite business benefits for plant owners and operators.

    By: Supertech | Date: December 21, 2020
    Read More
     

    Advice for Integrating New Digital Solutions with Existing Manufacturing Execution Systems (MES)

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    Over the years, generations of manufacturing technologies have provided the tools for individual workers to profitably convert raw materials into the affordable, quality goods that consumers wish to purchase. As plant owners seek to improve speed of operations, to lower production costs, and to minimize errors, a dilemma always presents itself: When is the right time to bear the expense of displacing the existing technology install base? The questions around technology decisions become especially acute when competitive and marketplace pressures mount and when new technology breakthroughs occur, such as the recent Industry 4.0 wave of digital solutions.

    We at Supertech, an automation systems integrator and certified Schneider Electric Alliance Partner and EcoXpert, are often asked by our clients to evaluate the validity of new technology investment decisions, particularly in the area of Manufacturing Execution System (MES).

    Why MES is Critical to Process Operations

    When we provide our evaluations, we are cognizant of our clients’ MES investments over time. Since the 1970’s, process manufacturing stakeholders have used MES to achieve efficiency and productivity goals. Over that period, MES has evolved as an important link between planning systems (such as ERP) and control systems (such as sensors, PLCs, and HMIs). Today, most MES’s serve as work-order-driven, work-in-progress tracking systems that manage and monitor production events and reporting activities. MES manages and records the events in processes and logistics as they occur, providing an information source that is current and accurate in near real time.

     

     

    Most of the processes within the Consumer Packaged Goods (CPG), Pharmaceutical, Food & Beverage (F&B), and Specialty Chemicals industries are batch processes.  MES helps compare batch cycle times, parameters, and variables across batches, and then produces trend reports that summarize the batch data. In this way, the operations benefit from batch process consistency, reduced variability, and improved overall quality.

    The International Society of Automation (ISA) has defined standards for the structuring of MES and its integration in a larger company-wide IT architecture independent of a particular solution vendor. ISA S95 “Enterprise-Control System Integration,” for example, defines a layer model that addresses integration aspects pertaining to ERP, MES, and production control levels. ISA S88 “General and Site Recipe Models and Representation,” on the other hand, defines a process state model for the batch industry.

    It has taken years to establish such standards. We have observed that the organizations who have deployed MES over that time have benefitted in multiple ways. In general, they have experienced:

    • 30 percent gains in quality improvement and equipment uptime,
    • 20 percent gains in Overall Equipment Effectiveness (OEE) and in manufacturing cost reduction, and
    • 10 percent increased productivity on average.

    Options for Integrating Digital Solutions with MES

    Yet, given this evolution and these impressive benefits, businesses still must look ahead and achieve further improvements in order to remain competitive. Over the last few years, trends like Industry 4.0-inspired smart manufacturing have been supported with new technologies such as cloud computing, the proliferation of industrial internet of things (IIoT) devices, digital twins, and artificial intelligence (AI) to name a few. These tools are helping manufacturers to overcome supply chain, production, and distribution complexity obstacles by linking core processes into a unified digital environment.

    Given this wave of emerging technologies, there has been much discussion as to whether MES is still relevant. When clients ask us these questions, we propose these options:

    • Pure Digital Approach — If the scope of digital transformation is limited to just one or two functions, such as data collection and dashboarding, then IIoT devices and analysis software can suffice.  Devices such as smart sensors can be used to collect data from disparate automation systems across the enterprise. This has the benefit of turning siloed data into corporate-wide actionable information that can be analyzed by cloud services for the purposes of benchmarking and process optimization.
    • Supplementing MES with Digital — If a plant is characterized by complex workflows, interoperability, a need for standardization, or an environment that is highly regulated, then MES systems will still provide core benefits above and beyond what some of the Industry 4.0 tools can deliver. Since MES offerings have evolved by industry sector, and the knowledge and best practices of customers has been built into these offerings, those existing benefits should be maintained. The operational process knowledge infused into MES solutions will be difficult to replicate through new digital solutions.

    Digitization technologies will, of course, continue to evolve and mature. However, it is unlikely that they will fully replace MES any time soon. For those who have already invested in MES systems, digital solutions will be a net productivity enabler and a complement, rather than a substitute, to MES. It is likely that both solution sets will collaborate in the future and expedite business benefits for plant owners and operators.

    By: Supertech | Date: December 21, 2020
    Read More

    Process Manufacturers: Align Digital Solutions with the ISA S88 Batch Processing Standard

    Batch processes are essential in the manufacturing of common everyday products such as chocolates, tomato ketchup, shaving cream, shampoo, toothpaste, fragrances, adhesives, medicines, paints, inks, polymers, lube oils, and pesticides to name a few. Products that use a batch process have a unique recipe and precise operating procedure that is usually controlled and managed through a variety of industrial automation digital solutions (read our blog series to learn more).

    The way manufacturers automate and manage their batch processes has a significant impact on plant profitability. In many cases, traditional approaches to batch processing constrain operations in a way that results in plants underperforming. Trends such as increasing complexity and scale of process, multilocational manufacturing, regulatory compliance, shortages of skilled and experienced manpower, and increased competition, all serve as incentives for manufacturers to revisit the way batch processes are run.

    The Challenges of Batch Operations

    The issue that many organizations face is that the bulk of their batch operations are still heavily dependent on human skill. Due to frequent changes in existing product formulas and the addition of new products, recipes and sequences need to be recalibrated more often. In order to carry out these modifications, the skills of expensive automation system engineers are frequently required. When outside vendors must be called in to perform the work, the manufacturer also risks revealing sensitive product formula information to third parties.

    Another major issue is that SCADA and DCS historical data are stored on a time basis and not on a batch basis. This makes it difficult for operators to track the performance and quality of a particular product batch. Operators have no means of recording raw materials consumed, key batch phase parameters, or even their own actions. If a batch is spoiled, stakeholders are not able to determine the reason why.

    How the ISA 588 Standard and Digital Solutions Provides Business Value

    Our company Supertech, an automation systems integrator and certified Schneider Electric Alliance Partner and EcoXpert, meets on a regular basis with process manufacturing clients who require modernization of their plant automation infrastructure.  In our discussions with executives and engineers, we often recommend the International Society of Automation (ISA) S88 standard (adopted in Europe as IEC 61512-1) as an important pillar for driving efficiencies and lowering costs.

    Although the ISA S88 standard was launched in 1995, and updated in 2010, it was not originally embraced by the industry. Back then, batch management systems based on the standard were far too expensive to implement.  A high degree of customization involving senior-level skilled engineers was required. Automation systems in those days were also not as open and flexible as they are today which made adopting such a batch management system difficult.  Now, however, with the advent of technology breakthroughs such as digitization, Industry 4.0, and cloud computing, implementing the standard is much less costly and can serve as an important pillar for driving competitive advantage.

    ISA S88 divides batch operation into three parts:  a process model that defines process stages, operations and actions, a physical model that defines the manufacturing equipment involved, and a procedural model for defining the recipe procedures.

    The physical model and the process model are one-time developments and do not change unless there are changes in the equipment or processing actions. The only aspect that changes on a per-product basis is the recipe. The recipes are easily developed and can be later adapted in the recipe module by a chemist, and the intervention of control systems engineers is not required.

    ISA S88 Benefits Include Better Quality and Higher Efficiency

    As a batch sequence is executed phase by phase, important batch data such as the raw material quantities added, status of key process parameters, quality parameters, and time stamps are tracked in an SQL database. By querying the batch data, the batch management system can develop various reports such as a batch log sheet (electronic batch record), raw materials consumption reports, energy consumption data, equipment utilization data, variance from pre-established benchmark figures, and more. The data can then be analyzed for performance comparisons of the various batches of the same product.

    Adopting the ISA S88 standard framework results in major benefits such as consistency in quality, easier traceability, richer analytics, reduced batch cycle time, better utilization of equipment, improved productivity, less energy consumption, and reduced dependence on human skill and manpower.

     

     

    By: Supertech | Date: December 3, 2020
    Read More
     

    Process Manufacturers: Align Digital Solutions with the ISA S88 Batch Processing Standard

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    Batch processes are essential in the manufacturing of common everyday products such as chocolates, tomato ketchup, shaving cream, shampoo, toothpaste, fragrances, adhesives, medicines, paints, inks, polymers, lube oils, and pesticides to name a few. Products that use a batch process have a unique recipe and precise operating procedure that is usually controlled and managed through a variety of industrial automation digital solutions (read our blog series to learn more).

    The way manufacturers automate and manage their batch processes has a significant impact on plant profitability. In many cases, traditional approaches to batch processing constrain operations in a way that results in plants underperforming. Trends such as increasing complexity and scale of process, multilocational manufacturing, regulatory compliance, shortages of skilled and experienced manpower, and increased competition, all serve as incentives for manufacturers to revisit the way batch processes are run.

    The Challenges of Batch Operations

    The issue that many organizations face is that the bulk of their batch operations are still heavily dependent on human skill. Due to frequent changes in existing product formulas and the addition of new products, recipes and sequences need to be recalibrated more often. In order to carry out these modifications, the skills of expensive automation system engineers are frequently required. When outside vendors must be called in to perform the work, the manufacturer also risks revealing sensitive product formula information to third parties.

    Another major issue is that SCADA and DCS historical data are stored on a time basis and not on a batch basis. This makes it difficult for operators to track the performance and quality of a particular product batch. Operators have no means of recording raw materials consumed, key batch phase parameters, or even their own actions. If a batch is spoiled, stakeholders are not able to determine the reason why.

    How the ISA 588 Standard and Digital Solutions Provides Business Value

    Our company Supertech, an automation systems integrator and certified Schneider Electric Alliance Partner and EcoXpert, meets on a regular basis with process manufacturing clients who require modernization of their plant automation infrastructure.  In our discussions with executives and engineers, we often recommend the International Society of Automation (ISA) S88 standard (adopted in Europe as IEC 61512-1) as an important pillar for driving efficiencies and lowering costs.

    Although the ISA S88 standard was launched in 1995, and updated in 2010, it was not originally embraced by the industry. Back then, batch management systems based on the standard were far too expensive to implement.  A high degree of customization involving senior-level skilled engineers was required. Automation systems in those days were also not as open and flexible as they are today which made adopting such a batch management system difficult.  Now, however, with the advent of technology breakthroughs such as digitization, Industry 4.0, and cloud computing, implementing the standard is much less costly and can serve as an important pillar for driving competitive advantage.

    ISA S88 divides batch operation into three parts:  a process model that defines process stages, operations and actions, a physical model that defines the manufacturing equipment involved, and a procedural model for defining the recipe procedures.

    The physical model and the process model are one-time developments and do not change unless there are changes in the equipment or processing actions. The only aspect that changes on a per-product basis is the recipe. The recipes are easily developed and can be later adapted in the recipe module by a chemist, and the intervention of control systems engineers is not required.

    ISA S88 Benefits Include Better Quality and Higher Efficiency

    As a batch sequence is executed phase by phase, important batch data such as the raw material quantities added, status of key process parameters, quality parameters, and time stamps are tracked in an SQL database. By querying the batch data, the batch management system can develop various reports such as a batch log sheet (electronic batch record), raw materials consumption reports, energy consumption data, equipment utilization data, variance from pre-established benchmark figures, and more. The data can then be analyzed for performance comparisons of the various batches of the same product.

    Adopting the ISA S88 standard framework results in major benefits such as consistency in quality, easier traceability, richer analytics, reduced batch cycle time, better utilization of equipment, improved productivity, less energy consumption, and reduced dependence on human skill and manpower.

     

     

    By: Supertech | Date: December 3, 2020
    Read More

    Hybrid Process Automation System Digital Solutions Components: 3 Tips for Selection

    To drive efficiencies, manufacturers are always pushing themselves and their machines harder to boost output and improve productivity. Implementing up-to-date plant automation system digital solutions is a proven way to support these goals and achieve growth and higher profitability. However, in industries where hybrid automation system environments are required (systems that address both the process and discrete steps of a manufacturing operation), a lack of information on selection of proper components often drives up costs unnecessarily and leaves end users with a less-than optimized system.

    A careful review of typical Distributed Control System (DCS) and hybrid DCS requests for quotations (RFQs) reveal included features that add cost to the digital solutions but that add little to no value to the end user. For instance, some consultants include products and features in their proposals that were originally designed to meet the requirements of refining, petrochemical, and heavy chemical industries. However, for industries like specialty chemicals, pharmaceuticals, food & beverage, paints, resins, inks, adhesives, polymers, and flavors & fragrances, where hybrid processes are common, such features are unnecessary to assure smooth operations.

     

    Three Ways to Cut Unnecessary Industrial Automation System Components in Digital Solutions

    When we at Supertech, an automation systems integrator, certified Schneider Electric Schneider Electric Alliance Partner and EcoXpert, and energy solution provider, meet with manufacturers who run hybrid processes, we help them avoid paying for automation components in digital solutions they don’t need. When selecting industrial automation system components that support hybrid manufacturing environments, be cautious in these three areas:

    1. Avoid unnecessary redundancies – In some cases, particularly in environments where risk analysis has been performed and the level of hardware component reliability is high, the chances that automation system components will fail due to a manufacturing defect are low. In such environments, some batch processes can be intermittently stopped and resumed without much of an issue. Advanced level diagnostics also ensure that systems can be restored within a short period of time if the critical spares are available. In such environments, paying for additional redundancies may not be essential.
    2. Opt for more open communication systems – Some legacy DCS manufacturers provide proprietary buses instead of cost-effective, open, and high-speed Ethernet for communication between the CPU and the system I/O. Industrial automation platforms that are more open allow end users to modernize and integrate more easily. By prioritizing Ethernet I/O, end users can avoid higher integration costs when modernization and upgrades are needed in the future.
    3. Verify whether G3 conformal coating is needed – Many RFQs specify automation system components that conform to G3 level of ISA Conformal Coating Standard 71.04. In pharmaceuticals, food & beverage, and performance chemicals industries, some control rooms and  plant environments are exceptionally clean. If that is the case, the G3 level coating may not be required. Therefore, the possibility exists that overall costs and component delivery lead times can be reduced.

    If these features are specified by a consultant who is managing an end user’s RFQ, end users should push back. By requiring an explanation for their inclusion and removing them if not relevant, you can save cost and avoid added complexity.

    Desirable Options that Bolster Hybrid Process Performance

    As end user stakeholders work through the automation system component selection process, look at functions that can significantly enrich the performance of the new system in the hybrid manufacturing environment.  For example, a system with template libraries that are industry-segment specific for batch process operations will help engineers to speed-up application development. Insisting on either Ethernet I/P, Modbus TCP/IP, or OPC UA protocol support for third-party communication to devices (i.e., tank weighing systems, mass flowmeters, variable frequency drives (VFDs), Intelligent motor starters, and PLCs) will simplify commissioning and allow for more seamless operations.

    By: Supertech | Date: November 26, 2020
    Read More
     

    Hybrid Process Automation System Digital Solutions Components: 3 Tips for Selection

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    To drive efficiencies, manufacturers are always pushing themselves and their machines harder to boost output and improve productivity. Implementing up-to-date plant automation system digital solutions is a proven way to support these goals and achieve growth and higher profitability. However, in industries where hybrid automation system environments are required (systems that address both the process and discrete steps of a manufacturing operation), a lack of information on selection of proper components often drives up costs unnecessarily and leaves end users with a less-than optimized system.

    A careful review of typical Distributed Control System (DCS) and hybrid DCS requests for quotations (RFQs) reveal included features that add cost to the digital solutions but that add little to no value to the end user. For instance, some consultants include products and features in their proposals that were originally designed to meet the requirements of refining, petrochemical, and heavy chemical industries. However, for industries like specialty chemicals, pharmaceuticals, food & beverage, paints, resins, inks, adhesives, polymers, and flavors & fragrances, where hybrid processes are common, such features are unnecessary to assure smooth operations.

     

    Three Ways to Cut Unnecessary Industrial Automation System Components in Digital Solutions

    When we at Supertech, an automation systems integrator, certified Schneider Electric Schneider Electric Alliance Partner and EcoXpert, and energy solution provider, meet with manufacturers who run hybrid processes, we help them avoid paying for automation components in digital solutions they don’t need. When selecting industrial automation system components that support hybrid manufacturing environments, be cautious in these three areas:

    1. Avoid unnecessary redundancies – In some cases, particularly in environments where risk analysis has been performed and the level of hardware component reliability is high, the chances that automation system components will fail due to a manufacturing defect are low. In such environments, some batch processes can be intermittently stopped and resumed without much of an issue. Advanced level diagnostics also ensure that systems can be restored within a short period of time if the critical spares are available. In such environments, paying for additional redundancies may not be essential.
    2. Opt for more open communication systems – Some legacy DCS manufacturers provide proprietary buses instead of cost-effective, open, and high-speed Ethernet for communication between the CPU and the system I/O. Industrial automation platforms that are more open allow end users to modernize and integrate more easily. By prioritizing Ethernet I/O, end users can avoid higher integration costs when modernization and upgrades are needed in the future.
    3. Verify whether G3 conformal coating is needed – Many RFQs specify automation system components that conform to G3 level of ISA Conformal Coating Standard 71.04. In pharmaceuticals, food & beverage, and performance chemicals industries, some control rooms and  plant environments are exceptionally clean. If that is the case, the G3 level coating may not be required. Therefore, the possibility exists that overall costs and component delivery lead times can be reduced.

    If these features are specified by a consultant who is managing an end user’s RFQ, end users should push back. By requiring an explanation for their inclusion and removing them if not relevant, you can save cost and avoid added complexity.

    Desirable Options that Bolster Hybrid Process Performance

    As end user stakeholders work through the automation system component selection process, look at functions that can significantly enrich the performance of the new system in the hybrid manufacturing environment.  For example, a system with template libraries that are industry-segment specific for batch process operations will help engineers to speed-up application development. Insisting on either Ethernet I/P, Modbus TCP/IP, or OPC UA protocol support for third-party communication to devices (i.e., tank weighing systems, mass flowmeters, variable frequency drives (VFDs), Intelligent motor starters, and PLCs) will simplify commissioning and allow for more seamless operations.

    By: Supertech | Date: November 26, 2020
    Read More

    Digital Batch Management Solutions for Simple Batch Processes

    In the past 20 years, several specialty chemicals, pharmaceutical, F&B, CPG companies have grown from having dedicated manufacturing facilities towards diverse multi-product facilities across the supply chain. Many of them also have 3rd party manufacturing sites. The point will be clearer if I give some examples – paints, toothpaste, chocolates, adhesives, pharmaceuticals, lube oils, packaged food, alcoholic and non-alcoholic beverages, flavours & fragrances, soaps & detergents, agrochemicals, specialty chemicals. How do they ensure that a product being produced at several facilities is meeting the same quality standards? In older times there was a belief that batch processes cannot be automated as the quality of the product depended on the skills and experience of the operator. Ageing and higher turnover of skilled manpower are posing challenges to this belief. Many products of these industries are for direct human consumption and therefore, subject to strict regulatory compliances and need end-to-end traceability.  More companies are turning to digital batch management techniques to meet these challenges. Digital batch management is a great solution for knowledge retention as it allows transfer of the operator skills to the system and enables the organization to protect the Intellectual Property. It also ensures data integrity in the operation by providing tamperproof batch records. These could be used to meet regulatory compliances and analyze the batch performance with reference to the benchmark and allow improvements. The new generation batch management systems can be integrated with ERP systems. It significantly increases organizational agility by reducing time and cost to bring new products to the market.

     

    Batch process involves executing steps one by one from a predefined sequence of operations called a “recipe”. Automated batch processes often involve some operations e.g. prechecks, small quantity additions, quality checks etc. that are easier and economical to perform manually. A Digital Batch Management System allows you to integrate the automatic operation with manual process steps. The level of automation is always a techno-commercial decision and depends on  factors such as the size of the plant (number of processing equipment), nature of process, whether having multilocational facilities along the supply chain, integration with ERP and budget etc.

     

    Supertech offers cost effective solutions for digital batch management for all types of batch processes. The solutions are built around “EcoStruxure Process Expert” the new generation DCS from Schneider Electric. For simple batch processes with dedicated plants, Sequencer template available in the customized Process Expert Library can be effectively used. This solution does not require any extra hardware or software. The Sequencer template is customized for each batch process by our experts to meet specific needs.

     

    For complex batch operations, multilocational manufacturing facilities, multiple recipes, flexible batch management based on ISA S88 batch standard with or without ERP integration, we have two options – one with “SUPERBatch”, by Supertech and second with “InBatch” – By Aveva (Schneider Electric). Details about SUPERBatch and free trial are available on Schneider Electric Exchange on the following link:  https://shop.exchange.se.com/en-US/apps/60517/superbatch—isa-s88-based-batch-management-software. Description about our solutions based on ISA S88 Based Batch Management systems will be covered in our subsequent blogs.

     

     

    Process Expert DCS based Batch Management with Sequencer Template

    A simple, cost effective recipe-based batch operation within the DCS is achieved with the Sequencer Template. The sequence of operations is carried out in either auto, semi-auto or manual mode. The template is designed for processes sequence up to 64 steps and 5 parameters control. The Individual steps transitions from one step to the other consecutive step depending upon the predefined logic conditions. The template provides informative and operator friendly sequence control with operator guide message feature. For more information on the Sequencer Template, 30 days free trial or purchase, please visit Schneider Electric Exchange on the following link:

    https://shop.exchange.se.com/en-US/apps/52223/hybrid-dcs-template-library—sequencer-for-batch-processes

     

    Following live example of a specialty chemicals plant in India will illustrate various features of the Sequencer Template based batch management. The process involves a batch reactor with following operations:

    1. Manual pre-checks
    2. Charging of two raw materials automatically
    3. Charging of two catalysts manually
    4. Agitation
    5. Heating
    6. Temperature maintenance
    7. Cooling

     

    The recipe is as follows:

     

    The recipe shows the batch steps with step description, quantities of raw materials to be charged, time and temperature set points for heating and cooling.

     

    Following screenshot of the DCS display shows the Reactor R-101. It is part of a multistage batch process involving three batch reactors. One reactor is shown in the example. Other two reactors are also having similar recipes. Each reactor is having a separate batch sequencer.

    On the top left corner, you can see the batch control panel, an expanded view of which is shown below for better understanding:

     

    It shows the Batch number, time elapsed since the batch started, time elapsed since the step started, step number, batch status whether running or stopped, Auto/ Manual status. It has control buttons for AUTO/ MANUAL, PAUSE/RESUME, ABORT, NEXT STEP, PREVIOUS STEP.

     

    On pressing the ↓ button, 5 steps of the running recipe are shown on top left corner. Current step is indicated by green background, completed steps are shown in gray background and further steps are shown in white background. At any point of time during the execution, you can pause the batch sequence, change from AUTO to MANUAL, advance or go back to the previous step. Recipe editor allows the operator to add, edit or delete steps in the sequence, modify the step transition criteria, the time, material quantity and temperature set points. These changes can also be done during batch execution for the remaining steps. You can also create multiple recipes and save in the DCS.

    The system is very user friendly as it continuously shows the live status of the batch, allows changes in the recipe even during the execution, has an easy to operate control panel and shows customized operator guide messages for each step. The template does not have any provision for creating batch reports. However, Batch logs are automatically created in the DCS event logger. For detailed Batch Reports, separate reporting module with standard as well as customized reports are available. In this plant, we have given a reporting module based on “Dream Reports” from Ocean Data Systems. A weekly KPI report is automatically generated every Monday at 7.00 am and e-mailed to the Director.

     

    With the DCS Sequencer based Batch Management system, customer has achieved 100% consistency in the quality of the product. The dependence on the skills of the operator has reduced. New operators could be easily trained as the operation now depends more on the system than the skills of the operator. This was particularly useful during and post COVID lockdown when the availability of skilled people was low. There was a 15% reduction in the batch cycle time and 10% saving in the energy consumption.

     

    In conclusion, Batch Management with Process Expert Sequencer Template  is a solution for knowledge retention and Intellectual Property Management. It allows meeting regulatory requirements by maintaining highly accurate and granular batch data and provides traceability. Depending on the size and budget of the plant, it allows integration of manual process steps in the recipe without compromising the data integrity. In current times this is an absolute necessity to survive in a fiercely competitive global market. Only those industries who recognize the changing needs and adopt such manufacturing automation technologies will survive and thrive.

    By: Supertech | Date: October 17, 2020
    Read More
     

    Digital Batch Management Solutions for Simple Batch Processes

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    In the past 20 years, several specialty chemicals, pharmaceutical, F&B, CPG companies have grown from having dedicated manufacturing facilities towards diverse multi-product facilities across the supply chain. Many of them also have 3rd party manufacturing sites. The point will be clearer if I give some examples – paints, toothpaste, chocolates, adhesives, pharmaceuticals, lube oils, packaged food, alcoholic and non-alcoholic beverages, flavours & fragrances, soaps & detergents, agrochemicals, specialty chemicals. How do they ensure that a product being produced at several facilities is meeting the same quality standards? In older times there was a belief that batch processes cannot be automated as the quality of the product depended on the skills and experience of the operator. Ageing and higher turnover of skilled manpower are posing challenges to this belief. Many products of these industries are for direct human consumption and therefore, subject to strict regulatory compliances and need end-to-end traceability.  More companies are turning to digital batch management techniques to meet these challenges. Digital batch management is a great solution for knowledge retention as it allows transfer of the operator skills to the system and enables the organization to protect the Intellectual Property. It also ensures data integrity in the operation by providing tamperproof batch records. These could be used to meet regulatory compliances and analyze the batch performance with reference to the benchmark and allow improvements. The new generation batch management systems can be integrated with ERP systems. It significantly increases organizational agility by reducing time and cost to bring new products to the market.

     

    Batch process involves executing steps one by one from a predefined sequence of operations called a “recipe”. Automated batch processes often involve some operations e.g. prechecks, small quantity additions, quality checks etc. that are easier and economical to perform manually. A Digital Batch Management System allows you to integrate the automatic operation with manual process steps. The level of automation is always a techno-commercial decision and depends on  factors such as the size of the plant (number of processing equipment), nature of process, whether having multilocational facilities along the supply chain, integration with ERP and budget etc.

     

    Supertech offers cost effective solutions for digital batch management for all types of batch processes. The solutions are built around “EcoStruxure Process Expert” the new generation DCS from Schneider Electric. For simple batch processes with dedicated plants, Sequencer template available in the customized Process Expert Library can be effectively used. This solution does not require any extra hardware or software. The Sequencer template is customized for each batch process by our experts to meet specific needs.

     

    For complex batch operations, multilocational manufacturing facilities, multiple recipes, flexible batch management based on ISA S88 batch standard with or without ERP integration, we have two options – one with “SUPERBatch”, by Supertech and second with “InBatch” – By Aveva (Schneider Electric). Details about SUPERBatch and free trial are available on Schneider Electric Exchange on the following link:  https://shop.exchange.se.com/en-US/apps/60517/superbatch—isa-s88-based-batch-management-software. Description about our solutions based on ISA S88 Based Batch Management systems will be covered in our subsequent blogs.

     

     

    Process Expert DCS based Batch Management with Sequencer Template

    A simple, cost effective recipe-based batch operation within the DCS is achieved with the Sequencer Template. The sequence of operations is carried out in either auto, semi-auto or manual mode. The template is designed for processes sequence up to 64 steps and 5 parameters control. The Individual steps transitions from one step to the other consecutive step depending upon the predefined logic conditions. The template provides informative and operator friendly sequence control with operator guide message feature. For more information on the Sequencer Template, 30 days free trial or purchase, please visit Schneider Electric Exchange on the following link:

    https://shop.exchange.se.com/en-US/apps/52223/hybrid-dcs-template-library—sequencer-for-batch-processes

     

    Following live example of a specialty chemicals plant in India will illustrate various features of the Sequencer Template based batch management. The process involves a batch reactor with following operations:

    1. Manual pre-checks
    2. Charging of two raw materials automatically
    3. Charging of two catalysts manually
    4. Agitation
    5. Heating
    6. Temperature maintenance
    7. Cooling

     

    The recipe is as follows:

     

    The recipe shows the batch steps with step description, quantities of raw materials to be charged, time and temperature set points for heating and cooling.

     

    Following screenshot of the DCS display shows the Reactor R-101. It is part of a multistage batch process involving three batch reactors. One reactor is shown in the example. Other two reactors are also having similar recipes. Each reactor is having a separate batch sequencer.

    On the top left corner, you can see the batch control panel, an expanded view of which is shown below for better understanding:

     

    It shows the Batch number, time elapsed since the batch started, time elapsed since the step started, step number, batch status whether running or stopped, Auto/ Manual status. It has control buttons for AUTO/ MANUAL, PAUSE/RESUME, ABORT, NEXT STEP, PREVIOUS STEP.

     

    On pressing the ↓ button, 5 steps of the running recipe are shown on top left corner. Current step is indicated by green background, completed steps are shown in gray background and further steps are shown in white background. At any point of time during the execution, you can pause the batch sequence, change from AUTO to MANUAL, advance or go back to the previous step. Recipe editor allows the operator to add, edit or delete steps in the sequence, modify the step transition criteria, the time, material quantity and temperature set points. These changes can also be done during batch execution for the remaining steps. You can also create multiple recipes and save in the DCS.

    The system is very user friendly as it continuously shows the live status of the batch, allows changes in the recipe even during the execution, has an easy to operate control panel and shows customized operator guide messages for each step. The template does not have any provision for creating batch reports. However, Batch logs are automatically created in the DCS event logger. For detailed Batch Reports, separate reporting module with standard as well as customized reports are available. In this plant, we have given a reporting module based on “Dream Reports” from Ocean Data Systems. A weekly KPI report is automatically generated every Monday at 7.00 am and e-mailed to the Director.

     

    With the DCS Sequencer based Batch Management system, customer has achieved 100% consistency in the quality of the product. The dependence on the skills of the operator has reduced. New operators could be easily trained as the operation now depends more on the system than the skills of the operator. This was particularly useful during and post COVID lockdown when the availability of skilled people was low. There was a 15% reduction in the batch cycle time and 10% saving in the energy consumption.

     

    In conclusion, Batch Management with Process Expert Sequencer Template  is a solution for knowledge retention and Intellectual Property Management. It allows meeting regulatory requirements by maintaining highly accurate and granular batch data and provides traceability. Depending on the size and budget of the plant, it allows integration of manual process steps in the recipe without compromising the data integrity. In current times this is an absolute necessity to survive in a fiercely competitive global market. Only those industries who recognize the changing needs and adopt such manufacturing automation technologies will survive and thrive.

    By: Supertech | Date: October 17, 2020
    Read More

    Digital Transformation in Hybrid Process Industries (Specialty Chemicals, Pharma, Food & Beverages, Consumer Packages Goods)

    This paper defines “Hybrid Process Industries” and explains how their unique automation requirements can be addressed by new generation DCS like “EcoStruxure Process Expert” from Schneider Electric. Supertech, with over 30 years successful track record in these industries and a Master Alliance Partner with Schneider Electric, will be your ideal partner not only in the plant automation but also the complete Digital Transformation journey. A real-life batch process where these techniques were successfully employed is also discussed. The customer has achieved 20% increase in productivity, 100% consistency in quality, 15% energy saving, 50% less manpower, 20% increase in availability of equipment, material traceability from finished goods to raw materials, tamper-proof electronic batch records, real-time integration with ERP by posting of raw material consumption and production after every batch.

     

    What are Hybrid Process Industries?

    When we started the automation system integration business in early nineties, the system integration was all about selling PLC based systems to OEMs and discrete segment of end users. DCS companies used to sell DCS to large process industries. The smaller process industries such as Specialty Chemicals, Pharma, F&B were by and large manually operated because the automation systems were not able to provide the agility and flexibility needed for their process and also openness in their integration with other third-party systems

     

    Examples of Hybrid Process Industries

    When the winds of liberalization started blowing, these industries felt the need for automation with their expanding capacity. Major driving factors were increasing size and complexity of processes, pressure of maintaining consistent quality in the light of global competition, need to improve productivity, regulatory compliances, and reduce dependence on human effort and skills. Smaller process industries involve processes with several automated batch operations, with manual interventions in between those steps. It comes with large number of discrete signals. PLC based system with their success in manufacturing industry were used for these applications primarily because of the boolean logic processing, lower cost and simplicity. Large process plants such as refineries, petrochemicals, use continuous process and has large number of analog signals. DCS were used due to its robust analog processing capabilities and algorithm library. As the smaller industries are getting more automated, the manual interventions are being eliminated. The automation needs of these industries have evolved from couple of discrete batch operation process to integrated batch and continuous processes with no manual interventions. These industries are therefore called Hybrid Process Industries.

     

    Till the new generation of Automation systems were launched, the automation in these industries was limited to automating  operation of valves and motors, transfer of liquid raw materials and solvents from storage tanks to day tanks, monitoring of process parameters, switching of utilities in multipurpose API reactors etc. However, it was still short of expectations of the end users. It was because of two reasons, first due to the lacunae in the automation systems and second the inexperience of the implementors, be it the system integrators or the DCS companies.

     

    Digital Transformation in Hybrid Industries

    Digital transformation is the process of using digital technologies to create new — or modify existing — business processes, culture, and customer experiences to meet changing business and market requirements. Among the various business processes to be transformed, manufacturing is one of the most critical. Digitalization of manufacturing processes in hybrid industries is in simpler words “Automation”.  To achieve the real benefits of Digitalization, a holistic approach towards automation is necessary.

    The key business values driving the need for Digital Transformation are:

    • Smart Design and Engineering :-

                                    Efficient Engineering

                                    Enhanced Commissioning

                                    Lifecycle Management

    • Asset Performance :-

                                    Asset Reliability

                                    Maintenance Excellence

                                    Asset Optimization

    • Investment Continuity :-

                                  Extended Lifespan

                                 Modernization

                                 Asset Portfolio Management

    • Energy Efficiency  :-

                                 Energy Management

                                 Demand- Response

     

    Let me explain how the new Generation DCS “EcoStruxure Process Expert” from Schneider Electric has helped in addressing the basic Automation needs as well as the overall Digitalization needs of the hybrid industries.

     

    • Majority of the hybrid industries are batch processes. Various options of Batch Management starting from Batch sequence templates available in the DCS library to ISA S88 based Batch Management using specialized Batch management software SUPERBatch (From Supertech) or InBatch (From Schneider Electric) are available.
    • Customized templates for liquid raw materials transfer from storage tanks to day tanks and from day tanks to reactors/ mixers/ blenders makes this automation plug and play.
    • Conventional PID control does not work for temperature control of Batch Reactors. Customized templates have been prepared for temperature control of exothermic or endothermic reactions, split-range control for high accuracy, controlled addition of reactants with simultaneous cooling with temperature control, automatic switching of utilities and adaptive temperature control for multipurpose API reactors.
    • Templates for Intelligent Motor Starters and Relays Tesys U and Tesys T, Altivar range of VFDs from Schneider Electric provide robust DCS-Intelligent MCC interface and monitoring of motor data.
    • Library for Energy Management. Easy connectivity with Multifunction meters, Intelligent breakers. Data from Energy Management softwares PME and PSO on OPC. Energy dashboards, specific energy consumption.
    • Open architecture based on Ethernet. Flexible system architecture with Ring, Star and Bus topologies
    • Seamless integration with MES, ERP and other IT systems.
    • IIoT solutions “Augmented Operator Advisor” for operator empowerment, Secure Connect” for secure remote connectivity for trouble shooting, program modifications, “Maintenance Advisor” for Predictive maintenance, “Equipment Efficiency Advisor” a real time software tool for process improvement that provides online monitoring of the OEE
    • With “AVEVA Insight”, cloud based Historian, you can collect data from multiple sources, store it in the cloud and have visualisation plus cloud based MES functionality, condition management, advanced analytics, machine learning, mobile reporting and more…
    • The awareness about Functional safety and IEC 61508 in increasing. Hybrid Industries having hazardous processes are carrying out HAZOP study and safety assessment. SIL 3 safety controllers are available in the same controller family. They are used for Emergency shutdown systems, safety interlock systems, Burner Management,  systems etc.
    • EcoStruxure Process Expert provides connectivity with third party systems on a variety of protocols such as Modbus TCP, Ethernet IP, Profinet, Profibus, Modbus serial etc. It helps interfacing with OEM equipment such as Boilers, Thermopacks, Chillers, Filling machines, Robots, Conveying systems, Storage systems etc.
    • End products of many hybrid industries such as Pharma, F&B and CPG are for direct human consumption and hence subject to strict regulatory compliances. Features such as User management, Audit Trails, compliance with 21CFR11 etc. help in meeting the regulatory requirements.

     

    An Example

    Following is an example of an Automation system consisting of many features mentioned above. It was implemented recently for a 100,000 TPA Paint manufacturing plant in India, which is likely to double its capacity shortly. The system architecture is as follows:

     

    The system consists of “EcoStruxure Process Expert” DCS from Schneider Electric with 2 no. Operation Servers, 1 no. Engineering Server, 8 nos. Operating Clients, 2 sets of M-580 Hot Standby Process Automation Controllers. 55 nos. remote I/O stations, 8 nos. Intelligent MCC panels with Tesys T intelligent relays and Altivar VFDs are connected on an Ethernet ring network. Third party PLCs for OEM systems with Modbus Serial, Modbus TCP/IP, Ethernet I/P, Profibus and Profinet have been integrated with the DCS on the same network with suitable gateways wherever required. Multifunction meters in Electrical panels have been connected to “Power Monitoring Expert” (PME) software for Energy management. Relevant energy data has been provided in the DCS and Batch through OPC DA. About 75 nos. Load-cell based weighing systems and 60 nos. mass flowmeters have been connected to the system through Ethertent I/P and Profinet respectively. The system has approx. 14,000 I/O. Archiving of critical data and customized reports have been provided through the Historian. Wonderware InBatch has been used to provide advanced ISA S88 based Batch Management. The system has on-line interface with the customer’s SAP system. Process orders are received from the SAP, scheduled in the InBatch, and executed in the DCS as per the recipes. On-line batch and process data is transferred to the SAP phase by phase. At the end of a batch comprehensive batch reports are automatically generated. The system will be shortly upgraded with MES to improve its analytical capabilities. A 64” display is provided in the control room to show the dashboards with critical operating parameters.

     

    Selecting the Right Partner

    Having the right partner with you is absolutely essential for a successful Digital Transformation Project. Your investment can go down the drain with a wrong selection. You can see that the process involves integration of various components, customization to your needs and support. Only experienced Service providers like Supertech with both the domain as well as the automation expertise can provide you the integration, services and support, all under one roof.

     

    Supertech is a leading automation solution provider with 30 years of proven track record in hybrid industries. Supertech is a Master Alliance Partner with Schneider Electric (one out of ten globally) for Control Systems and Hybrid DCS and a segment specialist partner in Consumer-Packaged Goods. Other Alliance partnerships with Schneider Electric include “Intelligent MCC Integration”, “EcoXpert – Critical Power Expert” for Energy Monitoring Systems and Wonderware software platforms. Supertech has in-house expert teams available in each of these areas and you will have a seamless experience through your digitalization journey. Supertech also undertakes the responsibility of supplying the smart and non-smart field instruments, valves, erection material from the best-in-class sub-vendors and services of installation, calibration and commissioning. Supertech supports its installed base through 24×7 customer support with telephone, e-mail, secure remote support and AMCs.

     

     

    By: Supertech | Date: September 17, 2020
    Read More
     

    Digital Transformation in Hybrid Process Industries (Specialty Chemicals, Pharma, Food & Beverages, Consumer Packages Goods)

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    This paper defines “Hybrid Process Industries” and explains how their unique automation requirements can be addressed by new generation DCS like “EcoStruxure Process Expert” from Schneider Electric. Supertech, with over 30 years successful track record in these industries and a Master Alliance Partner with Schneider Electric, will be your ideal partner not only in the plant automation but also the complete Digital Transformation journey. A real-life batch process where these techniques were successfully employed is also discussed. The customer has achieved 20% increase in productivity, 100% consistency in quality, 15% energy saving, 50% less manpower, 20% increase in availability of equipment, material traceability from finished goods to raw materials, tamper-proof electronic batch records, real-time integration with ERP by posting of raw material consumption and production after every batch.

     

    What are Hybrid Process Industries?

    When we started the automation system integration business in early nineties, the system integration was all about selling PLC based systems to OEMs and discrete segment of end users. DCS companies used to sell DCS to large process industries. The smaller process industries such as Specialty Chemicals, Pharma, F&B were by and large manually operated because the automation systems were not able to provide the agility and flexibility needed for their process and also openness in their integration with other third-party systems

     

    Examples of Hybrid Process Industries

    When the winds of liberalization started blowing, these industries felt the need for automation with their expanding capacity. Major driving factors were increasing size and complexity of processes, pressure of maintaining consistent quality in the light of global competition, need to improve productivity, regulatory compliances, and reduce dependence on human effort and skills. Smaller process industries involve processes with several automated batch operations, with manual interventions in between those steps. It comes with large number of discrete signals. PLC based system with their success in manufacturing industry were used for these applications primarily because of the boolean logic processing, lower cost and simplicity. Large process plants such as refineries, petrochemicals, use continuous process and has large number of analog signals. DCS were used due to its robust analog processing capabilities and algorithm library. As the smaller industries are getting more automated, the manual interventions are being eliminated. The automation needs of these industries have evolved from couple of discrete batch operation process to integrated batch and continuous processes with no manual interventions. These industries are therefore called Hybrid Process Industries.

     

    Till the new generation of Automation systems were launched, the automation in these industries was limited to automating  operation of valves and motors, transfer of liquid raw materials and solvents from storage tanks to day tanks, monitoring of process parameters, switching of utilities in multipurpose API reactors etc. However, it was still short of expectations of the end users. It was because of two reasons, first due to the lacunae in the automation systems and second the inexperience of the implementors, be it the system integrators or the DCS companies.

     

    Digital Transformation in Hybrid Industries

    Digital transformation is the process of using digital technologies to create new — or modify existing — business processes, culture, and customer experiences to meet changing business and market requirements. Among the various business processes to be transformed, manufacturing is one of the most critical. Digitalization of manufacturing processes in hybrid industries is in simpler words “Automation”.  To achieve the real benefits of Digitalization, a holistic approach towards automation is necessary.

    The key business values driving the need for Digital Transformation are:

    • Smart Design and Engineering :-

                                    Efficient Engineering

                                    Enhanced Commissioning

                                    Lifecycle Management

    • Asset Performance :-

                                    Asset Reliability

                                    Maintenance Excellence

                                    Asset Optimization

    • Investment Continuity :-

                                  Extended Lifespan

                                 Modernization

                                 Asset Portfolio Management

    • Energy Efficiency  :-

                                 Energy Management

                                 Demand- Response

     

    Let me explain how the new Generation DCS “EcoStruxure Process Expert” from Schneider Electric has helped in addressing the basic Automation needs as well as the overall Digitalization needs of the hybrid industries.

     

    • Majority of the hybrid industries are batch processes. Various options of Batch Management starting from Batch sequence templates available in the DCS library to ISA S88 based Batch Management using specialized Batch management software SUPERBatch (From Supertech) or InBatch (From Schneider Electric) are available.
    • Customized templates for liquid raw materials transfer from storage tanks to day tanks and from day tanks to reactors/ mixers/ blenders makes this automation plug and play.
    • Conventional PID control does not work for temperature control of Batch Reactors. Customized templates have been prepared for temperature control of exothermic or endothermic reactions, split-range control for high accuracy, controlled addition of reactants with simultaneous cooling with temperature control, automatic switching of utilities and adaptive temperature control for multipurpose API reactors.
    • Templates for Intelligent Motor Starters and Relays Tesys U and Tesys T, Altivar range of VFDs from Schneider Electric provide robust DCS-Intelligent MCC interface and monitoring of motor data.
    • Library for Energy Management. Easy connectivity with Multifunction meters, Intelligent breakers. Data from Energy Management softwares PME and PSO on OPC. Energy dashboards, specific energy consumption.
    • Open architecture based on Ethernet. Flexible system architecture with Ring, Star and Bus topologies
    • Seamless integration with MES, ERP and other IT systems.
    • IIoT solutions “Augmented Operator Advisor” for operator empowerment, Secure Connect” for secure remote connectivity for trouble shooting, program modifications, “Maintenance Advisor” for Predictive maintenance, “Equipment Efficiency Advisor” a real time software tool for process improvement that provides online monitoring of the OEE
    • With “AVEVA Insight”, cloud based Historian, you can collect data from multiple sources, store it in the cloud and have visualisation plus cloud based MES functionality, condition management, advanced analytics, machine learning, mobile reporting and more…
    • The awareness about Functional safety and IEC 61508 in increasing. Hybrid Industries having hazardous processes are carrying out HAZOP study and safety assessment. SIL 3 safety controllers are available in the same controller family. They are used for Emergency shutdown systems, safety interlock systems, Burner Management,  systems etc.
    • EcoStruxure Process Expert provides connectivity with third party systems on a variety of protocols such as Modbus TCP, Ethernet IP, Profinet, Profibus, Modbus serial etc. It helps interfacing with OEM equipment such as Boilers, Thermopacks, Chillers, Filling machines, Robots, Conveying systems, Storage systems etc.
    • End products of many hybrid industries such as Pharma, F&B and CPG are for direct human consumption and hence subject to strict regulatory compliances. Features such as User management, Audit Trails, compliance with 21CFR11 etc. help in meeting the regulatory requirements.

     

    An Example

    Following is an example of an Automation system consisting of many features mentioned above. It was implemented recently for a 100,000 TPA Paint manufacturing plant in India, which is likely to double its capacity shortly. The system architecture is as follows:

     

    The system consists of “EcoStruxure Process Expert” DCS from Schneider Electric with 2 no. Operation Servers, 1 no. Engineering Server, 8 nos. Operating Clients, 2 sets of M-580 Hot Standby Process Automation Controllers. 55 nos. remote I/O stations, 8 nos. Intelligent MCC panels with Tesys T intelligent relays and Altivar VFDs are connected on an Ethernet ring network. Third party PLCs for OEM systems with Modbus Serial, Modbus TCP/IP, Ethernet I/P, Profibus and Profinet have been integrated with the DCS on the same network with suitable gateways wherever required. Multifunction meters in Electrical panels have been connected to “Power Monitoring Expert” (PME) software for Energy management. Relevant energy data has been provided in the DCS and Batch through OPC DA. About 75 nos. Load-cell based weighing systems and 60 nos. mass flowmeters have been connected to the system through Ethertent I/P and Profinet respectively. The system has approx. 14,000 I/O. Archiving of critical data and customized reports have been provided through the Historian. Wonderware InBatch has been used to provide advanced ISA S88 based Batch Management. The system has on-line interface with the customer’s SAP system. Process orders are received from the SAP, scheduled in the InBatch, and executed in the DCS as per the recipes. On-line batch and process data is transferred to the SAP phase by phase. At the end of a batch comprehensive batch reports are automatically generated. The system will be shortly upgraded with MES to improve its analytical capabilities. A 64” display is provided in the control room to show the dashboards with critical operating parameters.

     

    Selecting the Right Partner

    Having the right partner with you is absolutely essential for a successful Digital Transformation Project. Your investment can go down the drain with a wrong selection. You can see that the process involves integration of various components, customization to your needs and support. Only experienced Service providers like Supertech with both the domain as well as the automation expertise can provide you the integration, services and support, all under one roof.

     

    Supertech is a leading automation solution provider with 30 years of proven track record in hybrid industries. Supertech is a Master Alliance Partner with Schneider Electric (one out of ten globally) for Control Systems and Hybrid DCS and a segment specialist partner in Consumer-Packaged Goods. Other Alliance partnerships with Schneider Electric include “Intelligent MCC Integration”, “EcoXpert – Critical Power Expert” for Energy Monitoring Systems and Wonderware software platforms. Supertech has in-house expert teams available in each of these areas and you will have a seamless experience through your digitalization journey. Supertech also undertakes the responsibility of supplying the smart and non-smart field instruments, valves, erection material from the best-in-class sub-vendors and services of installation, calibration and commissioning. Supertech supports its installed base through 24×7 customer support with telephone, e-mail, secure remote support and AMCs.

     

     

    By: Supertech | Date: September 17, 2020
    Read More

    Integrating Motor Control, Automation, and Energy Systems Create More Efficient Plant Operations and Reduce Cost

    Throughout most industrial operations, electric motors play a critical role in driving conveyor belts, pumps, compressors, agitators, fans, and other critical infrastructure assets. As the number of motors in process plants increases, management and monitoring of such assets is critical in preventing core process errors such as the proper mixing of ingredients. Motors also account for about 70 percent of the total energy consumed in a process plant. A strategy that links motor control, automation, and energy management, therefore, can help plants to simultaneously reduce costs while increasing production.

    Read More…

    By: Supertech | Date: July 1, 2020
    Read More
     

    Integrating Motor Control, Automation, and Energy Systems Create More Efficient Plant Operations and Reduce Cost

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    Throughout most industrial operations, electric motors play a critical role in driving conveyor belts, pumps, compressors, agitators, fans, and other critical infrastructure assets. As the number of motors in process plants increases, management and monitoring of such assets is critical in preventing core process errors such as the proper mixing of ingredients. Motors also account for about 70 percent of the total energy consumed in a process plant. A strategy that links motor control, automation, and energy management, therefore, can help plants to simultaneously reduce costs while increasing production.

    Read More…

    By: Supertech | Date: July 1, 2020
    Read More

    3 Ways Choosing the Right Hybrid Industry Automation Integration Partner Can Minimize Project Risk

    According to Fortune Business Insights, the global industrial automation market, which was valued at $157 Billion USD in 2018, is expected to reach nearly $297 Billion USD by 2026. As smart automation and digital solutions take hold, the role of industrial automation system integrators becomes more important than ever. Systems are more connected and data sharing is critical for executing end-to-end process optimization.

     

     

    Read More

     

    By: Supertech | Date: May 27, 2020
    Read More
     

    3 Ways Choosing the Right Hybrid Industry Automation Integration Partner Can Minimize Project Risk

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    According to Fortune Business Insights, the global industrial automation market, which was valued at $157 Billion USD in 2018, is expected to reach nearly $297 Billion USD by 2026. As smart automation and digital solutions take hold, the role of industrial automation system integrators becomes more important than ever. Systems are more connected and data sharing is critical for executing end-to-end process optimization.

     

     

    Read More

     

    By: Supertech | Date: May 27, 2020
    Read More

    Why New Generation Automation Solutions Excel in Hybrid Process Environments

    Emerging process industry segments such as small- to medium-sized manufacturers have a huge potential for growth and the right industrial automation systems can help fuel that growth. Take, for example, a paint manufacturer based in India who decided to invest in a new generation hybrid automation system (a system that addresses both the process and discrete steps of a manufacturing operation). Initially, the company was manually handling large quantities of raw materials. Barrels of liquid and bags of chemicals were delivered and dropped off on the plant production floor.

     

    Read More

     

     

    By: Supertech | Date: May 11, 2020
    Read More
     

    Why New Generation Automation Solutions Excel in Hybrid Process Environments

    CHANDRASHEKHAR LIMAYE
    Director- Supertech Instrumentation Services (I) Pvt. Ltd.

    Emerging process industry segments such as small- to medium-sized manufacturers have a huge potential for growth and the right industrial automation systems can help fuel that growth. Take, for example, a paint manufacturer based in India who decided to invest in a new generation hybrid automation system (a system that addresses both the process and discrete steps of a manufacturing operation). Initially, the company was manually handling large quantities of raw materials. Barrels of liquid and bags of chemicals were delivered and dropped off on the plant production floor.

     

    Read More

     

     

    By: Supertech | Date: May 11, 2020
    Read More

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