Case Study: Vinidex

Scope: Design, manufacture, install and commission a replacement control system for a Bulk Handling Plant control system.

The original system was installed and commissioned by Waeschle (AG) in 1990. The plant was controlled by a Siemens S5 135U PLC with over 1000 I/O and an unsupported Siemens MMC 216 Micro controller system for Batch control and production scheduling. Dry blend throughput capacity at the plant is 40,000tonnes per annum. The plant produces over 100 products/formulations by weighing and mixing (hot/cold) 46 possible resins, fillers, micro additives & colours. This product is automatically transferred to some 26 down-stream destinations.

Due to the lack of documentation, a detailed system analysis was required. I S Systems decided to replace the S5 central controller with a Siemens S7 400 and retain the existing S5 I/O racks. The “Black Box” MMC 216 was replaced with a PC based Wonderware InBatch system running InTouch as the HMI.

The plant upgrade and commissioning took place during a two-week maintenance shutdown and full automatic production was successfully resumed afterwards.

The new control system proved its worth by eliminating existing control related bottlenecks and increasing plant utilisation and throughput. Further improvements included unified recipe handling, editing and creation of new recipes, enhanced plant alarming, detailed reporting of plant utilisation and detailed individual batch reports for ISO9001/9002.

Client: Vinidex