Project Name
Extruder Line Automation Upgrade
Industry Sector
Paints & Coatings
Products & Services
- Siemens Simatic S7-1200 PLC
- Siemens TP1200 Comfort HMI
- Control Panel Designing
- Thermocouple Sensor
Client Expectation :
The client was looking for Design & Development of new control panels with latest PLC and HMI systems. Along with below requirements:
- Phase wise removal of existing old PLC control panels aged 15 years and above.
- Temperature control of extruder barrels.
- Replace existing sensors with new model.
- Complete field cable replacement
Project Highlights
Preventive Maintenance Scheduling
Our system included a feature called “Preventive Maintenance Scheduling”. This feature notifies the user periodically about equipment that are due for maintenance.
Temperature control of
extruder barrels
Effective temperature control is vital for 1 maintaining optimal barrel temperatures in single-screw & double-screw extruders. Our team perfectly tuned the Temperature control PID loops to achieve accurate temperature regulation.
Machine Safety
The outlet conveyors are moved towards the Extruders during production, and back for cleaning. We ensured this movement is within the safe operating range and that the cooling rollers move only in reverse direction when the unit is away from the extruder for operator safety.
Project Summary :
- Project completed in 3 months with max 4-day shutdown per line.
- New control panels built using Siemens S7-1200 PLC & TP1200 HMI.
- PID loops optimized for precise barrel temperature control.
- Upgraded with new sensors, safety interlocks, and access restrictions.
- Integrated historical trends and alarm logs for analysis.
- Field cabling replaced with proper tagging and ferruling.
- Commissioned with full training and documentation.
- Achieved 100% client satisfaction, strengthening ties with Jotun.