Our client asked us to develop a new in-line blending system for a liquid product that had been previously produced using a batching system. The goal was to reduce inventory by eliminating the need for bulk storage of product before packaging and to increase quality through accuracy of measurement of small ingredients. Due to increased demand for the product, a short development period of less than three months was required.

The Solution

Our engineering professionals delivered a control system solution using an Allen-Bradley PLC 5 and Wonderware InTouch HMI. The system required the use of advanced process control techniques for flow rate calculations and Ethernet communications to integrate this process throughout the client’s enterprise. Our client also required that new programming match existing applications as closely as possible.

The Results

The in-line blending system allowed the client to reduce costs dramatically by moving to just-in-time inventory. Uniformity of products was greatly enhanced with tighter controls on measuring minor ingredients and ensuring a consistent mixture of ingredients.

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