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McEnery Automation Completes Liquid Soap Expansion

Close coordination with our customer’s project team resulted in a successful expansion of a liquid batch process. McEnery Automation was selected by a private label manufacturer of body and hair care products to provide process control system integration for a project that would increase plant capacity of soaps and shampoos by forty percent.

The project added two new batch manifolds, three new batch tanks and product delivery to one new packing line, all of which needed to be implemented in a phased approach while the plant continued running a full production. Integrating with the existing raw material and finished product storage manifolds and piping without a production outage increased the project’s complexity and required close coordination between McEnery Automation and the customer’s team. Working without a production outage required McEnery Automation to “get it right the first time” by investing time early in the project to understand and document the details of the process operation, and then work with the customer to thoroughly test and simulate the changes off line. McEnery Automation engineers coordinated and supported FDA validation with the customer.

The control system used Rockwell Automation’s PlantPAx Modern DCS, including FactoryTalk Batch, eProcedure, FactoryTalk ViewSE and FactoryTalk Historian. Class-based recipes allowed the same recipes to run on all manifolds, even though the equipment configurations varied among the manifolds. The scalability of FactoryTalk products allowed for efficient expansion of the control system architecture and licensing.