Overview
Sopura, a leading chemical manufacturer based in Queensland, faced challenges in their batching process. Their existing system relied heavily on manual operations and PLC controls, which proved inefficient and prone to human error. To enhance productivity and ensure precision in their batching operations, Sopura turned to NWI Group.
NWI proposed the implementation of Minebea Intec’s Batch-PMS software, complemented by high-accuracy load cells and a robust process indicator. This case study explores the successful deployment and the transformative impact it had on Sopura’s manufacturing processes.
Challenges
Sopura needed to batch multiple products accurately and efficiently to produce a variety of chemical recipes. Their reliance on a PLC-controlled system and manual input by staff posed several challenges:
Inefficiency and Inaccuracy:
Manual operations were time-consuming and prone to errors in measurement, leading to inconsistencies in product quality.
Harsh Environment:
The chemical manufacturing environment at Sopura was particularly harsh, necessitating equipment that could withstand corrosive conditions.
Need for Automation:
Sopura sought a solution that would automate the batching process, reducing dependency on manual labor and minimising the risk of human error.
System Integration:
The new solution needed to seamlessly integrate with existing network and system structures for smooth operation and data management.
Solution
To address these challenges, NWI Group implemented Minebea Intec’s Batch-PMS software, along with the following key components:
Batch-PMS Software:
This software offers modern process control technology, including multi-user operation and integrated process visualisation. Its modular performance spectrum supports both simple and complex batching processes, ensuring seamless integration into existing systems.
Key features include:
- Process control
- Production management
- Recipe management
- Data management
- Integrated backup functionality for data security.
PR6212 S/S Load Cells:
These stainless steel load cells are corrosion-resistant, providing high accuracy and extreme durability in the harsh chemical manufacturing environment. The easy installation with mounting kits was a significant advantage.
Maxxis 5 Process Indicator:
Combined with the batch software, this process indicator can control up to 12 inputs and 8 outputs, facilitating customised batching solutions tailored to Sopura’s needs.
Challenges
The implementation of Minebea Intec’s Batch-PMS software by NWI Group transformed Sopura’s batching process, addressing key challenges and enhancing overall operational efficiency. The combination of high-accuracy load cells, robust process indicators, and advanced software automation proved to be a winning solution for Sopura’s demanding manufacturing environment.
This case study exemplifies how innovative technology and strategic partnerships can drive significant improvements in industrial processes, leading to greater productivity and reliability.
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Learn more about Minebea Intec’s PMS Batch Weighing system and request a quote here.
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