Manufacturing control solution for coordinating tank farm operations and a new filler line
A leading producer in the plant-based nutrition industry based in Belgium partnered with Contec to integrate its existing tank farm with a newly installed filler line. The objective was to ensure reliable coordination between multiple automation platforms and enable centralized monitoring and control of the production process.
To achieve this, Contec delivered connected Siemens PLC systems, batch management software, and visualization platforms into a single coordinated environment. The result was a fully operational production line with improved process visibility, control, and data logging across the facility.
Key outcomes:
-
Seamless communication between multiple Siemens PLC platforms
-
Integrated batch management and recipe control
-
Alignment with site-specific electrical standards
-
Centralized process visualization for operators
-
Secure multi-user access with role-based permissions
-
Complete process and alarm history through centralized data logging
The challenge
Integrating multiple automation systems into a coordinated production environment
The facility required the integration of several automation systems supporting tank farm operations and a new filling line. The challenge was to establish reliable communication between different PLC generations and software platforms while maintaining clear operator visibility and process control.
Another important requirement was to ensure that operational tasks could be managed through both batch management software and recipe-based production logic. In addition, the system had to support multiple operator stations across the factory and provide a robust historical database for diagnostics and performance analysis.
Our approach
Improving operator visibility and control of production processes
Contec implemented an architecture enabling reliable communication and coordination between multiple automation systems across the production line.
Several Siemens PLCs were interconnected using S7 Ethernet communication, enabling cooperation between SIMATIC Step7 CPU 400 controllers and TIA Portal-based CPU 1500 systems. This communication layer ensured synchronized control of tank farm operations and the filling process.
Operational commands were managed through two complementary systems. A Rockwell FactoryTalk Batch server handled batch-related tasks, while recipes developed within an AVEVA ArchestrA platform-controlled process logic and visualization.
The ArchestrA platform provided centralized monitoring of the installation and distributed visual interfaces to multiple Wonderware InTouch client viewers located throughout the facility. This allowed operators to monitor and control the process in real time from different areas of the plant.
To ensure secure access and clear operational responsibilities, the application servers implemented role-based authentication. Operators, technicians, supervisors, and administrators were assigned different access levels according to the client’s internal policies.
For operational analysis and troubleshooting, the system included a Wonderware Historian server that continuously logs alarms, events, and process data into an SQL database. Through the Historian Trend application, users can visualize historical data and analyze process performance using timeline-based graphical trends.
