Related Case Studies
Case Study: Solution for the Paint Market
One of the largest producers of paints and coatings in the world was facing numerous issues including product traceability, quality control, rebatching, operator traceability, inventory control, and reconciliation. The more costly and hazardous solvents required tighter controls.
The company compiles their raw material paint resins and solvents into large mixing tanks. Mixed materials are then analyzed against recipe specifications for quality control. Upon approval the finished product is made available to the container production line for filling of 5-gallon pails.
The compilation of raw materials is supported using a set of 7 positive displacement meters, mechanical preset registers, set-stop valves and diaphragm pumps. The operators manually connect the raw material tanks to the mixing tanks using hoses. There are as many as 29 raw material tanks storing both resins and solvents.
Once connections are verified, gallons are preset on the mechanical register and the operator starts the pump for delivery of raw material through the meter into the mixing tank. Operators are responsible for delivering the specified number of gallons of each raw material component for the given recipe. As many as four operators may be charged with delivering raw material batches into mixing tanks at any given time. For a given recipe, each of the 7 meters may be connected to any of the 29 raw material tanks, depending on the specification and prescribed order of delivery.
Upon meeting with the client and learning their process, Toptech worked in conjunction with LC distributor Liquitrol to propose 2 solutions.
Option #1 would use a batch control scheme utilizing 4 MultiLoad II’s and FCM II’s to control the 7 PD meters outfitted with pod pulsers. The 4 MultiLoad II’s would share the 7 meters and each meter would be assigned to a preset in each MultiLoad. Toptech’s engineering team designed a control scheme to allow one of the four MultiLoad II’s to control one or all of the 7 meters independent of all other MultiLoad II’s. The flexibility of MultiLoad II’s Inputs/Outputs and control logic paved the way for this innovative solution.
Option #2 was a more simplistic approach utilizing 7 MultiLoad II SMP’s; one for each meter.
Both options allowed the batching operators using system Access IDs to preset batches and deliver precise batch amounts into the mixing tanks. The MultiLoad II’s would be logging the batching activities of all operators and each transaction could be reported out to plant management for tracking and control.
The MultiLoad II system was successfully lab tested by plant personnel for Modbus communications to satisfy requirements for reporting and supervision of the control system. Upon completion of testing and product evaluation, plant management decided to move forward with Option #2 due to ease of implementation and a lower overall cost to the project for materials and labor.
This project is ongoing. Please check back often to read the results of the install.
Products used in case study
Related case studies
- One of Toptech’s global customers was using a homemade system designed to validate data from TMS5…
- One of the global leaders in oil and gas approached Toptech with a problem. The time from signing on…
- One of the largest railway companies in North America was losing accountability of fuel between trucks…