INDUSTRIAL AUTOMATION AND ENGINEERING SOLUTIONS

PLC/PC-based process control and integrated energy management to global competitive standards

For sustainable commercial success in today’s global markets, high product quality alone is not enough. A modern plant’s ability to stay competitive depends directly on maximising operational efficiency and keeping the specific energy consumption and skilled-labour costs to zero. Aware of these dynamics, our engineering department develops complete PLC- and PC-controlled electrical-automation systems that maximise plants’ efficiency, stability and traceability, and — with an experienced specialist team — offers quality, economical turnkey solutions across the design, software, panel-manufacture, installation and commissioning stages.

WORKING PRINCIPLE

MCC and control-panel systems — heavy-duty power-distribution and smart motor control centres: our MCC (Motor Control Center) and control panels, which manage the plant’s mechanical power and application flow, are engineered to run uninterruptedly in the harshest industrial conditions; all switchgear and equipment are selected from products certified to international quality standards and industrial norms, and our industrial panels use our own proprietary switchgear from our manufacturing and R&D, new-generation PLC units and hardware with the latest remote-access applications. Roller-mill control systems — digital smart roll software, synchronisation module: a separate smart control station developed specially for the high-technology roller mills we produce, whose design, hardware design and embedded software (firmware) are coded entirely by our own engineers. Jet-filter control systems — relay-output pneumatic pulse-timer technology: a stable electronic control module that manages the timing and energising of the high-pressure air valves (pulse valves) that clean the bags in industrial jet filters.

KEY ADVANTAGES

- Smart roll-control functional matrix: Precise speed regulation — instantly adjusts the feed motor’s speed, keeping the product-curtain thickness on the rolls uniform; main-motor current analysis — measures the crushing/milling main motor’s current, preventing overloads and tracking energy efficiency in real time; product-dome level control — gives a proportional output by feed-chamber fill, preventing the rolls from running empty and jamming; efficiency tracking and system synchronisation — full synchronous operation of multiple machines and transfer of all data to the main plant control system (SCADA, TSP connect); mechanical-life and periodic-lubrication tracking — extends bearing and gear life and eliminates unplanned stoppages; fault and warning logging — records all fault, alarm and warning codes to memory and notifies the operator, minimising the technical teams’ response time.

- Certified MCC and panel component base: The motor control centres (MCC) and control panels are engineered to run uninterruptedly in the harshest conditions; all switchgear is certified to international standards, while the proprietary switchgear, new-generation PLCs and remote-access tools provide reliability and traceability.

- Modular filter-control voltage options: The filter-control system consists of independently working rigid relay outputs; to suit the plant’s electrical instrumentation infrastructure and engineering preference, the outputs are produced in a flexible 24 V DC or 220 V AC configuration.

- Precise filter pulse parameters (duration & period): Pulse duration — precisely sets, in milliseconds, the open time of the compressed-air discharge (pulse) valves, determining the kinetic force of the air injected into the bag; Pulse period — regulates the time between the pulse cycles of the sequentially working valves, keeping the filter’s total pressure difference in balance.

ENGINEERING NOTE

Our PLC/PC-based industrial automation systems are the most powerful management mechanism for minimising the actively consumed energy index in flour and semolina mills. The mechanical synchronisation provided by the PLC units and roll software in our applications controls and tracks the motors’ start-up (inrush) currents, prevents mechanical faults and manages the raw-material flow with stable steadiness. The millisecond air- and speed-setting precision of the filter-control systems prevents the bags from clogging and allows no pressure drops on the compressor lines, keeping the plant’s overall energy efficiency at its maximum.