Batching Solution
Problem
A leading plastic-engineered solutions company was in need of a significant upgrade to their aging batching system. The existing setup had become a bottleneck for production due to its lack of flexibility and an inefficient recipe entry process that made day-to-day operations cumbersome and time-consuming. Moreover, the system offered little to no historization of batch data, limiting the company’s ability to troubleshoot issues, analyze trends, or ensure quality consistency over time.
Compounding these software and control limitations were hardware-related issues—specifically, ongoing problems with the physical control panel and unreliable solenoids. These components were not only outdated but also contributed to inconsistent batch performance and frequent system downtime, hindering overall plant efficiency.
Recognizing the critical need for a comprehensive upgrade, the company sought a solution partner who could provide a complete, turnkey system. Their ideal partner would oversee every aspect of the project—from the removal and disposal of the existing control panel to the design, installation, and commissioning of a modernized system tailored to their operational goals.
Beyond installation, the company also emphasized the importance of long-term reliability and support. They were looking for product enhancements that would significantly improve batch accuracy, reduce operator intervention, and provide robust data tracking for quality assurance and process optimization. Ultimately, they needed a partner capable of delivering a solution that would not only meet current needs but scale with future production demands.
Proposed Solution
Chordata Batch was selected as the ideal solution due to its flexibility and powerful control capabilities. It provided an intuitive recipe interface, comprehensive historization, and real-time tracking of batch parameters. Additionally, our offer of ongoing maintenance support ensured direct access to the software developers, allowing for quick resolution of field questions and requests.
The system was designed with a dual-platform architecture, integrating Rockwell PLCs with an Ignition front-end. This combination provided a robust, scalable, and user-friendly interface that enhanced accessibility and control over the batching process.
Outcome
The project was a resounding success, leading to significantly more efficient batch processing and intelligent, dynamic recipe control. The upgraded system unlocked a range of capabilities that were previously unattainable, enhancing both operational performance and process flexibility. Key improvements included:
- Conditional Pausing: The system can now pause operations automatically based on real-time process variables—such as temperature thresholds, pressure levels, or flow rates—ensuring greater safety, product consistency, and reduced waste during abnormal or out-of-spec conditions.
- Dynamic Raw Ingredient Selection: Operators can adjust recipes in real time based on inventory availability, quality parameters, or production needs. This feature improves material utilization, reduces downtime caused by stockouts, and enables agile responses to changing production demands.
- Comprehensive Data Tracking: End-to-end process data—spanning ingredient inputs, process steps, and final outputs—is now captured in a structured format. This enables improved traceability, easier regulatory compliance, and more informed decision-making through detailed trend analysis and reporting.
With these advancements, the company has realized enhanced operational flexibility, increased production efficiency, and a scalable foundation for future growth. The solution positions the batching process to meet evolving business and compliance demands while supporting continuous improvement efforts.
Testimonial
“We hired Polaris Automation to upgrade our SMC Mixing system with Chordata Batch. Polaris did a superb job from the very beginning of the project where they gathered information from the existing system to the very end where they fine-tuned the final system. Their support for the system today is unmatched by any other Integrator.”