Our PLC unit controls a set of input valves, a discharge valve, receives information about the quantity of liquid we’ve sent to the tank (via a simulated flowmeter), displays basic information about the system and allows the operator to send ingredients into the tank. Step 1 - Inputs, Outputs and PLC Program Layout We’ve also implemented a basic HMI design that will aid in the control as well as visualization of the process. In this section, we will take a look at a PLC programming example that controls a tank which is filled with three ingredients. As mentioned above, a mixing tank that receives a set of ingredients is that most basic example of a batch process. To better understand the batch production process, let us take a look at a simple system. Once the run is finished, the production team will sanitize the equipment, enter new batch parameters and start a new run. In other words, customers will typically request a limited quantity of a certain product. Batching allows the factory to control production runs based on demand.This reduces the amount of waste that may be created. Any deviation from the specification sheet allows the plant to discard the batch, eliminate the issues that caused the deviations and proceed with a new batch. As a batch is finalized, QC procedures are applied and the batch is thoroughly tested. SolisPlC GitHub PLC and HMI Files Why is batching important?Īs we had mentioned above, it is possible to create a process in which the end product would be continuously delivered as an output.
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Project Solution, HMI and PLC Files Download Note that although the total weight is the same in both cases, it may vary between batches. A different batch may contain 4500 pounds of water and 700 pounds of syrup. For example, a batch can be defined as 5000 pounds of water and 200 pounds of sweet syrup. In this case, a batch would be the action of creating a specific mixture of the two inputs in the mixing tank. An operator is able to open the flow of water or sweet syrup into the mixing tank. Let us look at the simplest example of a batch:Ī mixing tank has two in-feed pipes coming from a source of water and sweet syrup respectively. It is important to note that although batches are considered to be analog or continuous flow, most of them end up being packaged for consumption which converts them into a discrete manufacturing process.Ī batch is a certain volume of product to be produced in a single run. Although it is possible to design a flow that will continuously output the product, such production is often managed in batches. Examples include the production of beverages, sauces, raw ingredients, etc. An analog production process is where the plant will create a quantity of product that is quantifiable by weight. In other words, a production line may output one item, two items, three items, etc. A discrete process is a manufacturing methodology that will produce separate widgets. Generally speaking, there are two types of processes in manufacturing: discrete and analog.