Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)

This research results from the need for an effective, reliable, and highly flexible method of control of processes within a small pharmaceutical environment and will be programmed using Ladder Logic programming Language, Siemens Step 7, which entails integrating hardware and software to provide dependable and effective operations. The mixer is controlled through a Supervisory Control and Data Acquisition (SCADA) system and programmed using Ladder Logic in Siemens Step 7 PLC Programming Software. Temperature control, agitation control, and ingredient addition sequences were all integrated by the automated system. The performance of the modeled system is validated through computer simulations. The Batch Mixer is controlled using a Variable Speed Drive (VSD), enabling precise execution of the required processes throughout the entire mixing cycle. Each phase of the process is carefully controlled and monitored, with detailed simulation results demonstrating enhanced performance and efficiency in the proposed batch mixer system, as well as offering a mathematical model of the Batch Mixer and outlining the performance variables that the PLC systems use in detail. As a backup validation tool, Rockwell Automation's RSLogix 5000 PLC is used to verify the validation. The study demonstrates the effectiveness of using Siemens STEP 7 PLC for automation and validation, and with RSLogix 5000 PLC for confirmation of validation, ensuring reliable and efficient pharmaceutical batch mixing operations.