Advanced PLC-SCADA System for Toxic Solvent Mixing Process Control and Monitoring

Industries that work with dangerous solvents struggle with control of level, flow, and consistency as a result of the high toxicity of these solvents. This study, aims to solve these problems, using a Programmable Logic Controller (PLC) equipped with SCADA. The study objective is to develop and deploy an intelligent monitoring and controlling system for toxic solvent mixing processes based on PLC and WinCC. This system is designed for pharmaceutical, chemical, food, and beverage industries. It contains sensors for flow rate measurement and temperature control, as well as actuator control, which allow managing processes with high precision while minimizing risk exposure and involvement of people. The system has both automatic and manual Clean-In-Place (CIP) hygiene procedures. The system also has visualization and alarming features that guarantee control of processes flow, and WinCC enhances product quality and process effectiveness while assuring operator safety and cleanliness of equipment. This system is designed in a way that makes it easily adaptable, flexible, and allows integration with other system.