Success stories
Softening Water Treatment Plant, for Liquor Factory
Challenge
Treatment of Drinking Water to reach the maximum acceptable values from a microbiological point of view acceptable for human consumption, for the preparation of Liquors and alcohols.
Solution
Dechlorinator: The water intended for the preparation of liquors must be free of residual chlorine.
Softener: Drinking water should be used to hydrate alcoholic beverages; This must be distilled, demineralized and softened
Disinfection: The microbiological characteristics of water for human consumption must be framed within the following maximum acceptable values from the microbiological point of view, which are established taking into account the 95% confidence limits and for techniques with detection ability from 1 Unit Colony Forming (CFU) or 1 microorganism in 100 cm3 of sample.
pH adjustment in Preparation water: It is necessary to reduce the possibility of chemical reaction between the water constituting the liquor with the glass container, using water with a pH around 7.0, for which it is necessary to measure the value and of It may be necessary to adjust it automatically by adding acetic acid, without exceeding the value allowed in the standard.
Result
Purification of water, suitable for human consumption, under the norms and standards required for the preparation of Liquors and Alcohols.
Product Preparation System
Migration Control System for obsolescence, product preparation system and level control of packaging tanks and flow measurement system from return tanks to preparation and then to packaging, with control of product losses.
Product Preparation System – Ceramic Industry
Challenge
Product Standardization, Paste for manufacturing Ceramic Electrical Insulators, to reduce breaks and cracks in the finished product by a high percentage.
Solution
Implementation of SCADA supervision and control system, for Formulation, input parameters through recipe books, editable only by Quality personnel, protected with a password to guarantee that they are modified, only by qualified personnel.
Result
Achieve a reduction in breaks and cracks in the Product, in the following stages of the process, also integrating the next step, the automatic preparation in Product Preparation Vats.
Ceramic Production Plant Pumping Supervision
Challenge
Product standardization, through Control and Supervision of input supply pumps, for each process line or Ceramic Production unit.
Solution
Design and Implementation of SCADA System (Supervisory Control and Data Acquisition), to increase Reliability, with the constant collection of DATA, optimizing the time in opening and closing operations of process valves, turning on and off of pumps, for carrying out timely transfers, availability of raw materials on site and Level Control and Inventory of inputs and/or raw materials available for production.
Result
Redundant high availability SCADA system, with provision for future expansions with the aim of reducing development times and costs. The product is standardized, optimizing failure control, reducing downtime of pumps and measurement and drive equipment on the plant floor.
Liquor Factory Product Preparation System
Migration Control System for obsolescence, product preparation system and level control of packaging tanks and Flow Measurement and Control system from return tanks to preparation and then to packaging, with product loss control.
PTARC Water Neutralization Plant, Textile Production Plant
Neutralization of the water discarded from the process, so that it can be reused or poured into the river, through gas hydrocompression, with PH measurement at the exit of the Reactor, to determine controller actions.
Product preparation system Fiberglass Reinforced Polyester Pipe Production Plant, with a specialized Weighing System.
Challenge
Product preparation in DayTank, based on RESINS and STYRENE, for daily consumption, in the Reinforced Polyester Pipe and Accessories Line, Flowtite Technology.
Solution
Design and Implementation of a specialized SIEMENS Static Weighing System and Creation of Recipe Books, for the standard preparation of raw materials to be used in the daily production of Reinforced Polyester Pipe.
Result
Product preparation control system for daily potholes, and integration to the FLOWTITE Pipe production line, achieving inventory control and supervision in hoppers of up to 50 tons of resins, styrene and sands. With online plant supply, facilitating product calculations on the fly.
Weighing System for Finished Product Output Pipe – Free Zone Exit Parque Central - Cartagena
Commissioning on site for Weighing Platform in Patio, Finished Product Production Plant, Polyester Pipe reinforced with Fiberglass. Record of Product Exit from the Parque Central Cartagena Free Zone, with real-time information feed to the Oracle ERP platform.
Buenaventura Center Pumping Station
Wastewater and Combined Water Control System, at the Hydropacific Center Pumping Station in Buenaventura. Buenaventura Sewer.
Cutter – Post Puncher in Reinforced Fiber and Polyester, on Production Line – Cartagena
Online Cutting and Drilling System, Tip cutting with Saw, with 360° movement and movement or advance synchronized with the Post in manufacturing.
PTARI Water Treatment Plant – COB: Bancolombia Operations Center
Water Treatment Plant, with Chlorine Analyzer, supply and Control, Water Treatment and Washing with Filter saturation control. pH measurement and control.
Sending Real-Time Temperature Data from Ceramic Kiln
Sending data via Ethernet or USB memory. BigData of Temperature, Set Point and Drag Set Point, with dates and times to monitor product Quality, Product burning kilns – In Ceramic plant (Naber Kiln)
Electric Conditioners for Paste Cylinders
Implementation of an Electrical Conditioning System for controlled drying, even throughout, guaranteeing homogeneity of its humidity, according to Recipe Book for different types of References, by Times and Temperatures, Ceramic Plant. This is to reduce the failure or breakage of the Cylinders before moving on to the Piece Forming Lathes.
Tank Forming Machine - Vertical Filament Winding (Cylindrical Propeller)
Technological Update CONTROL SYSTEM of the vertical Filament winding machine, guaranteeing correct operation for the manufacture of cylindrical tanks of Polyester reinforced with fiberglass, in different diameters, heights, bandwidth and angle.
Sending Real-Time Temperature Data Ceramic Oven
Challenge
Sending data via Ethernet or USB memory. BigData of Temperature, Set Point and Set Point of Drag, with dates and times for monitoring Product Quality, Product burning kilns – In Ceramic plant (Naber Oven)
Solution
Implementation of HMI Operation Panel with communication networks such as 4G LTE, 5G and WIFI, for messaging applications and data train sending.
Result
Sending Data Train (Temperature, Process Variable, Process Set Point, Alarm Buffer, Date and Time) in Real Time to the Production Plant Server computer.
Electrical Conditioners for Paste Cylinders, for Ceramic Production
Challenge
Reduce the failure or breakage of the Paste Cylinders, before moving on to the Cold Forming Lathes, of virgin Ceramic Pieces.
Solution
Implementation of an Electrical Conditioning System for controlled and even drying throughout, guaranteeing homogeneity of its humidity, according to the Recipe Book for different types of References (Sizes), by Times and Temperatures, Ceramic Plant.
Result
Reduction of breakage of the Paste Cylinders, before moving to the Cold Forming Lathes. And a high percentage decrease in breakage of finished ceramic pieces, when leaving the kiln, at the end of production.
SAP Notification to Brazil Renault Vehicle Assembler
Challenge
Real-time notification, entry of Just in Time Cabs, by Individual Manufacturing Order of the Vehicle to be assembled at the Renault Envigado Colombia Plant to Brazil Directive.
Solution
A POKAYOKE system is implemented, with SIEMENS PLC, connected to the SAP System of SOFASA S.A.
When the operator enters the OFI, Individual Manufacturing Order, using a barcode gun, the SAP system captures various data such as:
a) Type of vehicle.
b) Engine Type.
c) Country
d) Lot
e) Cabin number in the Lot.
If the car is attempted to mount the line without notification, the hoist will be locked and a rotating, motorized red beacon will be illuminated. Indicating that there was no notification.
If in the Painting unit, the cabin was not notified and therefore it does not appear in the SAP, it will also block the hoist indicating the cabin not notified.
Result
Correct NOTIFICATION in real time, with reduced possibility of error, POKAYOKE system in Connection to SAP. Upon entry of each cabin to be assembled on the SOFASA Envigado Colombia production line. Notified to Colombia and Brazil.
Tank Forming Machine - Vertical Filament Winding (Cylindrical Propeller)
Challenge
Technological update of the CONTROL SYSTEM of the vertical Filament winding machine, guaranteeing correct operation for the manufacture of cylindrical tanks of Polyester reinforced with fiberglass, in different diameters, heights, bandwidth and angle.
Solution
Taking into account the physics of the cylindrical propeller. Helices can be understood as the three-dimensional version of spirals, and are caused by the simultaneous rotation and translation movement of a point around an axis.
The stretch of helix included in one complete turn of the curve is called a turn. The height of a turn is what is known as the pitch of the helix. There are different types of propellers depending on the movement with which they are generated.
Result
Updating the Control System for vertical Filament winding machine, with electronic equipment, new generation. With the capacity to manufacture Tanks from 4000 mm to 25000 mm in diameter and up to 8000 mm in height. Scope for exchange or reuse, taking into account the following main components:
- Vertical Winding Rail
- Reciprocating Cart
- Immersion Tank
- Rotating table
- Electrical Resin Supply System
- Thread Rack Control
AUTSOLUTION offers various automation solutions from unit devices to process control in order to effectively operate in industrial environments.
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