Factory Automation

The principle of operation of the factories are essentially the same. It contains exercise of various processes within a specific order to make a final product out of a raw material. Therefore, there are two requirements as the basis in the factory automation. The first scenario is related to the production process, which includes explanation of all the production processes in detail. The second is the customer’s demands. While preparing the automation system, all the spots and processes at the plant, field instruments, motor, valve, piston etc. all elements of the incoming electrical data are evaluated. This data is processed, tracked and used for command control through control elements at automation panels. Panel is displayed by user interfaces like screens. Maintained records are reported and analyzed on a periodical basis.

Therefore, automation solutions can be applied to any type of factory and facility, provided that machinery and equipment is appropriate. Once relevant work scenario and customer demand is known, it can be applied to almost every industrial business only except for specific fields that require special knowledge and experience, which could be performed only by a few automation firms.

Asphalt Plant

Software and hardware projects of asphalt plant automation systems are prepared customer-specifically. To ensure optimum efficiency, it is designed by taking into account factors including customer demands and needs, geographic location, climate and fuel. An advanced automation system is used in asphalt production plants,. All processes starting with raw material stage to the final product can be monitored through SCADA display and be controlled. The system contains a comprehensive prescribing capability. Accordingly, all aggregate, fillers, bitumen and other raw materials and additives can be precisely weighed and dosed according to determined prescription. Requested number of prescriptions are defining for the sake of flexibility. Data that is received from all sensors and receptive instrument can be mirrored to the relevant screen, measurements and calculations can be done. Burner and air system can be controlled via the SCADA. Current, temperature and voltage values related to energy consumption, can be monitored. Packing slip can be printed automatically at the end of production. Tolerance settings can be performed for the filling, lid on-off, weighing, according to the system sensitivity. Production reports can be taken and saved for daily, monthly and annual periods. All data can be monitored through remote access devices over online and mobile platforms.

Ready Mixed Concrete Plant

Concrete plant automation is based on a computer-controlled automatic dosing system. According to the different needs, concrete mixture formulas called prescription can be installed on the system. As the production command given, the formula-related materials (cement, aggregates, additives, water etc.) specific for the mixture are automatically weighed. Process is completed by mixing it in appropriate amounts. All phases are monitored through SCADA system, controlled and recorded starting from the preparation of prescription to transfer of concrete to transit mixer. Bill of parcels can be printed out by the computer at the end of the automatic production process. Dosage automation is the most important element of ready mix concrete plant. Process monitoring, production reporting, alarm monitoring, order management, production planning, inventory control, truck scale, transit mixer monitoring, quality control laboratory reporting, etc. and similar fields, are other elements of ready-mix concrete plant requiring automation. Reports of production statistics, fault records and efficiency analysis can be taken at a daily, monthly, annual periods. Thanks to remote access option, faults and their solutions are identified and production downtime is minimized.

Crushing And Screening Plant

Spread over a wide area, crushing and screening plants are run automatically by a low-cost automation system to achieve a considerable productivity. Also troubles, failures and losses caused from the manual control system are significantly prevented. Thus, in a short period of time, cost and efficiency gains can be achieved. The entire process points in the system are controlled, tracked, reported and recorded. Statistics can be obtained at requested periods; daily, monthly, yearly. By running and stopping the plant in the requested order parametrically, sudden loads on network are blocked and screens and crushers are kept safe. During operation, crushing streams are continuously followed and feeder speed is set. Thus, crusher motors are protected, blockages prevented and an optimal level of work is provided. Thanks to automatic sequential operation, in case of any failure, units feeding the defective portion will be stopped instantly and accretion of raw material is prevented, but crushers are not stopped unless necessary. The system is controlled via the PLC and touch panel. Along with many adjustable parameters, there are manual and automatic running options. It can be monitored through remote access devices over online and mobile platforms, defects can be repaired.

Gypsum Factory

Gypsum factory automation provides fully automatic plaster production. All the processes contained in the plaster production are controlled in an integrated manner so that high efficiency and economy is achieved. Local solutions as well as complete turnkey automation solutions for gypsum factories are offered. For Example; Mobile crushing unit, crushing and screening units, calcination unit, grinding and separation unit, storage unit, dry mixing unit, perlite expansion unit, thin calcite supply unit, lime feeder, coarse calcite grinding and feeding unit, compressed air unit, filter shock units. All points of the system can be monitored in real time. Periodically, daily, monthly, annual reports can be prepared. Data from all types of fault information and field instruments are processed, monitored and recorded in the database. Managing all of these processes with advanced technology compatible automation systems provides significant productivity and efficiency. Besides, the system be monitored through remote access devices over online and mobile platforms and fault detection can be made remotely.

Liwa Engineering offers turnkey solutions based on customer satisfaction, for gypsum factory automation systems. Both the hardware, software requirements, and technical support can be provided to newly established, expanded or revised gypsum plants.

Lime factory automation also has similar characteristics with gypsum factory automation and Liwa Engineering offers complete solutions in both areas.

Feed Factory

Feed factory automation, is an integrated SCADA application that includes a variety of automation modules. These can be listed as dosing / blending automation, micro dosing automation, mill automation, liquid dosing and adding automation, mixing automation, pellet line automation and packaging automation. Mimic diagram of all parts of the feed mill starting from raw material purchasing group including dosing, crushing, mixing and adding molasses, can be viewed on a computer screen. Through software suitable for processes and needs, all spots of the plant are monitored and controlled. The data from field instruments are constantly processed and fully automatic operation of the plant is ensured. All fine-tuning of the system, parameters and calibration can be done via SCADA screen. A comprehensive system is set up with a large number of modules, such as trend graphs for analog signals, user management and authorization, activity log and periodic reports. All information, data and fault records are kept in the database and displayed in the desired time period and in the required format. That enables obtaining production statistics and productivity analyses. Time, speed, and cost advantages are obtained.

The system can be constantly monitored through remote access devices over online and mobile platforms. Also remote technical support service is provided to ensure an uninterrupted flow of production.

Flour factory automation also has similar characteristics with feed factory automation and Liwa Engineering offers complete solutions in both areas.