food manufacturing plant french fries & vegetable line

The professional automatic potato French Fries & Vegetable

production line is specially designed for processing potatoes &

Vegetables into delicious potato crisps or French fries,

Vegetables and packaging of potato French fries with excellent

quality and less fat pickup.

Food Manufacturing Plant

French Fries & Vegetable Line

Advantages :

• Worldwide accepted technology.

• Customized solution to meet local conditions

• Fully automatic production line

• Low investment and high profitable

• Energy-saving, easy to maintain

• Professional personnel give full-course training for

operators.Capability of Plant Control System

• Condition Monitoring

• Historical data

• X-Y plotting, scalable architecture

• Time, temperature and speed control

• Alarm Event, Sequence events

• Drives & MCC controls

• Instrumentation

Softcon Systems Private Limited enables Industrial facilities to optimally deploy & maintain Control, Process, Power Automation

resulting in enhanced Productivity, Reliability, Safety, Compliance & flexibility of the Customer Asset.

Food Manufacturing Plant

French Fries & Vegetable Line



Area of Control & Monitoring

Vegetable Line

❖ Inspection Conveyor

❖ Belt Drives

❖ Cooler

❖ Blancher

❖ Washer

❖ Shaker

❖ Pre-cooler

❖ Freezer

French fries Line

❖ Brush Machine

❖ After Washer

❖ Trimming Table

❖ Buffer Tank

❖ Cutter

❖ Feeding Shaker

❖ Sleever Remover

❖ Blancher

❖ Fryer

Advanced automation is viewed as a tool that can help to minimize the impacts of operations, maintenance, and capital expenditures including increasing labor, energy, and chemical costs in Water utilities. Complete automation of water treatment plants, where the facilities run unattended for some period of time, is used by many utilities as a cost savings strategy.

Water Treatment Plant (WTP)

Advantages :

• Improve operation efficiency

• Decision-support information

• Enhanced reliability

• Less expensive

• Can be added easily to an existing plant

• Longer-life equipments

Capability of Plant Control System

• Graphical view of the process to the operator

• Historical data for analysis

• X-Y plotting, scalable architecture

• Can communicate from the plant to the remote site


• MCC controls

• Instrumentation, calibration



Water Treatment Plant (WTP)




Pre-Treatment

❖ Dosing Tank

❖ Dosing Pump

❖ Mixer

❖ Clarifier

❖ Holding Tank

❖ Transfer Pumps

❖ Multimedia filter

❖ Iron removal filter

❖ MMF Sequence

❖ IRF Sequence

Treatment

❖ Raw water supply pumps

❖ Bladder tank

❖ Reverse osmosis system

❖ Pre-filtration system

❖ R.O. High pressure Pump

❖ R.O. feed throttling

❖ R.O. Membranes

❖ Reject recirculation

❖ Dosing System

❖ R.O. Cleaning system

❖ Treated water tanks

SCADA is used in control of material transfer through long distance pipelines and also in smaller applications like wastewater treatment. Automation of wastewater treatment facilities saves money and conserves energy. The aim of wastewater treatment is to remove all the pollutants and produce treated water.

Waste & Sewage Water Treatment Plant (STP)

Advantages :

• Labor savings

• Chemical cost savings

• Energy Cost savings

• Maintenance cost savings

• Enhanced reliability

• Longer-life equipments

• Pollution control


• Graphical view of the process to the operator

• Utility Historical baseline data-percentage of savings

• Production data-percentage change in production

• Energy cost data-utility bills

• Utility Labor data-payroll data

• Chemical costs-invoices

• Maintenance data


• MCC controls

• Instrumentation, calibration



Waste & Sewage Water Treatment Plant (STP)




❖ Effluent collection tank

❖ Filter press

❖ Sludge drying bed

❖ Reactor clarifier

❖ Dosing tanks

❖ Filter feed tank

❖ Multimedia filter

❖ Neutralization tank

❖ Micron filter

❖ Ultra filtrate

❖ UF feed tank

❖ Regeneration tank

❖ Reverse osmosis

❖ High pressure pump

❖ Regeneration tank

❖ CIP

An Energy Management System (EMS) is a system of computer-

aided tools used by operators of electric utility grids to

monitor, control, and optimize the performance of

the generation and/or transmission system. The monitor and

control functions are known as SCADA; the optimization

packages are often referred to as "advanced applications".

Energy Management System (EMS)

Advantages :

• Energy and Energy cost savings

• Data can be used to better understand and make decisions

concerning energy use and consumption

• Can develop a policy for more efficient use of energy

• Can fix energy efficiency targets

• Energy efficiency improvements

• Can review the effectiveness of the energy policy• Reduces energy costs and improves profitability

• Understanding between predictable energy demand and

supply

• Gain credible external visibility of energy saving actions.

• Reduces vulnerability with respect to energy price fluctuation

and availability of energy

• Manage energy risks

Control & Monitoring:

• Graphical view of the System to the operator• Real Time Data Monitoring

• Trends – Real Time/ Historical

• Demand graphs• Customized report Generation

• Energy cost data -Billing


• Alarm events, Sequence events

• MCC controls



http://en.wikipedia.org/wiki/Public_utility

http://en.wikipedia.org/wiki/Electric_power_transmission

http://en.wikipedia.org/wiki/Electricity_generation

http://en.wikipedia.org/wiki/Electric_power_transmission

http://en.wikipedia.org/wiki/SCADA

Power management system prevents blackouts and disturbances of your

generation & distribution systems and enhances safety. It improves reliability

of your generation & distribution system and enhances operational &

financial efficiency. Also it ensures maximum power availability and quality.

Power Management System (PMS)

Advantages :

• Prevents Blackouts

• Pre-Load shedding schemes

• Load breaker controls

• Synchronizing breaker controls

• Reduced energy bills

• Improve operation sustainability

• Peak demand management

• Enhances the safety

• Maximum up-time of system

• Utility management

• Maintenance cost savings

• Manage power risks

• Less Man-Power


• Graphical view of the System to the operator

• Real Time Data Monitoring

• Trends – Real Time/ Historical

• Demand graphs

• Customized report Generation

• Energy cost data –Billing

• Utility Data



• Remote monitoring

• Distribution controls



There has recently been a vast improvement in networking technology that has changed very fast which is now feasible for power system automation in the substation. SCADA station acts as master station along with RTUs and microprocessor based intelligent devices IEDs to protect and operate the substations.

Substation Automation System (SAS)

Advantages :

• High availability

• High speed IED to IED communication

• Main Breaker control

• Isolator control

• Auto configurable

• Security support

• Voltage current sample data

• Protection & Control

• Wide area monitoring

• Transformer Monitoring & control

• Reduced outage times

• Maximum asset utilization

• Regulations, standards & policy compliances

• Safety, reliability



• Substation control & Monitoring

• Transformer monitoring

• Protection data & IED configuration

• Disturbance records & events

• Demand graphs

• Customized report Generation




• Remote controls



The fast Consumption of energy resources and contamination of fresh water resources are major areas of concern, with every need to educate the consumer of gas or electric and water utility management. Effective utility management System offers an array of exciting enhancement and improve performance in many critical areas.

Utility Management System (UMS)

Advantages :

• Operational optimization

• Product quality

• Water saving

• Financial viability

• Operational resiliency

• Water resource adequacy

• Customer satisfaction

• Infrastructure stability

• Employee & leadership development

• Improve efficiency

• Reduce operating cost


• Easy integration with existing applications



• More reliable & easy ways to provide data monitoring

• Process data monitoring

• Utility controls

• Batch data monitoring

• Customized report Generation of data




• Remote controls



Protection and Turbine control systems of old design are not up to

the mark to provide current requirements & cost effective

operations. Turbine control systems are the perfect solution to

increase the high availability and enhance operation reliability.

Turbine control System (TCS)

Advantages :

• Operational Flexibility

• High Availability

• Increased life time

• Reduced maintenance cost



• Easy integration with existing applications


• Graphical view & control of the System to the operator


• Governor & AVR controls

• Start-up & shutdown sequence


• Protection & controls

• Measurements & monitoring

• Historical & real time data monitoring & reports


• Remote controls



Turbine control System (TCS)




❖ Governor Control

❖ AVR Control

❖ Auxiliary control oil pump

❖ Auxiliary oil pump

❖ Gland vent condenser

❖ Barring gear motor

❖ LP Actuator

❖ HP Actuator

❖ Oil mist separator

❖ Condensate extraction pump

❖ Emergency oil pump

❖ ESV control

❖ SV control

❖ Oil tank level

❖ Hot well level

❖ Control oil pressure

❖ Trip oil pressure

❖ Temperatures

❖ Lube oil filter

❖ Speed monitoring

❖ Vibration monitoring

❖ Cooling water system

Grease & Lube oil blending plant integrates soap formation reactors,

mixing, thermal fluid transfers. Process automation system combines the

plant-wide control technologies and unmatched scalability of Integrated

Architecture with all the core capabilities expected in a world-class

distributed control system (DCS).

Process Control Solutions(Grease & Specialty Product Plant)

Advantages :• Improve Productivity with better asset utilization and

system performance

• Sequence control

• Batch control

• Recipe management



• Increased system flexibility and technical risk mitigation






• Batch records & reports


• Recipe control & configuration

• Security & safety





• Instruments & calibrations



Process Control Solutions

(Grease & Specialty Product Plant)




Tank Farm Area

❖ MEG tank farm

❖ 500N tank farm

❖ Day tank

❖ Coolant service tank

❖ Day tanks

Utility Area

❖ Steam system

❖ Air compressor system

❖ Thermic fluid heater

❖ Furnace oil tank

❖ Thermic fluid storage

❖ Cooling water distribution

❖ Water distribution

❖ Hot oil expansion

❖ Cooling tower

Process Area

❖ Reactor Control

❖ Kettles

❖ Mixing

❖ Stirring

❖ Heating/Cooling

❖ Pressure control

❖ Weighing System

❖ Transfer system

❖ Filling

Distillation is one of the most common liquid-liquid separation processes,

and can be carried out in a continuous or batch system. Process

automation system combines the plant-wide control technologies and

unmatched scalability of Integrated Architecture with all the core

capabilities expected in a world-class distributed control system (DCS).

Process Control Solutions (PCS)Distillation Plant

Advantages :

• Improve Productivity with better asset utilization and

system performance

• Continuous process control

• Automatic operation









• Process records & reports








• Instruments



Process Control Solutions (PCS)

Distillation Plant




❖ Liquefaction

❖ Fermentation

❖ Beer stripper column

❖ Vent scrubber column

❖ ED column

❖ Rectification column

❖ Polishing column

❖ Recovery column

❖ Decantation

❖ Utility system

❖ Cooling water tower

❖ Soft water system

❖ Water storage

❖ Product storage

❖ Grain handling & milling

system

❖ Evaporation system

❖ Boiler

To meet the FDA requirements, and to replace a manual system, the S88

standard of the Instrumentation, Systems, and Automation Society (ISA)

defines a common set of models and terminology that can be used to

describe and define batch manufacturing systems in accordance with GMP.

The modular batch automation’ methodology breaks down each

manufacturing module into a pyramid of smaller and smaller process steps,

known (in descending order) as ‘procedures’, ‘unit procedures’,

‘operations’ and ‘phases.

Process Control Solutions (PCS)Pharmaceutical Processing Plant

Advantages :

• Batch process control

• 21 CFR Part 11 compliant automation system

• Audit logs

• Electronic records & e-signatures

• Reduction in regulatory compliance cost

• System validation

• High Availability, better asset utilization

• Improve productivity




• Improved efficiency




• Batch records & reports







• Alarm events, Sequence events, Audit logs, e-signature



Process Control Solutions (PCS)

Pharmaceutical Processing Plant




Process

❖ Charging

❖ Level control

❖ Agitator speed control

❖ Heating

❖ Mixing

❖ Dissolution

❖ Make up

❖ Cooling

❖ Transfer

❖ Part transfer

Pressure Holding Test

❖ Pressurization

❖ Stabilization

❖ Holding

SIP

❖ Sterilization

❖ Sterilization Holding

❖ Jacket cooling

CIP

❖ 3/5/7 Step CIP

❖ Level control

❖ Recirculation

❖ Conductivity

❖ Air blow

The boiler control which is the most important part of any power plant,

and its Automation. The automation process helps the company having the

power plant to reduce the amount of errors that occur , reduction in the

human resources, increased efficiency, and most importantly very cost

effective.

Boiler Automation System

Advantages :

• Easy to operate


• Safe operation

• Efficiency Analysis


• Feeder control, Fuel control

• High Availability, better asset utilization



• Increased system flexibility


• Environment Safety, reliability



• Closed & open loop controls










Boiler Automation System




❖ Damper Control

❖ Burner control

❖ Fuel control

❖ Super heater

❖ Evaporator

❖ Economizer

❖ Condensate preheating

❖ Feed water

❖ LP dosing system

❖ HP dosing system

❖ Drum level control

❖ Deaerator

❖ Expansion tank

❖ Make up tank

❖ PRDS

❖ Steam flow

❖ Steam temperature

Material Handling & conveying system is making vital roll in any

production industry and this is necessary & significant component. Now

days many of the production industries are deploying automated

material handling & conveying systems to reduce transportation, man

power cost & safe operation.

Material Handling & Conveying System

Advantages :

• Reduced damage of material

• Reduced man power

• Reduce overall cost

• Minimize accidents with safe operation


• Ensure the quantity & right placement of material

• Timely transport






• Automated controls


• Graphical view of the system



• Customized production reports








❖ Transfer

❖ Packing

❖ Storage

❖ Pick & place

❖ Grading

❖ Weighing

❖ Counting

❖ Stacking

❖ Lifting

❖ Loading, Unloading

❖ Quality

Automation in automotive assembly lines is most beneficial to meet the

today's demanding output schedules. Useful to achieve quality, increase

the availability of machines, better performance and speed of

production by means of automation processes. To achieve the specific

application requirements like transporting of vehicle chassis, conveying

systems & robots automation is key to automotive industry.

Automotive System

Advantages :

• Reduced man power

• Reduce overall cost

• Minimize accidents





• Saving of space & energy



• Automated controls

• Monitoring equipment downtime causes

• Root cause analysis

• Production data & event collection

• Graphical view of the system



• Customized production reports








❖ Assembly line

❖ Transfer

❖ Welding operations

❖ Cutting operations

❖ Mounting

❖ Machining

❖ Casting

❖ Assembling Components

❖ Pressing

❖ Molding

❖ Framing

❖ Painting

❖ Loading, unloading

❖ Inspection

❖ Quality

food manufacturing plant french fries & vegetable line

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