Confidential Batching System
F. BALL AND CO. LTD.
F. BALL AND CO. LTD.
Cheddleton, Leek
Confidential
Chemical
System Integration & Commissioning
F. Ball and Co. Ltd. is the UK’s leading manufacturer of specialist flooring adhesives and floor preparation products for the contract flooring industry.
CXControls were engaged to design and commission a chemical batching control system at F-Ball’s manufacturing site.
“CXControls were diligent in understanding our requirements and successfully delivered a fully functioning control system which meets our expectations and supports our investment in additional manufacturing capacity.
CXControls now support our site wide control systems under a Service Level Agreement.”
The system encompassed a fully integrated control system with a central six-metre panel suite, housing all VSD drives and a PLC section.
The CXControls team integrated a centralised Siemens S7 CPU 1515 F-2 PN PLC with several distributed ET200 I/O stations on the plant. Functional safety to SIL2 compliance was achieved using Siemens fail-safe I/O cards and Profisafe communications.
The SCADA system utilised WINCC flexible on 5 Siemens TF1500 HMI’s.
CXControls provided a fully integrated system that improved manufacturing quality, batching times, and efficiency.
CXControls implemented a bespoke recipe control system, enabling the client to run batches in parallel and eliminate variability, resulting in improved batch times and more repeatable product quality.
Recipe-controlled mixing phases, combined with inverter controls, have enabled the client to reduce energy usage by running agitators only when required and at optimum speeds.
CXControls continue to support F-Ball’s site wide control systems under a service level agreement, ensuring that the system is maintained and operates at maximum efficiency.