Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)

Augustine Kweku Mbeah; Erwin Normanyo

doi:doi:10.11648/j.acis.20241204.11

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Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)

Augustine Kweku Mbeah^*

, Erwin Normanyo

Published in Automation, Control and Intelligent Systems (Volume 12, Issue 4)

Received: 9 August 2024 Accepted: 5 November 2024 Published: 26 November 2024

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Abstract

This research results from the need for an effective, reliable, and highly flexible method of control of processes within a small pharmaceutical environment and will be programmed using Ladder Logic programming Language, Siemens Step 7, which entails integrating hardware and software to provide dependable and effective operations. The mixer is controlled through a Supervisory Control and Data Acquisition (SCADA) system and programmed using Ladder Logic in Siemens Step 7 PLC Programming Software. Temperature control, agitation control, and ingredient addition sequences were all integrated by the automated system. The performance of the modeled system is validated through computer simulations. The Batch Mixer is controlled using a Variable Speed Drive (VSD), enabling precise execution of the required processes throughout the entire mixing cycle. Each phase of the process is carefully controlled and monitored, with detailed simulation results demonstrating enhanced performance and efficiency in the proposed batch mixer system, as well as offering a mathematical model of the Batch Mixer and outlining the performance variables that the PLC systems use in detail. As a backup validation tool, Rockwell Automation's RSLogix 5000 PLC is used to verify the validation. The study demonstrates the effectiveness of using Siemens STEP 7 PLC for automation and validation, and with RSLogix 5000 PLC for confirmation of validation, ensuring reliable and efficient pharmaceutical batch mixing operations.

Published in	Automation, Control and Intelligent Systems (Volume 12, Issue 4)
DOI	10.11648/j.acis.20241204.11
Page(s)	71-107
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Automation, Batch Mixer, Human Machine Interface (HMI), Ladder Logic Diagram, Programmable Logic Controller (PLC), Supervisory Control and Data Acquisition (SCADA)

References

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[4]	Harchandani, R. and Bindu, R. Automation of Kiln Mill Drive in Cement Industry using PLC and SCADA. 2014 International Journal of Engineering Research and Technology, Vol. 3 Issue 1, pp. 626-630. https://doi.org/10.17577/IJERTV3IS10251
[5]	Pandey, R. and Bhatt, N. Industrial Burner Automation based on PLC HMI and SCADA. 2015 International Journal for Scientific Research and Development\| Vol. 3, Issue 09, pp. 87-90.
[6]	Setiawan, A., Sugeng, Koesoema, K. I., Bakhri, S. and Aditya, J. The SCADA System Using PLC and HMI to Improve the Effectiveness and Efficiency of Production Processes. 2019, IOP Conf. Series: Material Science and Engineering 550012008 https://doi.org/10.1088/1757899X/550/1/012008 pp. 1-9.
[7]	Mishra, A. “Home Automation using PLC and SCADA. 2020, International Journal of Innovative Research in Electrical, Electronics, Instrumentation and Control Engineering, Vol. 8, Issue 6, pp. 27-32. https://doi.org/10.17148/IJIREEICE.2020.8605
[8]	Howimanporn, S., Chookaew, S. and Silawatchananai, C. Real-Time Evaluation Position Control of Directional Wheel Conveyor Using Fuzzy Embedded PLC and SCADA. 2021 International Journal of Mechanical Engineering and Robotics Research, Vol. 10, No. 6, pp. 328-336.
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[13]	Dhiman, J. and Kumar, E. D. Hybrid Method for Automatically Filling of the Chemical Liquid into Bottles using PLC and SCADA. 2014, International Journal of Engineering Research and General Science, Vol. 2, Issue 6, pp. 1-8.
[14]	Aung, H. H. and Aung, T. T. I. Simulation and Implementation of PLC based for Nonstop Filling Process using PLCSIM and HMI. 2019, IJCIRAS, Vol. 2 Issue. 3, pp. 134-137.
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APA Style

Mbeah, A. K., Normanyo, E. (2024). Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA). Automation, Control and Intelligent Systems, 12(4), 71-107. https://doi.org/10.11648/j.acis.20241204.11

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ACS Style

Mbeah, A. K.; Normanyo, E. Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA). Autom. Control Intell. Syst. 2024, 12(4), 71-107. doi: 10.11648/j.acis.20241204.11

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AMA Style

Mbeah AK, Normanyo E. Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA). Autom Control Intell Syst. 2024;12(4):71-107. doi: 10.11648/j.acis.20241204.11

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@article{10.11648/j.acis.20241204.11,
  author = {Augustine Kweku Mbeah and Erwin Normanyo},
  title = {Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)
},
  journal = {Automation, Control and Intelligent Systems},
  volume = {12},
  number = {4},
  pages = {71-107},
  doi = {10.11648/j.acis.20241204.11},
  url = {https://doi.org/10.11648/j.acis.20241204.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.acis.20241204.11},
  abstract = {This research results from the need for an effective, reliable, and highly flexible method of control of processes within a small pharmaceutical environment and will be programmed using Ladder Logic programming Language, Siemens Step 7, which entails integrating hardware and software to provide dependable and effective operations. The mixer is controlled through a Supervisory Control and Data Acquisition (SCADA) system and programmed using Ladder Logic in Siemens Step 7 PLC Programming Software. Temperature control, agitation control, and ingredient addition sequences were all integrated by the automated system. The performance of the modeled system is validated through computer simulations. The Batch Mixer is controlled using a Variable Speed Drive (VSD), enabling precise execution of the required processes throughout the entire mixing cycle. Each phase of the process is carefully controlled and monitored, with detailed simulation results demonstrating enhanced performance and efficiency in the proposed batch mixer system, as well as offering a mathematical model of the Batch Mixer and outlining the performance variables that the PLC systems use in detail. As a backup validation tool, Rockwell Automation's RSLogix 5000 PLC is used to verify the validation. The study demonstrates the effectiveness of using Siemens STEP 7 PLC for automation and validation, and with RSLogix 5000 PLC for confirmation of validation, ensuring reliable and efficient pharmaceutical batch mixing operations.
},
 year = {2024}
}

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TY  - JOUR
T1  - Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)

AU  - Augustine Kweku Mbeah
AU  - Erwin Normanyo
Y1  - 2024/11/26
PY  - 2024
N1  - https://doi.org/10.11648/j.acis.20241204.11
DO  - 10.11648/j.acis.20241204.11
T2  - Automation, Control and Intelligent Systems
JF  - Automation, Control and Intelligent Systems
JO  - Automation, Control and Intelligent Systems
SP  - 71
EP  - 107
PB  - Science Publishing Group
SN  - 2328-5591
UR  - https://doi.org/10.11648/j.acis.20241204.11
AB  - This research results from the need for an effective, reliable, and highly flexible method of control of processes within a small pharmaceutical environment and will be programmed using Ladder Logic programming Language, Siemens Step 7, which entails integrating hardware and software to provide dependable and effective operations. The mixer is controlled through a Supervisory Control and Data Acquisition (SCADA) system and programmed using Ladder Logic in Siemens Step 7 PLC Programming Software. Temperature control, agitation control, and ingredient addition sequences were all integrated by the automated system. The performance of the modeled system is validated through computer simulations. The Batch Mixer is controlled using a Variable Speed Drive (VSD), enabling precise execution of the required processes throughout the entire mixing cycle. Each phase of the process is carefully controlled and monitored, with detailed simulation results demonstrating enhanced performance and efficiency in the proposed batch mixer system, as well as offering a mathematical model of the Batch Mixer and outlining the performance variables that the PLC systems use in detail. As a backup validation tool, Rockwell Automation's RSLogix 5000 PLC is used to verify the validation. The study demonstrates the effectiveness of using Siemens STEP 7 PLC for automation and validation, and with RSLogix 5000 PLC for confirmation of validation, ensuring reliable and efficient pharmaceutical batch mixing operations.

VL  - 12
IS  - 4
ER  -

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Author Information

Augustine Kweku Mbeah

Marine Electrical and Electronic Engineering Department, Regional Maritime University, Accra, Ghana

Contact Email

http://orcid.org/0009-0003-6276-0507
Erwin Normanyo

Electrical Electronics Engineering Department, University of Mines and Technology, Tarkwa, Ghana

Contact Email

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Plain Text BibTeX RIS

APA Style

Mbeah, A. K., Normanyo, E. (2024). Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA). Automation, Control and Intelligent Systems, 12(4), 71-107. https://doi.org/10.11648/j.acis.20241204.11

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ACS Style

Mbeah, A. K.; Normanyo, E. Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA). Autom. Control Intell. Syst. 2024, 12(4), 71-107. doi: 10.11648/j.acis.20241204.11

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AMA Style

Mbeah AK, Normanyo E. Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA). Autom Control Intell Syst. 2024;12(4):71-107. doi: 10.11648/j.acis.20241204.11

Copy | Download

@article{10.11648/j.acis.20241204.11,
  author = {Augustine Kweku Mbeah and Erwin Normanyo},
  title = {Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)
},
  journal = {Automation, Control and Intelligent Systems},
  volume = {12},
  number = {4},
  pages = {71-107},
  doi = {10.11648/j.acis.20241204.11},
  url = {https://doi.org/10.11648/j.acis.20241204.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.acis.20241204.11},
  abstract = {This research results from the need for an effective, reliable, and highly flexible method of control of processes within a small pharmaceutical environment and will be programmed using Ladder Logic programming Language, Siemens Step 7, which entails integrating hardware and software to provide dependable and effective operations. The mixer is controlled through a Supervisory Control and Data Acquisition (SCADA) system and programmed using Ladder Logic in Siemens Step 7 PLC Programming Software. Temperature control, agitation control, and ingredient addition sequences were all integrated by the automated system. The performance of the modeled system is validated through computer simulations. The Batch Mixer is controlled using a Variable Speed Drive (VSD), enabling precise execution of the required processes throughout the entire mixing cycle. Each phase of the process is carefully controlled and monitored, with detailed simulation results demonstrating enhanced performance and efficiency in the proposed batch mixer system, as well as offering a mathematical model of the Batch Mixer and outlining the performance variables that the PLC systems use in detail. As a backup validation tool, Rockwell Automation's RSLogix 5000 PLC is used to verify the validation. The study demonstrates the effectiveness of using Siemens STEP 7 PLC for automation and validation, and with RSLogix 5000 PLC for confirmation of validation, ensuring reliable and efficient pharmaceutical batch mixing operations.
},
 year = {2024}
}

Copy | Download

TY  - JOUR
T1  - Automation of a Pharmaceutical Batch Mixer Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA)

AU  - Augustine Kweku Mbeah
AU  - Erwin Normanyo
Y1  - 2024/11/26
PY  - 2024
N1  - https://doi.org/10.11648/j.acis.20241204.11
DO  - 10.11648/j.acis.20241204.11
T2  - Automation, Control and Intelligent Systems
JF  - Automation, Control and Intelligent Systems
JO  - Automation, Control and Intelligent Systems
SP  - 71
EP  - 107
PB  - Science Publishing Group
SN  - 2328-5591
UR  - https://doi.org/10.11648/j.acis.20241204.11
AB  - This research results from the need for an effective, reliable, and highly flexible method of control of processes within a small pharmaceutical environment and will be programmed using Ladder Logic programming Language, Siemens Step 7, which entails integrating hardware and software to provide dependable and effective operations. The mixer is controlled through a Supervisory Control and Data Acquisition (SCADA) system and programmed using Ladder Logic in Siemens Step 7 PLC Programming Software. Temperature control, agitation control, and ingredient addition sequences were all integrated by the automated system. The performance of the modeled system is validated through computer simulations. The Batch Mixer is controlled using a Variable Speed Drive (VSD), enabling precise execution of the required processes throughout the entire mixing cycle. Each phase of the process is carefully controlled and monitored, with detailed simulation results demonstrating enhanced performance and efficiency in the proposed batch mixer system, as well as offering a mathematical model of the Batch Mixer and outlining the performance variables that the PLC systems use in detail. As a backup validation tool, Rockwell Automation's RSLogix 5000 PLC is used to verify the validation. The study demonstrates the effectiveness of using Siemens STEP 7 PLC for automation and validation, and with RSLogix 5000 PLC for confirmation of validation, ensuring reliable and efficient pharmaceutical batch mixing operations.

VL  - 12
IS  - 4
ER  -

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