Detergent production line-recipe control, dosing, and process monitoring

+40 752 296 086

+40 753 104 251

+40 753 104 252

idustrial@automatix.com

Intro:

I developed a complete automation system for a liquid detergent factory, designed to precisely control the dosing, mixing, and homogenization of chemical substances according to the selected recipe.
The goal was to create a fully automated, safe, and flexible process that guarantees consistent product quality.

General Description:

‍The process starts from a main 20-ton tank where various substances are combined to obtain the desired detergent.
The operator selects the recipe directly from the HMI interface, where parameters such as:
• mixing time,
• homogenization duration,
• resting period for composition stabilization,
• type of fragrance or additive added,
can be adjusted.

Mixing is performed either by a high-power agitator or by recirculation pumps, automatically controlled depending on the recipe type.The entire substance flow is controlled through a network of pneumatic solenoid valves monitored in real time by the PLC.

For process control and safety, we integrated:
• pressure sensors,
• flow sensors,
• precision flowmeters,
all permanently monitored both automatically and on the HMI, with alarms and notifications for any deviation from normal parameters.

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HMI Interface and PLC Programming:

‍The system is entirely controlled by an industrial PLC, fully integrated with an intuitive and graphical HMI interface, allowing:

real-time visualization of process status and measured values (pressure, flow, rate),
adjustment of production parameters based on operator access level,
monitoring of mixing, homogenization, and fragrance-adding stages.

‍The system manages over 10 different recipes, each with unique sequences and timings.

Complete Implementation:

‍Our team ensured the full implementation of the project, from concept to final commissioning:

design and construction of the electrical diagram and automation panel,
PLC and HMI programming,
installation and complete on-site wiring,
integration of sensors and flowmeters,
testing, calibration, and final commissioning.

Some processes are fully automatic, while others include controlled pause stages for sample collection and quality verification.

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Results and Benefits:

Complete automation of the detergent production process;
Precise control and continuous monitoring of pressure, flow, and substance transfer;
Ability to quickly define and modify recipes;
High safety and traceability;
Significant reduction of manual interventions and risk of human error.‍‍