Challenge
A beverage plant needed a complete control system for its syrup preparation. The radial jet mixing system had to fill its mixer tanks and circulate the syrup at a controlled pump speed for a set time. It also had to work with the plant's CIP system, all operated from a screen at the tank.
Solution
We designed the control system around a Siemens S7-1200 PLC with I/O modules and two Yaskawa VFDs. A Siemens SIMATIC HMI sits at the tank, in a stainless-steel enclosure with an emergency stop. The PLC runs the process sequence in automatic mode: filling of the jet mixer tank, circulation against a time setpoint, and control of the process valves.
The VFDs control pump speed, and the HMI shows the speed setpoint and actual value next to the live tank level. The CIP-ready status is used as an interlock and shown on the screen, and alarms are reset from the HMI.
We integrated the instruments and I/O, including a pressure switch, then tested and commissioned the system and optimized the process on site.
Scope of work
- Control system design
- Control panel with a Siemens S7-1200 PLC, I/O modules and two Yaskawa VFDs
- Siemens S7-1200 PLC programming
- SIMATIC HMI screens for the jet mixer tanks
- Filling, circulation and valve sequence in automatic mode
- Pump speed control with setpoint and actual value
- Tank level, circulation timers and CIP-ready interlock
- Instrumentation and I/O integration
- Testing and commissioning
- Troubleshooting and process optimization
Result
The syrup preparation system runs its filling and circulation sequence automatically, and operators follow pump speed, tank level, circulation time and interlock status on the HMI at the tank.
