Chemicals: FSI Controls the Mix with Unitronics Controllers + Remote Operator

When FSI, a fast-growing company in the polyurethane sector, wanted to implement a new batch mixer that could be controlled via mobile—turning to Unitronics was a natural choice.

Summary

FSI needed a reliable controller that could implement recipes for polyurethane production, that supported communications with the devices used to run batches—and that could be easily accessed and controlled via mobile. Partnering with Unitronics brought them all that and more.

The Company

FSI was started in 1972 in a suburban home. Quickly expanding into an industrial environment, the innovative mindset of its founders led them to pioneer a number of industry firsts in the field of polyurethane systems. These include the first computer-controlled “in-line” blender, the first patented CFC-free rigid foam technology, the first developed systems using HFC-134a—and FSI preempted regulatory mandates with its early introduction of Ecomate®, an environmentally sustainable blowing agent technology and the first high-performance zero-GWP, VOC-free blowing agent on the market.

Today, as a leading independent provider of polyurethane systems with an international presence, FSI is at the forefront of technology development in its sector.

The Challenge

Jeff Havlin, a controls engineer with FSI, needed to develop control for a semi-autonomous chemical batch making mixer. The application had to support remote access and control of the mixer via mobile. In addition to recipe support, communications were a key factor; the PLC chosen for the task would need to integrate with the existing system.

The Solution

Mr Havlin chose a Unitronics’ Vision 700 PLC + HMI installed with snap-in I/O modules for control and communications, and the Unitronics Remote Operator mobile app enables operators to view, access, and control the system via cell phone.

The V700 provides the ability to run batch recipes, which can be configured—and edited on the fly—via secure Remote Operator.

Integrating perfectly with the existing system, the V700 communicates with the bulk tanks that automatically supply chemical fill, pneumatic ball valves and solenoid valves, and communicates with system pumps via a 0-10v analog signal, as well as with the Rice Lake 1280 scale that measures the weight of chemicals used in a batch via Modbus TCP.

Benefits

FSI was able to increase productivity by using the Remote Operator application, which frees the operator to do other tasks, while monitoring the batch making process with utmost confidence.

In addition, the ability of the V700 to easily communicate with multiple scales via a Modbus TCP connection enable FSI to use a single indicator with multiple scales, saving time, money and space.

The compact design of the Unitronics V700 PLC + HMI + snap-in I/O modules both saved space and reduced wiring, while offering great versatility via both analog and digital inputs and outputs.

Engineer Havlin reported:

“ The combination of a Vision PLC + HMI + snap-in I/O, combined with Unitronics Remote Access app, saves us time, and money—while simultaneously boosting production.”