Mixing plant
Process visualisation for mixing plants shows mixing speeds, mixing times, recipe ratios and alarms on dashboards in real time. Operators spot deviations immediately rather than at the end of the shift and document every batch completely.
Mixing plant at a glance
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Verified projects featuring Mixing plant
Smart factory without code – six lines integrated, from SCADA to dashboard
Pharma 4.0 made easy: IT/OT integration for safe, smart GMP solutions
Efficiency boost through process visualisation and monitoring in chemical production
Digital services and after sales in special machinery
Customer portal improves customer communication and project management
Process visualisation for mixing plants: spotting deviations at once
In the solution examples, the data comes from existing control systems. At an Indian food manufacturer, a Kepware OPC server takes the values from the ABB control system to Itanta's no-code platform, which visualises mixer and cutter speeds or flour-to-cream ratios and reports deviations via an app. In pharmaceutical production, sensors record temperature, pressure, mixing time, viscosity and fill volume. secunet edge secures the data as a gateway at each site, and the Orchestra low-code platform from soffico brings it together for quality management. In chemicals, Daubert works with GENESIS64, Hyper Historian and WebHMI from ICONICS, while machine builders such as RAMPF and the HESS GROUP use the EquipmentCloud from Kontron AIS.
The examples come from food, pharmaceutical and chemical production and from special machine building. Daubert Chemical started small with ICONICS at 75 tags and is now at 5,000, and the number of unresolved problems has fallen by 75%. The pharmaceutical company uses batch management to document every production step for each batch, which makes GMP compliance easier to demonstrate. RAMPF Production Systems, a supplier of mixing and dosing systems for liquid adhesives, supports its customers via a customer portal from planning through to service.
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Process visualisation for mixing plants: frequently asked questions
How is data from a mixing plant's SCADA system visualised?
An analytics platform reads the data from the existing SCADA or control system via standardised OPC protocols and displays it on dashboards. This is how an Indian food manufacturer used Itanta to connect six lines, from mixing to packaging. Manual data entry was completely replaced by real-time logging. A dedicated dashboard for the mixing process shows shift supervisors the key figures live, reports are generated automatically, and all of this without a single line of code.
How is batch traceability achieved in pharmaceutical production?
It works when every production step is documented automatically and tamper-proof for each batch. At a pharmaceutical company, mixers, granulators and tablet presses supply the process data, including temperature, pressure, mixing time and viscosity. secunet edge transmits it in encrypted form, and Orchestra from soffico integrates it into the quality management system in near real time. Audit trails record every change to the data, and batch management ensures complete traceability.
What does better alarm management bring to chemical production?
It reduces downtime because teams notice problems earlier and can prevent them. Daubert Chemical, a manufacturer of corrosion protection, adhesives and speciality coatings, started with ICONICS precisely because it needed alarm functions and data acquisition. Today, 5,000 tags run on GENESIS64 and Hyper Historian, and 44 WebHMI clients bring the process screens to computers across the company. The number of process incidents has fallen, and unresolved problems are down by 75%.
How does a customer portal support service for mixing and dosing systems?
A customer portal brings all documents, tasks and service processes for a system together in one place. RAMPF Production Systems builds customised mixing and dosing systems for liquid adhesives and introduced the Project Cockpit, based on the EquipmentCloud, with Kontron AIS. Assembly instructions, protocols and spare parts lists are synchronised automatically via a RESTful API. The portal replaces many Excel forms and most of the applications used previously.
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