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Dry Powder Ingredients Factory - Process CIP System
Drytech Processes | May, 2023 to Aug, 2023
Opportunity
Drytech Automation in Nagpur faced challenges with their manually operated pasteurization and CIP (Clean-in-Place) systems, which lacked historical data logging and limited their ability to track quality control measures and optimize processes. A key client’s increasing demand for enhanced hygiene and product consistency prompted Drytech to seek an automated solution. The objective was to upgrade to a SCADA-based (Supervisory Control and Data Acquisition) system that would improve operational accuracy, enable historical data backup, and minimize downtime and production losses at their existing facility.
Solution
PMG engineered a solution to automate Drytech’s pasteurization and CIP systems, integrating full SCADA functionality. The upgraded system now allows for precise control of process parameters, ensuring optimal pasteurization temperatures and effective CIP cycles, which enhances product quality and hygiene. Historical data logging and reporting features were implemented, enabling operators to analyze trends, troubleshoot issues efficiently, and maintain high-quality standards. PMG's solution involved retrofitting automation equipment such as sensors, control valves, and programmable logic controllers (PLCs) without disrupting ongoing production. A custom SCADA interface was designed to provide a user-friendly platform for real-time monitoring, control, and data storage, meeting the specific needs of Drytech's premium clients. To minimize production downtime, installation was strategically planned during low production periods, and rigorous Factory Acceptance Tests (FAT) were conducted to ensure system readiness.
Outcome
The automated system now enables Drytech Automation to meet the elevated hygiene and consistency expectations of their premium clients. Operational control has been enhanced with minimal manual intervention, and historical data backup has improved process traceability and troubleshooting. The SCADA system’s flexibility allows for future adjustments to meet evolving requirements. Thanks to PMG’s meticulous planning and execution, downtime was minimized, ensuring a seamless transition with no significant production losses. This upgrade has strengthened Drytech’s ability to deliver high-quality products with improved process reliability and hygiene standards.
Project Highlights
Successful Real-Time Monitoring and Data Backup
Completion with Minimal Production Downtime
Flexibility Design for Future Upgradation
Work Completion Within Two Months
Qualified Customer’s Audit in the First Go
Key Challenges
Unavailability of Plant Shutdowns
Stringent Audit Timelines
Compatibility with Existing Systems
Hygienic Standards in Retrofitted Equipment
Managing Downtime for SCADA Installation and Testing
Construction Supervision
₹1 Cr
Production per day
30 TPD
Services Provided
Site Supervision & Execution Oversight
Instrumentation Engineering
Automation & Control Design