Industrial Mixer Automation Modernization

A functional mechanical mixer that needed real automation.

The customer had an existing industrial mixer whose mechanical equipment remained functional, but the machine required a properly engineered automation system.

The objective was not simply to install a PLC. Meray first needed to understand how the machine was supposed to operate, then translate that mechanical process into a complete control strategy.

The operating process, captured with the plant team.

Meray evaluated the mixer and worked closely with the customer's mechanical team to understand how it needed to run. That understanding became the foundation for the new automation architecture.

• ·Machine operation and required operating sequence
• ·Discrete inputs and outputs
• ·Analog signals
• ·Motor starters and sensors
• ·Operator requirements and equipment states
• ·Safety requirements

A control system designed around the process.

From the captured process, Meray designed the control system — the architecture that turns a mechanical machine into an automated one.

• ·I/O architecture
• ·Analog signals
• ·Motor control
• ·Sensors
• ·Machine sequence
• ·Operator controls
• ·Safety logic

Engineered automation, instrumentation and safety behavior.

Meray implemented the automation: controls engineering, programming, installation and integration with the existing mechanical equipment. Safety was considered as part of the controls design and machine operating sequence, with appropriate control measures incorporated based on the machine's operating requirements and project scope.

• ·Controls engineering
• ·Programming
• ·Installation
• ·Integration with the existing mechanical machine
• ·Safety functionality within the operating sequence

Sequences and safety behavior verified before commissioning.

Meray verified the machine's operation, sequences and safety behavior, then commissioned the system with the customer's team.

• ·Verify operation
• ·Verify sequences
• ·Verify safety behavior
• ·Commission machine

A mechanically sound machine, now properly automated.

Meray completed the automation and controls integration for the existing mixer, bringing the mechanical equipment together with a newly engineered operating sequence, controls architecture, instrumentation and safety functionality. The completed system was tested and commissioned with the customer's team.

Modernization can support production, reliability and maintainability objectives without requiring replacement of every mechanically viable asset.