PLC Programming Services for Factory Operations
Modern industrial process control and automated operations can produce high quality, robust, and repeatable products for manufacturing companies. Coupled with flexible PLC based control, systems can scale from a single system to a full plant model to support evolving production and business objectives. These PLC based process systems can also serve as the conduit to higher level systems such as SCADA, process historians, diagnostic software, manufacturing metrics, material management, production management, quality management, and more, allowing for better overall management and success of factory operations.
Our Approach to Rockwell Allen Bradley PLC Programming
For faster development, deployment and testing with quality and reliable results, NeoMatrix has developed our own PLC standards based on the Rockwell Automation / Allen Bradley platform. Our approach standardizes input/output management, alarm management, control/equipment module management and phase/automated operation management in the PLC. Our PLC code adheres to the S88 standard for batch control for batch manufacturing processes, and we have utilized our standard PLC code for continuous industrial process controls as well.
We’ve also assisted clients in developing their own PLC code standards. In addition to the code design and development, we aided in the documentation and the procedural controls for the on-going life cycle of their standards.
PLC Programing for Your Industry
In most customer use cases, PLC based automation systems provide solutions that create new products, assist with any secondary need for creating those products, and conform to any necessary regulations in order to manufacture products in a safe and compliant manner. NeoMatrix has helped our customers build new and impactful products across many industries using PLC based controls utilizing our standards, customer standards, or Rockwell’s PlantPax/FactoryTalk Batch platforms.
For life science companies, the raw materials used in production of in-process and finished goods could be media and buffer solutions. Another example would be Water for Injection (WFI) which would need to adhere to pharmaceutical standards. For extrusion process-based companies, an example of a raw material for subsequent operations may be chemical formulations mixed prior to utilization.
For in-process production for the life science industries, PLC based systems can handle the production processes for bioreactors, fermenters, centrifuges, tangential flow filtration (TFF) systems, virus TFF systems, liquid chromatography systems, purification pool tanks, etc. For extrusion process-based companies, the extruded web is created, and further processes are required before the creation of the final product.
For finished good production for life science companies, PLC based systems can handle fill and finish equipment which may include aseptic vial filling machines. For extrusion process-based companies, the web may be used to create final product using portions of the web, or the web is directly sold in bulk rolls for commercial use. For example, many plastics-based extrusion processes sell the bulk rolls as a finished product.
Extending the Value of PLC Programming Services
In certain applications, PLC solutions may not be directly related to the raw materials, in-process or finished products. Instead, the required solutions solve other needs necessary for successful manufacturing plant operations. In life science companies, the required solutions may be clean in place (CIP) systems to properly clean industrial equipment in between processing. Another example would be to perform steam in place (SIP) in order to properly sterilize equipment in between processing. As an example, glassware washers and autoclave sterilizers clean and sterilize portable materials used in processing of raw materials, in-process and finished materials.
Other examples of ancillary needs of manufacturing plants may be water filtration systems, reverse osmosis systems, water for injection (WFI) systems, clean steam generators, particle counters, environmental controls (clean rooms), cold rooms and environmental monitoring systems. And then for some manufacturers, a solution needs to address environmental regulations such as water neutralization systems, continuous emission monitoring systems (CEMS) or a baghouse system.
PLC Platform and Process Expertise
To readily meet the unique needs of manufacturing clients, our team of PLC programmers maintain software licenses for a multitude of platforms,. And with years of experience in providing PLC programming services, can apply their expertise in implementing and/or updating the following applications: