Sectors

Coloronda, a manufacturer of ceramic frits and glazes, has carried out an ambitious technological modernization project focused on improving the automation, integration and operational efficiency of its plant.

First, the obsolete SCADA system developed in Visual Basic, operating on Windows XP, was replaced by a modern SCADA system based on Indusoft with .NET technology, running on Windows 11. This new system not only improves the stability and capacity of the software, but was also integrated with the NAVISION ERP system. Thanks to this integration, production orders generated in the ERP, including formulas and materials, come directly to the SCADA, allowing operators to simply select preconfigured tasks. This eliminates manual data entry, minimizing the risk of human error and improving accuracy in filling silos and dosing materials for the furnaces.

At the same time, the three KOYO PLCs, responsible for the furnace, conveying and compounding areas, were replaced by state-of-the-art OMRON PLCs with direct access to databases. In addition, the old PROFACE control screens were replaced by more modern and intuitive Weinteks HMIs. As part of the process, the plant SCADA was also adapted to point to the new memory addresses of the newly installed PLCs, ensuring seamless integration between the equipment and the software.

It included the design and assembly of electrical panels, the associated engineering, the programming of PLCs and HMIs, and the commissioning of the system. This work ensured efficient and precise control of the milling processes, reducing time and optimizing resources.

An advanced SCADA system was implemented to control the filling of tanker trucks directly from the silos. This system, linked to the NAVISION ERP, ensures that operators select only the correct materials for each load, eliminating errors and ensuring product traceability.

Another significant advance was the installation of a SCADA and web application to record and manage energy consumption and production of mills and dryers. This system cross-references energy consumption data with production levels, providing a comprehensive view to optimize energy efficiency. In addition, the system monitors differential pressures of suction filters, helping to maintain optimal operating conditions or quality and safety in the production chain.

A specific solution was developed for the automatic printing of labels on Big Bags, eliminating the need to fill them manually. This system not only speeds up the process, but also ensures full traceability of the bagged material, improving logistics management and reducing errors.

The benefits obtained are plausible: greater precision and control in operational processes, reduction of human errors through integration with the ERP and automation of critical tasks. Also, energy optimization with detailed monitoring of consumption and production, as well as full traceability of materials, ensuring quality and safety in the production chain.

Radiadores Ordóñez, manufacturer of water, air and oil coolers, is a supplier of prestigious automotive brands such as BMW, Ferrari and Aston Martin.

The plant required an automated system to capture, manage and analyze production data in real time, integrating with existing systems (ERP and MES) and adapting to a variety of machines and processes in the different work centers.

We designed and implemented a data acquisition system based on PLCs and industrial equipment, which allows to automatically record the parts processed at each stage of production. This information is displayed in a web application developed by INGESOM, where operators can monitor the status of the process and record incidents in real time.

The system was fully integrated with the factory’s existing platforms, facilitating both the exploitation of production data (such as the count of good parts per production order) and the analysis of incidents. In addition, the project included the automation of specific processes, such as the installation of artificial vision cameras to verify the assembly of critical components and avoid human errors.

We participated in the improvement of control systems by collecting and centralizing field signals for detailed monitoring of operational data. This solution allowed us to optimize process monitoring and analysis, increasing efficiency and reducing potential points of failure in operations.

The control system was modernized due to recurring failures in the retentive memories of the existing Beckhoff PLC. This equipment was replaced by a new Beckhoff PLC, ensuring greater reliability and processing capacity. This change not only improved the stability of the system, but also allowed the integration of advanced functions for more efficient control.

The conclusions of what was achieved were greater reliability in the control systems, eliminating problems associated with obsolete equipment. Optimization of operational data monitoring, facilitating more efficient management of plant processes. And the reduction of the risk of interruptions in operations, improving service continuity.

This leading company in the production of packaging solutions, has carried out a technological modernization process focused on ensuring the operational efficiency and safety of its facilities. Our collaboration in this project included the design and implementation of advanced control and monitoring systems, adapted to the specific needs of their plant.

An advanced system was implemented to detect possible blockages in the cardboard trim suction pipe. Consequently, a new control panel equipped with HMI and flow sensors distributed along the pipeline was installed.
The system monitors the suction flow rate in real time and, if it falls below a threshold configurable from the HMI, an acoustic and audible beacon is activated to alert operators of a possible blockage.
For safety, the system automatically stops the suction turbine motor, preventing damage to the equipment and guaranteeing the continuity of operations.

The four control panels that manage Martin’s palletizing machines and cardboard package forming tables were updated as follows:

Comprehensively identifying field signals and marking them for efficient transition.
Replacing the original switchboards, with the manufacturer’s proprietary electronics, with state-of-the-art PLCs and industrial HMIs, improving control capacity, reliability and ease of maintenance.
The benefits were clear, obtaining a greater operational safety, the funnel detection system reduces the risk of failures and possible damage to the suction equipment.
Improved process efficiency, operators are alerted in real time, allowing them to act quickly in the event of any anomaly.
And in terms of technological modernization, control panel upgrades ensure longer equipment life, better performance and reduced maintenance costs.
Finally, flexibility in control with the new HMIs, key parameters are easily adjustable, adapting to changing production needs.

At the aquaculture research center of La Ràpita, we have carried out a complete digitization project that includes:

• Development of a SCADA application for the supervision of all installations.
• Installation of a centralized PLC to manage alarms in RAS systems, refrigerators and freezers in the laboratories.
• Creation of a Web application that allows real-time monitoring of machine status and access to data from all probes and sensors.
• This solution has optimized the center’s operations, guaranteeing total, real-time control of its critical facilities.

At IRTA’s poultry facilities in El Morell, we developed an advanced system for the integrated management of their research farms:

• Installation of a central PLC to supervise all farms.
• Incorporation of remote PLCs in each farm for the complete automation of the experimental rooms, allowing the control of windows, refrigerators, heaters, fans and extractors.
• Implementation of a Web application that ensures that experiments are performed under controlled and previously defined conditions.
• This solution allows precise and automatic control, optimizing the quality of experiments and reducing manual intervention.

IRTA adopted INGESOM’s CMMS Software as a corporate tool for the 16 research centers it manages. This system allows:

• Manage the tasks of maintenance personnel.
• Organize operators’ schedules.
• Monitor the status and progress of assigned tasks.
• With this implementation, IRTA has significantly improved the efficiency of its maintenance processes, unifying the management in all its centers.

At IRTA we have installed 7 RAS IRTAmar systems, designed for recirculation and water treatment in fish tanks. These systems stand out for:

• Full automation through PLC, HMI and variable frequency drives.
• Robustness and ease of operation, the result of years of perfecting these modules.
• These solutions have optimized aquaculture processes, ensuring ideal conditions for research.

At the Institute of Aquaculture Torre de la Sal (IATS) of the CSIC, we have carried out:

• Installation of several RAS IRTAmar systems for water treatment.
• Development of a SCADA application for the operational management of a building.
• Creation of a Web application for data mining.
• Implementation of a video recording system with IP video cameras to facilitate experimentation.
• These tools allow advanced monitoring and detailed analysis, improving aquaculture research processes.

Two RAS IRTAmar modules were installed in a new experimental building at the Polytechnic University of Valencia. These solutions ensure efficient and automated water management in the tanks, providing valuable tools for university research.

All this has been achieved:

• Optimize the supervision and control of critical processes.
• Reduce manual intervention and operational errors.
• Increase efficiency in the management of facilities and resources.
• Facilitate decision making based on real-time data.
• These experiences reflect our commitment to technological innovation and digital transformation in industrial and research environments.