Retrofit of an Active Ingredient Mixer

During the plant inspection, it became apparent that the active ingredient mixer required modernization in terms of its operation and control systems. CTE was commissioned to carry out the retrofit. This included, in particular:

• Upgrade of PC Workstations and Visualization Systems

• Replacement of the existing frequency converters

• Reprogramming the PLC

• Implementation using zenon Batch Control and the CTE Basic Function Concept

• Optimization of Operations and Process Workflows

In collaboration with Acino, the existing plant functions were assessed and documented in a new functional specification. Based on this, CTE developed the PLC program and the zenon visualization.

Prior to the retrofit, the entire system was simulated using WinMOD and tested in a software FAT together with the operator. In addition, production-ready recipes were prepared and employees were trained using the test system.

Thanks to the thorough preparation, the work required during the plant shutdown was kept to a minimum. The on-site SAT was completed after just two days. The CIP recipe that had been prepared in advance could also be used directly for cleaning the plant.

Following training sessions for production, maintenance, and management staff, the modernized active ingredient mixer was successfully handed over to operations.