New batching control system brings productivity improvements for MacDermid
Weighing and Batching Process Control System
A comprehensive weighing and batching control system installed by process control specialists Procon Engineering Ltd is playing a vital role at MacDermid’s new 7500 m2 plant in Birmingham, West Midlands, UK.
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Founded in 1922 and headquartered in Denver, Colorado, MacDermid Incorporated is a leading worldwide manufacturer of specialty chemicals and processes for the metal and plastic finishing, electronics and graphic arts industries.
The Procon process control system includes 12 bespoke control panels, weight indicators and specialist load cell mounting assemblies fitted to 12 vertical mixing tanks. The control panels are mounted on the floor above the tanks, which range in size from 4000 to 10000 litres. Each panel also provides automatic temperature control for the tanks’ heaters together with high and low level controls and alarms. Procon have extensive experience in designing and building customer specific control panels for a wide range of industry sectors. They claim this versatile in-house capability sets them apart from many of their competitors and ensures customers receive best-engineered solutions for their application.
The new Birmingham facility, which employs over 100 people, has enabled MacDermid to integrate four separate production areas onto one site. It was essential that such a move was carried out with the minimum of disruption to production and the complete transfer of existing plant, equipment and stocks was carried out over an eight week period. In parallel during this time the new Procon batching control equipment was also installed.
The batching processes involve the blending of recipes made up from over 600 raw materials, including acids and alkalis, to produce a similar number of finished products. To ensure the highest quality and consistency of finished product, all raw materials are controlled within MacDermid’s strict formulation specifications. Typical batches range from simple two part blends up to more complex batches with upwards of 15 different ingredients, whilst batch times vary from approximately 30 minutes up to four hours. The majority of ingredients are gravity fed into the mixing tanks from IBCs, together with pre-weighed hand-added ingredients. Controlled quantities of hot and cold water and ammonia can be added to the tanks via fixed pipe work. To facilitate cleaning and optimise batch turnaround times, each tank is dedicated to specific parts of the product range. Finished products are dispensed into 25 and 200 litre drums as well as standard IBCs.
Procon have a long-standing working relationship over the past 20 years with MacDermid and although they supplied new control panels and weighing instrumentation for the new plant, the existing Procon load cell assemblies were removed, checked and refitted to the tanks transferred from the existing installations. This is testimony indeed to the durability and quality of the load cells, which were shown to be in perfect working order. To meet the harsh working environment the fully hermetically sealed stainless steel shear beam load cells feature a proprietary epoxy coating.
MacDermid’s Managing Director Lance Phasey is delighted with the new installation and as he concludes: “The improved batching control capabilities, together with the increased efficiencies provided by the streamlined production and stock areas, are already bringing overall improvements to productivity and reductions in batch turnaround times. Precise pre-planning was essential for this project and Procon came through with flying colours. Their engineers worked closely with our own team on site to ensure a smooth transition was achieved within the tight time restraints.”
Procon Engineering Ltd
Vestry Estate
Seven Oaks
Kent
TN14 5EL
Tel: 01732 781300
E-mail: sales@proconeng.com
