Batch Process Automation | Automation System

How We Can Help

Turnkey batch automation system design, implementation & installation for new production lines

Increase production capacity & reduce cycle time
Reduce process automation lifecycle costs
Uncover operational performance metrics & processing analytics – including OEE
Upgrade obsolete process control systems

Capabilities

Project Management & Oversight

Main Automation Contractor (MAC), Electrical Contractor (EC) & General Contractor (GC)
Construction management
Production equipment relocation & modification

Safety

Safety upgrades
Electrical design for hazardous locations

Design, Development & Deployment

Design for batch standard S88.01
Distributed Control System (DCS) development for Siemens PCS7 & Rockwell Plant PAx platforms
HMI development
SCADA process control systems development
PLC programming for Siemens, Rockwell, Schneider, GE & others
Production reporting, including process reliability, OEE KPI calculation & dashboard development
Process historian integration
Predictive maintenance deployment & support
Electrical design using EPLAN & AutoCAD Electrical
Panel design & fabrication for UL-508A requirements
Asset management system deployment
Tank, pump & valve sizing
Instrumentation integration & calibration
Networking & fiber optic cabling

Other Services

Simulation – process, control & batch – for virtual commissioning & operator training
Operations & maintenance manual development
Coordinated drive systems & variable speed drive troubleshooting
Emergency support

Batch Process Automation Case Studies

Portable manufacturing system delivers multi-site production for pharmaceuticals company

Skid-based batch process control system supports increased global market share Problem Our customer needed a way to allow foreign manufacturers to formulate their vaccine in a way that they could ensure would comply with their own manufacturing standards. Solution A&E was a sub-contractor to a prime contractor for this project. The prime contractor delivered the
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Manufacturing Control System Upgrade – Batch Process Automation – Liquid Ingredients

Problem Our customer was looking for ways to save on physical labor and material handling costs while improving their supply chain. One of the ingredients used in their manufacturing process is shortening. The process was very manual and prone to operator error. It used solid shortening cubes that required unboxing, unbagging, slicing, weighing, and delivering
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Oil Delivery Control System Upgrade at a Baking Facility

Problem This manufacturing facility makes baked goods. Part of the process involves delivering oil and PB (peanut butter) paste from one area to another. The hardware controlling the area was obsolete, not maintainable, and unreliable. There was a high probability of production downtime, affecting the entire bakery. Solution We upgraded the oil & PB
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OEE/Downtime Monitoring and Reporting System for a Food & Beverage Plant

The client wanted to be able to compare production performance (OEE / downtime) across manufacturing plants to facilitate continuous improvement for the manufacturing teams & keep a pulse on production efficiency at the executive level. A&E helped them standardize the data collection and reporting of business/production metrics across all facilities in all 3 divisions of the company.
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Multi-plant Control System Upgrade for Improved Production Capacity for a Speciality Chemical Plant

This Fuel Additive plant needed to improve their production capacity and improve the overall reliability of their system. A&E helped by integrating/automating around 300 pieces of new equipment and updating controls for existing equipment and instrumentation.
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Enabling Remote Factory Acceptance Testing of an Automation System for a Specialty Chemicals Manufacturer

A major specialty chemicals manufacturer located hundreds of miles away had been working with A&E to implement batch processing automation. Due to lock-down restrictions as a result of the COVID-19 pandemic, A&E had to pivot their delivery strategy, implementing remote FAT to begin testing and optimization.
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How We Can Help

Capabilities

Project Management & Oversight

Safety

Design, Development & Deployment

Other Services

Batch Process Automation Case Studies

Portable manufacturing system delivers multi-site production for pharmaceuticals company

Manufacturing Control System Upgrade – Batch Process Automation – Liquid Ingredients

Oil Delivery Control System Upgrade at a Baking Facility

OEE/Downtime Monitoring and Reporting System for a Food & Beverage Plant

Multi-plant Control System Upgrade for Improved Production Capacity for a Speciality Chemical Plant

Enabling Remote Factory Acceptance Testing of an Automation System for a Specialty Chemicals Manufacturer

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