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Types of Allen Bradley PLCs: A Comprehensive Guide

Posted on 29 February, 202429 February, 2024 by aghosby

From giant manufacturing plants to modern assembly lines, programmable logic controllers (PLCs) are the unsung heroes of industrial automation.

Among the leading brands in the PLC world, Allen Bradley stands tall, with a history of innovation and quality that’s as dependable as it is vast.

For engineers and technicians navigating the complex world of industrial automation, understanding the types of Allen Bradley PLCs available is essential to implementing efficient and robust control systems.

This in-depth guide will dissect Allen Bradley’s primary PLC series, from their applications to selection criteria, to equip professionals with the knowledge needed to choose the right PLC for their specific requirements.

Whether you’re a seasoned automation expert or setting your first foot on the ladder of control engineering, this comprehensive overview will demystify the world of Allen Bradley’s PLC offerings.

PLC Basics

Before we plunge into the specifics of Allen Bradley’s PLC lineup, it’s crucial to comprehend the role of PLCs in the industrial context.

Think of PLCs as the brains behind the brawn of machinery and equipment in complex manufacturing processes.

These robust industrial computers execute programming logic for process control, human-machine interfacing, and data acquisition, making them indispensable in maintaining precision and efficiency within critical operations.

PLCs enable automation by monitoring inputs from sensors and switches, making decisions based on programmed instructions, and delivering outputs to control various industrial processes.

PLCs come in a wide range of sizes and capabilities, varying from simple controllers with limited I/O (input/output) points to high-end modular systems with extensive networking capabilities. Allen Bradley’s PLC series caters to different levels of automation needs, with each series having its own unique features and functionalities.

Popular Allen Bradley PLC Series

Allen Bradley offers a range of PLC series, each tailored to different application sizes and industry niches. Understanding the distinctions between these series is the first step in determining which one aligns with your project’s demands. Here are some of the most popular PLC series from Allen Bradley:

MicroLogix Series

The MicroLogix family is Allen Bradley’s compact, low-cost PLC range, ideal for small to mid-sized applications.

It’s known for its ease of use and versatility, making it a favorite among those integrating automation in less complex systems. Some key features of the Micro800 series include:

Support for up to 132 I/O points
Built-in Ethernet and serial ports for easy connectivity
User-friendly programming software, CCW (Connected Components Workbench)
Ability to expand with plug-in modules for increased I/O capabilities

CompactLogix Series

Sitting in the mid-range, the CompactLogix series provides a balance of performance and scalability. These PLCs support multiple I/O modules and offer communication flexibility, accommodating various industrial networking requirements. The CompactLogix series features:

Support for up to 30 local I/O modules
Compatibility with various communication protocols, including Ethernet/IP and DeviceNet
Built-in motion control capabilities
Flexible programming options such as ladder logic, structured text, and function block diagramming

ControlLogix Series

At the top end, the ControlLogix series delivers power, modularity, and high-performance capabilities suitable for the most complex and demanding automation systems.

Their distributed control system (DCS) compatibility and extensive redundancy options are renowned in the industry. Here are some key features of the ControlLogix series:

Support for up to 128 local I/O modules and thousands of distributed I/O points
Redundancy options, including redundant controllers and power supplies, for increased system reliability
Advanced motion control capabilities with integrated servo drives and motors
Compatibility with various programming languages, including structured text, sequential function charts, and instructions list
Compatibility with third-party devices through a variety of communication protocols, including EtherNet/IP and ControlNet

Despite their differences, all three series share the same software development environment – Connected Components Workbench (CCW).

This user-friendly programming software offers a common platform for all CompactLogix and ControlLogix PLCs, making it easier to develop and maintain automation projects.

Features and Applications

Each Allen Bradley PLC series contains a distinct set of features that cater to different industrial needs and applications. Some key features and applications of these PLCs are discussed below.

MicroLogix Series

The MicroLogix series is ideal for small-scale operations, such as stand-alone machines or simple process control. Its compact size, low cost, and easy programming make it a popular choice among system integrators and machine builders. Here are some common applications of the MicroLogix series:

Basic machine control, such as packaging and material handling
Simple process control, such as batching and temperature control
Small-scale data acquisition and monitoring systems

CompactLogix Series

The CompactLogix series is designed for mid-range applications that require more flexibility and scalability. It offers a wider range of I/O options, advanced communication capabilities, and the ability to handle larger amounts of data. Some typical applications of the CompactLogix series include:

Multi-axis motion control
Complex process control with high-speed sequencing and precision
Data-intensive applications, such as SCADA systems and remote monitoring.

ControlLogix Series

The ControlLogix series is the most powerful and versatile PLC family from Allen Bradley. It is designed for large-scale and complex operations that require high-performance and reliability. With its advanced features, the ControlLogix series can handle demanding applications in various industries, such as:

High-speed production lines in manufacturing
Sophisticated process control in oil and gas, chemical, and pharmaceutical industries
Plant-wide automation systems with multiple controllers.

Industries Specific Applications

A single musical composition can elicit various emotions based on its surroundings; likewise, the utilization of Allen Bradley PLCs differs among different sectors, each contributing its distinct melody to the industrial landscape.

Manufacturing

ControlLogix in the manufacturing industry orchestrates the production line with its precision, ensuring just-in-time manufacturing and throughput efficiency.

Oil and Gas

The rigorous environment of oil and gas operations requires the robustness and resilience of Allen Bradley CompactLogix to keep the show running even in the harshest conditions.

Automotive

MicroLogix may be the score that the automotive industry needs for its local operations, where efficiency is combined with the nuances of customized control systems.

Selection Criteria

When it comes to selecting the right PLC for your project, there are several key factors to keep in mind. These include:

Performance and Power

Assess the computational performance and power of the PLC to ensure it’s capable of handling your application’s processes without strain.

Consider factors such as processing speed, I/O capacity, and memory capacity.

Flexibility and Scalability

Choose a PLC that offers flexibility and scalability to accommodate future expansion or changes in your application.

Look for features like expandable I/O modules, communication options, and software compatibility. This will save you time and money in the long run.

Reliability and Durability

PLCs are often used in harsh industrial environments, so it’s essential to consider their reliability and durability.

Look for PLCs with high-quality components, protective enclosures, and certifications for extreme conditions.

Programming Options

PLCs can be programmed using various methods, including ladder logic, structured text, and function block diagrams.

Consider the programming options available and choose one that aligns with your team’s skills and preferences.

Support and Maintenance

Choose a PLC from a reputable manufacturer with a reliable support system in place. This will ensure any issues are quickly resolved, minimizing

Communication Capabilities

Evaluate the communication capabilities of the PLC, including wired and wireless options, to ensure it can easily integrate with your existing systems.

Look for features like Ethernet ports, serial communication, and industrial protocols.

I/O Count and Types

Consider the input/output requirements of your application. Does it need digital, analog, or specialty I/O? How many points are needed for each type?

Networking and Communication

The ability of a PLC to integrate into existing systems through various networking protocols is critical. Evaluate communication options like Ethernet/IP, DeviceNet, and serial connections to ensure compatibility.

Physical Environment

Choose a PLC that can withstand the environmental conditions of the installation site, whether that means extreme temperatures or exposure to dust, moisture, or vibration.

Software and Programming

Evaluate the software that accompanies the PLC for programming ease and the availability of advanced features like simulation and troubleshooting tools.

Cost

Finally, consider the cost of the PLC and its accessories, including software licenses and I/O modules.

Make sure to factor in not only the initial purchase cost but also maintenance and upgrades over the lifetime of the PLC.

Comparison and Recommendations

To provide a comprehensive comparison, we will highlight the strengths and weaknesses of each Allen Bradley PLC series.

MicroLogix Series

Pros:

Affordable entry point into automation systems
Easier learning curve and user-friendly software
Compact size and location flexibility

Cons:

Limited processing power and I/O capability
Less scalability for future expansion compared to larger series
Not suitable for high-speed or complex operations

Recommended For: Start-ups or small businesses dipping their toes into automation, or for specialty tasks within larger systems where local decision-making or control is required.

CompactLogix Series

Pros:

Enhanced performance and expandability compared to Micro800
Flexibility in communication and networking options
Ability to handle more sophisticated applications

Cons:

Higher upfront cost
Complexity may require more experienced personnel
Not always necessary for applications that could fall within the capabilities of Micro800

Recommended For: Mid-sized companies or projects that require a balance between performance and cost.

ControlLogix Series

Pros:

Unmatched performance, redundancy, and expandability
Suitable for the most complex automation tasks
Aligns with the highest industry standards and expectations

Cons:

Significant investment required
Over-engineered for smaller systems or operations not requiring such high specifications
Steeper learning curve for newcomers to PLC programming and operation

Recommended For: Large-scale applications or critical processes where uptime, reliability, and expandability are non-negotiable.

Conclusion

Selecting an Allen Bradley PLC is more than just a choice of hardware; it’s about investing in the sustainability and efficiency of your industrial operation.

By understanding the scope of each series and matching their capabilities to the unique demands of your application, you can ensure a seamless integration that brings value both in the short and long term.

To reiterate, your selection process should involve a thorough assessment of the performance, I/O, networking, and environmental factors specific to your project’s needs.

In doing so, you not only harness the power of automation but also the reputation of Allen Bradley’s commitment to quality and innovation.

Whether you opt for the entry-level Micro800, the versatile CompactLogix, or the powerhouse ControlLogix, remember that the right choice of PLC is the foundation upon which you build the future success of your industrial automation system.

Now equipped with this guide, take the next step with confidence and precision — just as an Allen Bradley PLC would.

Predictive or Preventive Maintenance?

Posted on 29 November, 202330 November, 2023 by aghosby

Maintenance is crucial in industrial engineering as it affects the dependability, durability, and effectiveness of operations. Two methods have become popular in this field for their proactive approach to equipment maintenance: predictive and preventive maintenance.

These techniques not only anticipate potential problems but also enhance resource utilization, minimize downtime, and promote a more seamless operational atmosphere.

Understanding Predictive Maintenance.

Predictive Maintenance is a crucial aspect of modern industrial engineering that utilizes advanced technologies and data-driven insights to predict potential machinery failures. By incorporating IoT devices, sensors, and sophisticated analytics, it continuously monitors equipment in real time, analyzing performance metrics and identifying patterns that indicate impending breakdowns.

This predictive ability allows for early detection of anomalies or signs of wear, enabling timely interventions. By strategically scheduling maintenance, it reduces unexpected downtimes, optimizes resource allocation, and minimizes unnecessary maintenance costs. The integration of predictive maintenance leads to a shift from reactive to proactive maintenance strategies, improving overall equipment effectiveness.

Exploring Predictive Maintenance

On the other hand, scheduled preventive maintenance involves regular check-ups, maintenance, and repairs to avoid any possible equipment failures or damage. This approach is based on past records, manufacturer suggestions, and industry standards to keep the machinery in top-notch condition.

Although it may not be as accurate as predictive maintenance, preventive measures are proactive and greatly minimize the chances of sudden breakdowns, while also prolonging the equipment’s lifespan. Lubrication, part replacements, and calibration are some of the common preemptive measures taken to prevent gradual wear and tear of the machinery.

Comparative analysis

It is important to distinguish between predictive and preventive maintenance. Predictive maintenance uses data and real-time insights to anticipate problems, while preventive maintenance follows a set schedule to maintain equipment health.

These two approaches work well together and can improve operational efficiency when integrated. The choice between them depends on factors such as equipment type, criticality, and operational context.

By combining both methods, engineers can create a strong maintenance framework that ensures timely interventions and preserves equipment health.

Implementation

There are obstacles to implementing maintenance strategies, such as incorporating predictive technologies into current systems, training employees, and overcoming financial barriers.

Nevertheless, the advantages of cost reduction, less downtime, and enhanced safety outweigh these challenges. It is essential to train a competent workforce that can utilize these technologies and create a culture that values preventive and predictive maintenance to achieve successful implementation.

Impact on Business Performance

The significance of predictive and preventive maintenance on operational efficiency and business performance cannot be emphasized enough. The measurable advantages consist of saving costs, boosting productivity, enhancing safety, and creating a more sustainable operational setting.

Furthermore, these approaches promote a safer work environment by reducing accidents and ensuring the welfare of employees. By preventing unforeseen failures and optimizing resources, industrial engineering processes can function more effectively, resulting in improved business performance and a competitive advantage in the market.

Challenges and future trends

Ongoing challenges still exist despite the potential benefits of predictive and preventive maintenance. The integration of new technologies, addressing workforce training needs, and adapting to industry trends are some of the challenges that need to be addressed.

However, the future of maintenance in industrial engineering looks promising with the emergence of AI-driven predictive analytics, machine learning, and remote monitoring. These advancements have the potential to revolutionize maintenance practices by enabling more accurate predictions and proactive interventions.

In conclusion

The foundation of proactive and sustainable industrial engineering lies in predictive and preventive maintenance. By integrating these approaches, operational efficiency is improved, downtime is reduced, safety is enhanced, and the industrial ecosystem becomes more streamlined.

Adopting these methodologies goes beyond equipment preservation; it also safeguards productivity, profitability, and the future of industrial endeavors. The combination of data-driven insights, technological advancements, and proactive strategies creates a smoother operational landscape and strengthens the reliable, efficient, and forward-thinking practices of industrial engineering.

Notable Ways Siemens Automation Advances The F&B Industry

Posted on 26 September, 202326 September, 2023 by aghosby

In the present era of rapid advancements, the food and beverage industry is challenged with increasing expectations for excellence and productivity. Siemens, a prominent worldwide authority in automation and digitalization, has been a trailblazer in transforming this industry. By offering cutting-edge automation solutions, Siemens aids food and beverage manufacturers in optimizing their operations, minimizing inefficiencies, elevating product standards, and adapting to the ever-changing preferences of consumers.

This piece explores how Siemens utilizes automation to enhance innovation and efficiency in the food and beverage industry. It provides insights into the technologies and strategies that have revolutionized the sector.

Optimizing Production through Process Automation

Siemens plays a significant role in the food and beverage industry by providing process automation solutions. Through Siemens’ automation systems, manufacturers can enhance their production lines, resulting in improved consistency and quality of food and beverage products.

PLCs (Programmable Logic Controllers) and SCADA (Supervisory Control and Data Acquisition)

Systems play a vital role in automation. Together, they provide the ability to monitor and control operations in real-time. Hence, smooth functioning of every food production stage is guaranteed.

Modular Production Lines

Siemens advocates for the implementation of modular production lines that offer flexibility and adaptability. This enables manufacturers to seamlessly transition between diverse product lines without experiencing substantial downtime.

Efficient Batch Processing

The food and beverage industry heavily depends on batch processing in which Siemens’ automation solutions play a crucial role in its optimization. By precisely controlling ingredient proportions, temperature and mixing, Siemens ensures consistent product quality and reduces production cycles, leading to increased efficiency.

Enhancing Quality and Traceability

Maintaining standards of food safety and quality is of utmost importance in the industry. Siemens’ automation systems ensure that these standards are met.

Energy Management

Siemens offers automation solutions with energy management systems that effectively optimize energy usage, minimize waste, and decrease operational expenses.

Water Management

Siemens aids food and beverage manufacturers in implementing strategies to conserve water, recognizing its value as a premium resource. Through the use of automation systems, water usage can be monitored and controlled, resulting in reduced waste and the promotion of responsible water management practices.

Packaging Optimization

Siemens’ automation technology covers packaging processes as well. Manufacturers can achieve material waste and energy consumption reduction while simultaneously ensuring product safety and quality, through the optimization of packaging lines.

Ensuring Compliance and Food Safety

In the food and beverage industry, ensuring food safety and adhering to regulatory compliance are essential and cannot be compromised. Siemens provides automation solutions that are equipped with strong features to assist manufacturers in meeting these critical regulations.

Compliance Automation

Configurable automation systems can be utilized to ensure that each stage of production conforms to pertinent regulations and standards. This mitigates the potential of non-compliance and the resulting financial and reputational consequences.

Siemens offer solutions that encompass remote monitoring and control functionalities, proving particularly advantageous in guaranteeing food safety within distant or demanding settings.

Digitalization and Industry 4.0<>/span

Siemens supports Industry 4.0, which is the notion of the fourth industrial revolution that involves the integration of digitalization, automation, and data exchange into manufacturing processes.

IoT and Data Analytics

Siemens utilizes the Internet of Things (IoT) and data analytics to collect valuable information from production processes. By harnessing real-time data, this approach allows for predictive maintenance, resulting in decreased downtime and enhanced equipment efficiency.

Cloud-based Solutions

They enable data storage and analysis, allowing convenient access to vital information from any location worldwide is provided by Siemens. This feature is particularly advantageous for multinational food and beverage corporations that have dispersed operations.

Digital Twins

Siemens employs digital twin technology, creating virtual replicas of physical production systems. These digital twins allow for comprehensive testing and optimization before implementing changes in the physical environment, saving time and resources.

Collaboration with Partners and Clients

Siemens engages in active collaboration with its clients to create customized solutions that effectively tackle their unique challenges and objectives. This collaborative approach also extends to partnering with equipment suppliers and systems integrators; fostering innovation and enhancing efficiency across the entire supply chain.

In conclusion

Siemens’ dedication to automation and digitalization has significantly contributed to the transformation of the food and beverage industry. Through the optimization of production processes, improvement of product quality and traceability, promotion of sustainability, adherence to regulations, and embracement of digital technologies, Siemens assists food and beverage manufacturers in meeting the requirements of a constantly changing market.

As the industry continues to expand and challenge new obstacles, Siemens continues to be a reliable partner in driving innovation and enhancing operational effectiveness.

For more information on Siemens trainings, installation and purchasing, send an email to sales@greenpegltd.com

Industrial Processes: A Beginner’s Guide

Posted on 17 August, 202317 August, 2023 by aghosby

Industrial processes bring up thoughts of huge factories, complicated technology, and bustling production lines in the modern age. But what specifically are industrial processes, and why are they vital to our society? We will dig into the core of industrial processes, revealing their importance, elements, and roles in creating the products we use every day.

Explaining Industrial Processes

An industrial process is essentially a set of procedures or activities that convert material resources into finished commodities. To guarantee efficiency, precision, and quality, these processes are painstakingly executed.

Industrial processes are the force that drives modern manufacturing, from manufacturing daily things such as cellphones and apparel to developing complicated machinery and infrastructure.

Components

Industrial processes involve a wide variety of activities, all of which assist in the transformation of raw materials into finished goods. These elements are roughly classified into different phases:

Preparation of Materials: The procedure starts with the acquisition and preparation of raw materials, which could include metals, polymers, textiles, or chemicals. These materials are cleaned, cut, shaped, and made ready for the desired use.

Raw materials transportation: The actual conversion of raw materials into different forms or components occurs at this step. Shape, connect, or change the materials as the product design requires using specialized tools such as lathes, presses, and molding equipment.

Assembling: Each of the parts is brought together to form the final product at this step. Assembly lines, where numerous employees or robotic arms operate in tandem, enable efficient and precise part integration.

Packaging and Distribution: After passing quality inspection, the items are expertly packed for safety and shipment. Packaging is about more than just appearance; it is also about ensuring that the product reaches consumers in pristine condition.

To read more about product packaging, click here

The Importance of Industrial Processes

Industrial processes are critical to economic growth, technical innovation, and societal progress. This enables mass manufacturing of items, making products more available to a larger population while pushing prices lower through economies of scale. This accessibility has changed a wide range of sectors, from vehicles to electronics, making technology and innovation more accessible than ever before.

Furthermore, industrial processes help generate jobs while honing skills. As factories and manufacturing units grow, they create careers for a wide spectrum of people, from skilled technicians and engineers to assembly line employees.

Environmental Issues and Long-Term Sustainability

Industrial processes have undoubtedly resulted in major developments they however also raise questions about environmental safety and sustainability.

Industries are rapidly implementing environmentally friendly practices, such as recycling, waste reduction, and energy-efficient production, in order to reduce their carbon footprint and contribute to a future that is environmentally friendly.

Conclusion

Industrial processes are the basis of contemporary manufacturing, covering a complex network of operations that convert raw materials into the things we use and rely on every day. These processes demonstrate the confluence of innovation, equipment, and human knowledge from the initial material preparation to the final product distribution. Understanding and managing these processes is critical for driving development, promoting economic growth, and defining a sustainable future as we traverse the shifting environment of industry and technology.

Why Sinamics Is a Superior Choice to Micromaster

Posted on 16 August, 202318 August, 2023 by aghosby

Drive technology is critical in industrial applications, as it is a key player in machinery and operations in various sectors. In the world of industrial automation and drive technology, selecting the right equipment is crucial for achieving optimal performance, efficiency, and reliability. Siemens, a pioneer in this field, offers two prominent drive families: Sinamics and Micromaster. While both product lines serve as reliable solutions, Sinamics stands out as a superior choice due to its advanced features, versatility, and cutting-edge technology.

In this blog post, we’ll compare two of Siemens drives – Micromaster and the newly improved drive, Sinamics.

Understanding Sinamics and Micromaster

Before diving into the reasons why Sinamics is superior to Micromaster, it’s important to briefly understand the characteristics of both drive families:

Micromaster

Micromaster drives are well-regarded for their simplicity, cost-effectiveness, and suitability for basic applications. They are ideal for small-scale operations, such as simple conveyor systems or pump drives. Micromaster drives are relatively easy to install and configure, making them an excellent choice for applications with straightforward requirements.

Sinamics

Sinamics drives, on the other hand, are designed to cater to a wider range of applications, from basic to highly complex. They are equipped with advanced features, connectivity options, and compatibility with various control systems. Sinamics drives are known for their flexibility, precision, and adaptability, making them suitable for demanding applications in industries like manufacturing, robotics, and energy.

Why Sinamics Prevails

Application Versatility

One of the key reasons Sinamics outshines Micromaster is its unmatched versatility. Sinamics drives are engineered to handle a broad spectrum of applications, from simple speed control to high-performance motion control. Whether it’s a basic conveyor system, a complex CNC machine, or a multi-axis robotic setup, Sinamics can be tailored to meet the unique requirements of each application.

Advanced Features

Sinamics drives come equipped with advanced features that empower industries to achieve higher levels of efficiency and productivity. These include built-in safety functions, integrated motion control, energy-saving algorithms, and predictive maintenance capabilities. Such features allow businesses to optimize their processes, reduce downtime, and enhance overall system performance.

Connectivity and Integration

In today’s era of Industry 4.0, seamless connectivity and integration are paramount. Sinamics drives offer extensive connectivity options, including Ethernet-based communication protocols, which enable easy integration into modern industrial networks. This connectivity fosters data exchange, remote monitoring, and centralized control, enabling better decision-making and real-time adjustments.

Scalability

As businesses grow and technologies evolve, the scalability of drive solutions becomes essential. Sinamics drives are designed with scalability in mind, making it easier to expand systems or upgrade equipment without facing compatibility issues. This adaptability future-proofs investments and reduces the need for complete overhauls as requirements change.

Precision and Performance

For applications demanding precise control and high-performance motion, Sinamics stands as the optimal choice. The advanced control algorithms and feedback mechanisms inherent in Sinamics drives provide exceptional accuracy, speed regulation, and torque control. This level of precision ensures consistent quality, reduced waste, and improved overall system efficiency.

Conclusion

While Micromaster drives have their place in simpler applications, the comprehensive features, adaptability, and performance of Sinamics drives make them the superior choice for industries requiring advanced drive technology. Sinamics’ ability to handle diverse applications, its advanced features, connectivity, scalability, and precision all contribute to its position as the leader in the field of industrial automation and drive solutions. When aiming for optimized productivity, efficiency, and future-proofing, Sinamics is the clear winner.

To order any of the SINAMICS drives range, please send a mail to sales@greenpegltd.com

For training on the handling of SINAMICS, please contact academy@greenpegltd.com

Navigating The Challenges Faced By Industrial Waste Water

Posted on 21 June, 202317 August, 2023 by aghosby

Introduction

Industrial wastewater is generated through many industrial processes such as manufacturing, mining, power generating, and chemical production.

Its composition varies, but it has significant amounts of organic molecules, heavy metals, hazardous chemicals, suspended particles, and other pollutants.

Given the complex nature and potential harm to ecosystems and public health, these toxins can be difficult to remove or remediate. Proper industrial wastewater treatment has become critical as enterprises expand and regulations tighten.

Let’s explore the specific problems of industrial wastewater and highlight novel ideas and technologies that can help industry traverse this complexity while guaranteeing sustainability for the environment.

Problems of industrial wastewater

Complex Composition: Toxic compounds, heavy metals, oils, solvents, and organic pollutants can all be found in industrial effluent. When compared to municipal wastewater, the heterogeneous composition makes treatment and disposal more difficult.

Variability in Volume and Flow Rates: Industrial processes frequently generate enormous amounts of wastewater with varied flow rates. Managing changing wastewater volumes need adaptable treatment systems capable of efficiently handling both high and low flow rates.

Regulation Compliance: Industries must adhere to severe environmental laws and discharge requirements enforced by governmental organizations. To assure wastewater quality and avoid penalties, meeting these standards frequently necessitates advanced treatment technologies, continual monitoring, and documentation.

Cost and Infrastructure: For industries, establishing and maintaining appropriate wastewater treatment infrastructure can be costly. The building, operation, and maintenance of treatment facilities, including the installation and upkeep of specialized equipment and systems, are all expensive.

Implementing appropriate wastewater treatment methods necessitates experience and knowledge of various treatment procedures, equipment, and monitoring approaches. Some sectors may lack the requisite technical knowledge and resources, making efficient wastewater treatment procedures difficult to implement.

Industrial Processes and Variation: Based on its manufacturing processes, raw materials, and products, each industry has distinct wastewater characteristics. The treatment of various forms of industrial wastewater necessitates specialized approaches, and standard methods are not always efficient.

Stakeholder Engagement and Public Perception: Industrial wastewater management can cause fret in neighboring communities and stakeholders. Building trust and addressing concerns about environmental consequences, odors, and potential health hazards need a public opinion, communication, and dialogue.

Managing industrial wastewater

These procedures differ depending on the industry, local rules, and the amount of protection needed to protect human health and the environment. Industries that generate extremely complicated or toxic wastewater may necessitate specialized treatment techniques or are subject to more strict laws.

Pre-treatment: These techniques include screening, sedimentation and filtering. It is done to remove big particles, grease, oil, or any pollutant that could impede the treatment process.

Collection and containment: Industrial wastewater is collected and managed via a system of drains, sewers, or dedicated pipelines. To avoid contamination, industrial effluent must be separated from home wastewater.

Reduce source of waste: Seek measures to reduce wastewater generation at the point of emission. Enhance manufacturing processes, put in place water-saving measures, and explore recycling where feasible. The most successful technique is to reduce the volume and polluting load of wastewater generated.

Create a wastewater control plan: Create a thorough plan including the strategies, procedures, and technologies for successfully handling wastewater. Evaluate your industry’s specialized needs, regulatory regulations, and environmental concerns. Engage environmental specialists and wastewater treatment professionals.

Monitoring and testing: Frequently examine and conduct tests on the wastewater, before and after treatment, to ensure compliance with regulations and the efficacy of the treatment approaches. Also analyze factors such as pH, COD (chemical oxygen demand), BOD (biological oxygen demand), and contaminants particular to your industry.

Proper disposal or reuse: Based on the quality of the treated wastewater and local restrictions, determine the best technique for disposal or reuse. If the effluent fulfills the required standards, it can be dumped into surface waterways or sanitary sewage systems. Consider the potential for water reuse in your industrial processes or for agricultural purposes.

Adhere to guidelines: Ascertain that your practices are in accordance with the necessary permits, discharge limitations, reporting duties, and other legal requirements.

In conclusion

Proper industrial wastewater management is crucial for limiting environmental damage, adhering to regulations, and supporting sustainable practices.

Industries can drastically reduce the contaminants and volume of wastewater released into the environment by implementing measures such as source reduction, pre-treatment, centralized treatment, and correct disposal or reuse. Regular monitoring, adherence to rules, and ongoing improvement are critical to the success of wastewater management operations.

We can aim for a cleaner and more sustainable future for our water resources and the Earth as a whole by focusing on ethical practices, industry collaboration, and continual innovation.

The Role of Packaging in Food and Beverage Manufacturing

Posted on 5 June, 202317 August, 2023 by aghosby

Introduction

Product packaging is critical in the food and beverage manufacturing industry, serving as the first point of contact between a product and its potential consumers. Packaging has evolved beyond its functional purpose of containing and protecting contents to become a powerful tool that influences consumer perceptions, drives brand recognition, and ultimately influences purchasing decisions. In today’s highly competitive market, where consumers are constantly bombarded with options, the importance of strategic and innovative packaging cannot be overstated.

Product Integrity:

Physical Damage Protection: Packaging acts as a protective barrier, protecting products from physical damage during handling, transportation, and storage. It protects items from impacts, vibrations, compression, and other external forces that may jeopardize their integrity.

Containment and Hygiene: Packaging provides a clean and controlled environment for products. It protects them from contamination by insulating them from dirt, dust, moisture, and other potentially dangerous elements. Properly sealed and designed packaging also prevents bacteria from entering and causing spoiling or health hazards.

Freshness and Shelf Life Preservation: Packaging is critical in keeping freshness and increasing the shelf life of perishable commodities such as food and pharmaceuticals. It may include elements such as barrier coatings, oxygen absorbers, desiccants, or changed atmospheres to assist retain product quality, flavor, and nutritional content.

Tamper-Evident Packaging: Tamper-evident packaging is required for many items to protect consumer safety and product integrity. Tamper-evident seals or features provide obvious signals whether the packaging has been tampered with, reassuring consumers that the product is secure and has not been tampered with.

Creating an Identity Through Branding

In the ever-competitive food and beverage sector, packaging is a potent instrument for building a distinct brand identity. Color schemes, typography, logos, and visuals are all meticulously intended to attract customers and reflect the brand’s values and personality. It affects consumer perception, elicits emotions, and increases brand recognition. Here’s a detailed explanation of how packaging affects product branding:

Packaging design establishes a product’s visual identity. It incorporates elements such as colors, typography, graphics, and logos that are consistent with the brand’s overall visual identity. Consistency in design across packaging variations aids in brand recognition and the formation of a cohesive brand image.

Brand Personality and Storytelling: Packaging design can communicate the brand’s personality and elicit emotional connections with consumers. The packaging tells a story about the brand’s values, heritage, and mission by using design elements, imagery, and copywriting. It creates a distinct brand experience that resonates with customers and distinguishes the product from competitors.

Target Audience Appeal: Packaging design should align with the preferences and expectations of the target audience. Understanding the target market’s demographic, psychographic, and cultural aspects enables firms to design packaging features to resonate with their individual tastes. Packaging can efficiently attract and engage the desired audience in this manner.

Quality Perception: High-quality packaging materials and design help to create the perception of a high-quality product. Packaging that is strong, made of high-quality materials and integrates deliberate design features conveys a sense of quality and attention to detail. It can improve consumers’ perceptions of product quality and increase their readiness to pay a premium.

Brand Extension and Consistency: Packaging design should connect with the broader brand strategy and ensure consistency across multiple product lines or variations. Consistent packaging features, such as color schemes, typography, and brand logos, establish a consistent brand identity that boosts recognition and trust. Packaging can also help with extension of brands by including familiar brand components when introducing new product lines.

Unboxing Experience: Packaging contributes to the overall customer experience, particularly during the unboxing process. Paying attention to small details in packaging design, such as distinguishing opening mechanisms, protective inserts, or personalized touches, improves the unboxing experience. A pleasant unboxing journey increases consumer happiness, generates social media a stir, and fosters brand advocacy.

Packaging, when intelligently designed, can successfully portray a brand’s identity, differentiate products, build emotional connections, convey quality, and add to a memorable customer experience. It is a powerful tool for reinforcing brand values, engaging consumers, and fostering long-term brand loyalty.

Information Communication

Packaging acts as a method for transmitting critical information to consumers, in addition to being aesthetically pleasing. It contains critical information that helps consumers make informed decisions, such as nutritional facts, ingredient lists, allergy warnings, and cooking directions. Over time, the desire for transparent packaging has grown as it promotes sustainable and ethical behaviors.

Functionality and convenience

Packaging, in addition to providing protection and branding, can also improve consumer convenience and functionality. Single-serve alternatives, resealable packaging, and on-the-go solutions have evolved to meet changing consumer lives and tastes.

Solutions for Sustainable Packaging

The food and beverage manufacturing business is embracing sustainable packaging options as environmental concerns grow by decreasing packaging waste, using recyclable and biodegradable materials, and implementing environmentally responsible practices throughout the package lifetime.

In conclusion

Packaging is the face of the food and beverage manufacturing industry, safeguarding the product while also communicating the essence of the brand. It plays an important role in molding customer impressions and driving purchasing decisions, from guaranteeing product purity to attracting consumers with eye-catching designs.

Manufacturers must aim for sustainable packaging solutions that blend functionality, aesthetics, and environmental responsibility as the business evolves. This helps elevate their brands and develop a strong presence in the competitive market by acknowledging the critical role of packaging in the success of products.

How Automation Has Changed the Manufacturing Industry Over Time.

Posted on 5 May, 202317 August, 2023 by aghosby

Nigeria, like many developing countries, has undergone significant changes.

Case study – the manufacturing industry which has evolved from being primarily agriculture-based to incorporating other industries such as textiles, automobile, and electronics.

With the introduction of automation, manufacturing in Nigeria has undergone a revolutionary change, with numerous benefits to businesses and the economy as a whole.

In the previous times, the industry faced a lot challenges like manual labour, unoptimized business processes , low productivity, unsafe working conditions, low yield and repeatability.

Despite these challenges, the country remains a significant manufacturing hub in Africa, producing a wide range of products from processed foods, textiles, cement, and pharmaceuticals.

Nevertheless, automation has helped to overcome some of these challenges and has brought about significant improvements in the manufacturing industry in Nigeria.

As a result ,businesses have been able to increase productivity, efficiency, and safety while reducing the costs of production.

As of today, the emergence of technology has influenced the use of machines, robots, sensors, and software to perform tasks that were previously done by humans.

For example , we now have the application of laser technology in manufacturing. In the past, materials were cut to shape using regorious methods and process , however with the advent of lasers, we now have materials that can we designed , passed into laster cutting machines and the machine cuts the material in 2 Dimentional space or even better , in 3D dimensions.

Taking a look at the food industry, Nigeria being the largest producer of cassava in the world has benefited hugely from the introduction of automation into the industry, of course, helping improve their processing methods and significantly increasing their output. Amongst other benefits industry leaders have enjoyed from automation, experts in manufacture have experience most importantly, a drastic reducing in processing time. Also, improve product quality, and increased efficiency. Another fun fact is that automation has also helped to improve the production of textiles in the country. As the largest producer of cotton in Africa, with automation, textile companies have been able to increase their output and improve the quality of their products.

Greenpeg Engineering is one of the companies in Nigeria that has been at the forefront of automation in the manufacturing industry. Established in 2009, the company provides solutions for automation, instrumentation, electrical engineering, mechanical engineering, and maintenance, and manpower development.

We have been helping businesses in Nigeria to implement automation in their manufacturing processes and have seen significant improvements in product output.

Despite the benefits of automation, implementing it in Nigeria poses some challenges. It requires a high initial investment, reliable electricity, and internet connectivity, a skilled workforce, and a supportive legal and regulatory framework.

These challenges are not insurmountable, and with the right support and infrastructure, businesses can reap the benefits of automation.

In conclusion, automation has revolutionized the manufacturing industry in Nigeria, bringing about significant improvements in productivity, efficiency, and safety while reducing costs and waste.

With the right support and infrastructure, businesses can implement automation in their processes and take advantage of the numerous benefits it offers. The manufacturing industry is poised for further growth, and automation will undoubtedly play a significant role in this.

Machine Condition Monitoring Techniques with SKF

Posted on 19 July, 202217 August, 2023 by aghosby

What Is Condition Monitoring?

Hands-on condition monitoring is essential for maximum bearing service life and machine health. To help ensure long bearing service life, it is important to determine the condition of machinery and bearings while in operation. Good predictive maintenance will help reduce machine downtime and decrease overall maintenance costs.

What is the purpose of condition monitoring?

Condition monitoring is a key component of managing the maintenance and operability activities in a modern operating and maintenance organization for nuclear and sophisticated power plants.

In essence, condition monitoring aids in maintaining the efficiency and safety of plant operations. The corresponding decision contexts are represented as process models in order to create a framework for comprehending issues and solutions linked to the use of condition monitoring data in strategic and operational maintenance decision-making.

The following condition monitoring products are the essential monitoring tools that no industrial manufacturing plant should be without:

Temperature Monitoring

Thermometers

Thermometers are essential for accurate temperature measurement of general equipment.

Since the dawn of the industrial age, operators and technicians know that abnormal temperatures often indicate that something is wrong with the machine.

Thermometers can help find and then measure these hotspots, allowing for further analysis.

SKF has a variety of thermometers and thermocouple probes to complement your condition monitoring or predictive maintenance program by assessing and reporting on temperature.

General-purpose thermometers
Contact thermometers
Infrared thermometers
Contact and infrared thermometers
Dual laser infrared and contact thermometers
K-type thermocouple probes

Thermal camera

A thermal camera enables you to detect hot spots before they cause trouble

Using an SKF Thermal Camera is a proactive way to help you detect problems before they occur, increasing uptime and improving safety. They allow you to be able to visualize potential problems, invisible to the naked eye, by presenting a picture of the heat distribution of an asset.

The thermal image, presented on a large LCD screen, shows you where the temperature is either too hot or too cold allowing you to pinpoint potential problems fast.

Thermal camera TKTI 21
Thermal camera TKTI 31

Speed Monitoring

Digital tachometer

Pinpoint accuracy combined with measurement versatility

The SKF TKRT 10 is a fast and accurate tachometer utilizing laser or contact to measure rotational and linear speeds. Equipped with a laser and a range of contact adapters, it is a versatile instrument and suits many different applications

Wide speed measurement range: up to 99 999 r/min for laser measurement and 20 000 r/min using contact adapters
Measurement modes include; rotational speed, total revolutions, frequency, surface speed and length in both metric and imperial units
A laser can be used for safe and quick, non-contact rotational speed measurements at distances up to 0.5 m (20 in.)
A large back-lit LCD display enables easy reading in almost all light conditions
The angular range of ±45° to target helps facilitate easy measuring
Up to 10 readings can be stored for later reference
Compact design; one-hand operated instrument
Supplied in carrying case for protection and portability

Multi-functional digital tachometer

The Multi-functional digital tachometer TKRT 20 is a user–friendly and accurate digital tachometer utilising laser or contact for measuring rotational and linear speed. Equipped with a laser and contact adaptor, it offers excellent speed measurement versatility in five different modes.

With this digital tachometer the user can select to measure:
– rpm, rps, m, ft or yards per minute or second,
– length or revolution counting, or
– time interval
The wide speed range and the various measurement modes make the TKRT 20 suitable for measuring speed in many applications
A large angular range of ± 80° to target facilitates easy measuring in areas where straight-line access is difficult
The large inverting LCD display facilitates easy reading even when pointing the unit down into the machinery
Compact design; one-hand operated instrument
Supplied in carrying case for protection and portability
The digital tachometer TKRT 20 can also be equipped with a remote laser sensor, which is optionally available

Visual

Endoscopes

Fast and easy inspection with video function

SKF Endoscopes TKES 10 series are first-line inspection tools that can be used for the internal inspection of machinery. They help minimise the need to disassemble machinery for inspection, saving time and money.

The compact display unit, with a 3.5” backlit screen, allows images and video to be saved and recalled, or to be downloaded and shared with others.

Three different models cater to most needs and are equipped with powerful variable LED lighting allowing inspections in dark locations.

A high-resolution miniature camera, with up to 2™ digital zoom, gives a clear and sharp full-screen image.
Available with a 1 meter (3.3 ft) insertion tube in three different variants; flexible, semi-rigid or with an articulating tip.
A small tip diameter of 5,8 mm (0.23 in.), with a wide field of view, allows easy access to most applications.
Supplied with a side view adapter allowing inspection of applications such as pipe walls.
Powerful magnets, and a tripod mount on the back of the display unit, allow the display unit to be used “hands-free”.
Up to 50 000 photos or 120 minutes of video can be stored on the SD memory card supplied.
Longer flexible and semi-rigid insertion tubes are available as accessories.
Supplied in a sturdy carrying case complete with all necessary cables, universal mains charger and cleaning kit.

Sound

Stethoscopes

Easily pinpoints bearing and machine noise

The SKF Electronic Stethoscope TMST 3 is a high-quality, sensitive instrument enabling the determination of troublesome machine parts by the detection of machine noises or vibrations.

TMST 3 includes a headset, two different length probes (70 and 220 mm) and a pre-recorded audio CD demonstrating the most commonly encountered troublesome machine noise, all supplied complete in a sturdy carrying case.

Excellent sound quality helps to reliably identify the possible cause of the noise
User friendly and easy to operate, no special training required
The lightweight ergonomic design makes it easy to operate with one hand
Excellent quality headset for optimum sound quality even in very high-noise environments
Pre-recorded demonstration CD and output for analogue recording help facilitate analysis and comparison
Supplied with two probes, 70 and 220 mm (2,8 and 8,7 in) enabling reach almost anywhere
Adjustable digital volume control up to 32 levels to reach the desired volume

Ultrasonic leak detector

Quick and easy detection of air leaks

Any compressed air system can experience leaks, which amplify the load on compressors and increase costs. The TKSU 10 helps users to easily find leaks from a distance, even in noisy industrial environments, via its ultrasound measurement sensor.

The built-in LED display assists the user in adjusting sensitivity and shows the measured ultrasound noise from leaking air, allowing the quantification of leaks and prioritization of repairs.

The TKSU 10 is designed for use in all industries utilizing compressed air, and it is particularly recommended for paper and chemical industries, as well as workshops with air-driven power tools.

Easy to use; no training required
Leak detection from a distance in noisy industrial environments
The Colour LED display assists in adjusting sensitivity settings and shows measurement values
Reduces energy and maintenance costs via leak identification and repair
Lightweight, handheld device with industrial headset included
Independently adjustable sensor sensitivity and headset volume
A flexible probe helps find leaks in difficult-to-access locations
The headset features a neckband design to wear with a protective helmet

Vibration

Basic handheld vibration sensor

Now both novice users and experts can easily, quickly, and accurately check the condition of rotating equipment throughout your facility.

Equipping your maintenance and operations personnel with this rugged, ergonomic and easy-to-use instrument can provide early warning of potential machine problems before a costly failure occurs.

Features

Quick and easy to set up and use, measurements are shown on a bright display viewable in low light to direct sunlight. Free online training is also available.
Lightweight, compact, and ergonomically designed, the SKF Machine Condition Advisor fits neatly at the belt line, in a pocket or in a tool kit. Exceptionally durable, the unit is rated IP 54 for use in industrial environments.
Alert and Danger prompts provide increased diagnostic confidence.
Measuring velocity, enveloped acceleration and temperature simultaneously saves time.
Efficient, economical and environmentally friendly, the rechargeable SKF Machine Condition Advisor operates for 10 hours on a single charge.
Flexible enough to work with standard 100 mV/g constant current accelerometers, an optional external sensor can be used for hard-to-reach locations and for more repeatable and accurate measurement results.

Multiple measurements with a single device

The SKF Machine Condition Advisor provides an overall “velocity” vibration reading that measures vibration signals from the machine and automatically compares them to pre-programmed International Organization for Standardization (ISO) guidelines.

An “Alert” or “Danger” alarm displays when measurements exceed those guidelines. Simultaneously an “enveloped acceleration” measurement is taken and compared to established bearing vibration guidelines to verify conformity or indicate potential bearing damage.

The SKF Machine Condition Advisor also measures temperature using an infrared sensor to indicate uncharacteristic heat.

Accuracy, flexibility and confidence

When performing measurements, the SKF Machine Condition Advisor’s acceleration sensor input signal is processed to produce two different measurements for each POINT on the machinery – overall velocity and enveloped acceleration.

At the same time, the SKF Machine Condition Advisor’s non-contact infrared sensor measures the surface temperature of the measurement location and simultaneously displays all three measurement values.

Depending on the SKF Machine Condition Advisor’s System setting, the front-panel LCD simultaneously displays:

Metric or Imperial units
Velocity in mm/s RMS or in./s derived Peak
The temperature in Celsius or Fahrenheit
Acceleration enveloping readings in gE

Quick Collect Sensor

The SKF QuickCollect sensor is an easy-to-use Bluetooth-enabled handheld sensor that connects to apps that work with both iOS and Android tablets and smartphones (and iOS smart watch). Combining vibration and temperature sensing, overall data can be viewed on the spot in real-time or pushed to the cloud for future analysis.

This SKF QuickCollect sensor is ideal for service, reliability, operations, or maintenance personnel as part of a walk-around data collection program.

Features

Velocity, acceleration enveloping, and temperature measurements
Bluetooth communication with tablets, smartphones, smartwatches
Easy to use sensor and apps
Easy to understand indications of machine condition
Rugged industrial design – Drop test 1,8 m (6 ft.), water and dust resistant (IP65)
Suitable for use in hazardous environments (ATEX Zone 1, Class 1, Div 1) (pending)
Rechargeable lithium battery (8 hours normal usage)
Option to connect, store and share data on the Cloud
Option to connect directly to SKF Remote Diagnostic Services
Connects to apps that work with both iOS and Android tablets and smartphones (and iOS smart watch).

Benefits

Gets you started quickly
Can be used with minimum training and experience
Identify developing rotating machinery issues before they become problems
Connect directly to expert advice when you need it
Expand functionality via apps to grow and complement your existing maintenance program

Measurements taken by the sensor are shown on your mobile device, which displays velocity, acceleration, and temperature as shown below. Each reading displays a current overall measurement, including alarm status, minimum and maximum values, and alert and danger thresholds

Static vibration sensor

The SKF Machine Condition Indicator is an economical vibration sensor and indicator for monitoring non-critical machines. It is ideal for machinery with constant operating conditions not previously monitored in plants.

The device can be compared to the “check engine” light in a car. What the “check engine” light does for the car, the SKF Machine Condition Indicator does for industrial machinery.

Internal sensors measure velocity, enveloped acceleration (bearing or gear impulsive vibration) and machine surface temperature.

The included magnetic read-key is used to activate the SKF Machine Condition Indicator, change operating modes, set vibration baselines and acknowledge alarms.

The unit features three LEDs to indicate the machine and bearing condition. Once the unit is illuminated, it alerts the predictive maintenance technician to do a root cause analysis on the machine.

In addition, it features a barcode with a serial number for machine identification purposes and easy incorporation into an Operator Driven Reliability (ODR) program, maintenance routes or scheduled check-ups.

Electrical discharge detector

Detect electrical discharges in electric motor bearings

The SKF Electrical Discharge Detector Pen (EDD Pen) is a simple to use hand-held instrument for detecting electrical discharges in electric motor bearings.

Electrical discharges are a result of motor shaft voltages discharging to earth through the bearing, causing electrical erosion, lubricant degradation and ultimately bearing failure.

Electric motors are more vulnerable to suffering electrical erosion in bearings when controlled by a Variable Frequency Drive.

When incorporated into a predictive maintenance programme, the EDD Pen can help detect bearings more susceptible to failure, and significantly prevent unplanned machine downtime.

A unique remote solution allows operation at a distance from the motors. This helps protect the user from touching machinery in motion
SKF technology*
No special training required
Capable of detecting electrical discharges on a time base of 10 seconds, 30 seconds or indefinite
LED Backlit screen, allows use in dark environments
IP 55 can be used in most industrial environments
Supplied standard with batteries, a spare antenna and language-free Instructions for use in a carrying case

To help you achieve this goal, SKF has developed a wide range of instruments for analyzing the critical environmental conditions that have an impact on bearing and machine performance. GREENPEG as an authorized SKF distributor and SKF partner in Nigeria is positioned to support you with SKF products and SKF condition monitoring services to reduce downtime and extend the lifetime of your equipment.

Improving Energy Efficiency in Wastewater Treatment Plants

Posted on 1 July, 202217 August, 2023 by aghosby

A wastewater treatment plant separates solids from the liquid and consists of two basic stages: primary treatment and secondary treatment.

In the primary treatment stage, larger solids are removed from wastewater by settling.

Secondary treatment is a biological process for further removal of the remaining suspended and dissolved solids through a biological process of adding microorganisms to the wastewater. This process is accomplished in an aeration basin.

The purpose of this white paper is to contribute to a better understanding of how to improve energy efficiency in wastewater facilities, it is known for a fact that one of the biggest expenses in wastewater treatment operations is the cost of energy to run the blowers and compressors that produce air for the aeration basins. Improvements in energy efficiency allow the same work to be done with less energy.

The figures most often cited are that 40 to 50 per cent of a wastewater plant’s total energy usage can be attributed to the aeration process. By measuring the system’s air flows with an accurate, repeatable Dissolved Oxygen sensor, the aeration process can be better controlled to optimize the process and minimise plant energy costs. Especially with the increasing costs of energy which is a major concern of plant operators. Typically, treatment plants have a high potential for energy savings.

Dissolved Oxygen Measurement is a means to improve energy efficiency

The organic wastes entering a wastewater treatment plant are broken-down using biomass. The biomass must be kept alive by maintaining the proper dissolved oxygen concentration throughout the treatment process.

The ability to maintain the proper concentration of Dissolved Oxygen in an aeration basin is necessary to keep microorganisms alive for a breakdown of the organic waste.

A precondition for effective measures is built around the knowledge about the process characteristics of the individual plant sections.

Sewage that flows into a treatment plant is sent to a Primary clarifier tank to remove the garbage and sludge. Thereafter, it is routed to an Aeration basin where biomass is added and oxygen is blown into the mixture to agitate it. The microorganisms in the biomass thrive on oxygen and cause the organic substances in the sludge to proliferate and the generated solids to be precipitated.

In the absence of enough dissolved oxygen, at least some of the biomass will die, and the organic wastes will not be properly treated. Contrarily, when there is too much-dissolved oxygen, usually from over aerating, the wastewater treatment plant is needlessly wasting costly energy.

Monitoring dissolved oxygen is an essential part of the activated sludge process. It assists in ensuring that there is sufficient dissolved oxygen in the process for the biological activity to take place, and helps to optimize energy usage through controlled air addition.

Maintaining a proper level of dissolved oxygen can only be accomplished by using an online instrument such as the Endress+Hauser On-line Dissolved Oxygen (DO) sensor that will accurately and continuously measure the dissolved oxygen concentration at various stages throughout the treatment process.

Equipping the aeration basin with online DO measurement automates the aeration system to maintain the correct amount of DO. With the presence of the Dissolved Oxygen sensor and the monitoring system in the Aeration tank:

Oxygen levels are controlled by comparing the measured oxygen concentration and the oxygen set-point
Optimized blower usage for reduced energy consumption which leads to a significant reduction in energy costs for the wastewater treatment plant

Greenpeg Engineering is one of the leading industrial, distribution and service companies in Nigeria that aims to revolutionize the industry through offerings in unrivalled product bouquet and engineered industrial solutions, applied by seasoned engineers with first-class technical know-how.

Our industrial services cut across industries such as Food & Beverages, Oil & Gas, Primary (mining, metals, cement), Power & Energy, Chemicals, Petrochemicals, Water & Wastewater, Life Sciences, Pulp & Paper and Renewable Energy industries.

13 Things to Consider Before Choosing Your PLC

Posted on 30 June, 202217 August, 2023 by aghosby

The importance of programmable logic controllers (PLC) across the manufacturing industry cannot be overemphasized. If there is one thing you should know: these mini-computers relevance goes beyond the manufacturing industry. They are now used in power, automobiles, and many more industries. Many companies manufacture quality and top-notch PLCs, such as Schneider Electric.

If there is one thing you might be curious about, it is your PLC selection criteria. You might be curious about what you need to consider when picking your own PLC.

You do not need to worry anymore, and we will discuss the perfect plc selection criteria for you. We will also give you the things you need to consider when selecting your plc.

Things to Consider when Choosing your PLC

Regarding PLC selection criteria, you will have to consider many things. Below is a list of the things you should consider when choosing your PLC.

Size

This is the first thing you need to consider if you are looking for a PLC selection criteria for your business. You should pay a lot of attention to the size of the plc. PLC comes in different sizes, and you should pick the one that is just okay for the purpose you need it for.

Regarding size as a plc selection criterion, you must ask yourself several questions. ” How big do I want my PLC? What are the functions the size can accommodate? Based on the location of the PLC, do I need a large or a small-sized PLC? All these questions play a vital role in PLC selection criteria.

You need to consider the size, especially if you move the plc from one place to another.

CPU Speed

It would be best if you considered this. It would be best to consider this when considering the plc selection criteria. You need to consider the CPU speed and how fast you want your plc to process information or give outputs.

There are different PLCs in the market today, each with a different CPU speed. The CPU speed largely influences the functions of the plc. If you need the plc for a large-scale business such as power transmission, you need a plc with a fast CPU speed.

Memory Capacity

Just as there are different types of plc regarding sizes and CPU speed, you should also know that there are various PLCs regarding memory capacity. Memory capacity is something you should consider necessary when you are looking at a plc selection criteria.

Does the plc I won’t have enough memory in its RAM and ROM? Do I need to get external storage to the plc? Is there enough space in the plc? It would be best if you asked yourself all these questions regarding the plc selection criteria.

Redundancy

When it comes to PLCs, some exhibit some level of redundancy; there are also some whose processing speed is much faster than the pieces of equipment connected.

You have to consider the redundancy rate regarding the plc selection criteria. What is the redundancy rate? Does the rate have to be reduced or enhanced? It would be best to consider all of these when choosing your plc.

Communication Technique

Another thing you must consider critical when looking at different plc selection criteria. It would be best if you took your time to know the plc communication technique or communication processes.

How does the input method work? Which device or equipment does it communicate with? What are the communication protocols? All these questions are pretty necessary when it comes to communication protocols as a plc selection criteria.

INPUT/OUTPUT (I/O)

PLCs come with different I/Os, and you should pay a lot of attention to them when you want to buy one for yourself. Regarding the PLC selection criteria, the I/O is relevant as it affects the mode of your operation.

You need to know how many devices or equipment you plc will or can control. You also need to confirm if any requirement is necessary for it to function with remote I/O interfaces.

Power Method

You should also consider the power method regarding the PLC selection criteria. You need to confirm if the plc has an inbuilt power source or if it has an external power source.

Some people prefer PLCs with an inbuilt power source, and others prefer an external power source when it comes to PLCs. Regardless of the one you like, do well to check the type of power source it uses when it comes to PLC selection criteria.

Compatibility

If you want to get your plc, you need to ascertain the compatibility of the plc. You need to know if the plc will be built from scratch. If it is being made from scratch, will it be uniquely created just for the purpose you want to use it for, or can you use it for other purposes?

Will the plc be able to interface with existing software or hardware? Are they compatible with just any device? All these questions are things you need to ask regarding compatibility as a plc selection criteria.

Scalability

When it comes to production, the output hardly remains static. This is why you need to consider scalability regarding PLC selection criteria. If the business needs expansion, can the PLC accommodate the expansion?

Can the plc accommodate new devices being added to it? If there is a need to reduce or scale down, can the plc be reprogrammed to do such? Scalability is essential when it comes to plc selection criteria.

This is because you can determine the amount of output you need for the production process as long as the plc is scalable.

External Environment

The external environment where the PLC will be placed is one thing that plays a vital role in plc selection criteria. Some settings are relatively harsh, and you would likely need particular casing types if you use PLCs in such an environment.

It would be best if you asked yourself the environment you will be using the plc. You also need to ask if your plc will need any protective gear or more once you look at the background.

Tasks / Actions

Some advanced PLCs can often perform individual actions such as robotics, safety, etc. If you want your plc to perform these actions, you must consider the tasks it can do when choosing a place selection criteria.

Although, the more advanced the action, the greater the cost. It would be best if you considered the exact purpose or reason for getting the plc.

If you want a simple or basic plc, you will not enjoy things such as motion control and a host of other things. However, If you’re going to enjoy motion control and other things, you must consider it when looking at the plc selection criteria.

Reliability

Nobody likes to get something that would stop working after a couple of months, and you need to consider the reliability and durability of the Plc the moment you are looking at the selection criteria.

Will plc last for a long time? What is the workload? Is there any guarantee or warranty? What happens if it develops a fault?

All these questions must be asked when looking at the plc selection criteria. The durability of the Plc will go a long way in determining how valuable the plc can be over a long time.

It doesn’t just determine the usefulness; it also determines how well you get the value of your money.

Cost

This is the most important thing to consider when choosing a plc selection criteria. It would be best if you thought about the cost of the plc you would like to get for yourself.

If there is one thing that is obvious about PLCs, it is that they come at various prices. Your budget will decide the plc you can buy regarding PLC selection criteria.

If a brand-new plc is too expensive for you, you can choose a fairly used one. However, they usually do not come with any guarantee. Regarding PLC selection criteria, the plc cost is the first thing or measure that should be on your list.

How Long Does a PLC Last?

PLCs are long-lasting and can easily continue functioning for up to 20 years or even longer, provided they are correctly maintained and occasionally upgraded. Let’s have a look at how.

Make sure that you keep it neat and clean.

The dust produced as a byproduct of industrial processes may contain corrosive or conductive components. To avoid potentially hazardous buildup, dust and particles should be removed regularly using bottled air.

Put the PLC away and inspect the air filters in the ventilation system.

Install the PLC in an enclosure that has a low level of dust. You can prevent it from overheating by often replacing the ventilation filters and ensuring that air can flow freely throughout the enclosure.

Verify your various power sources.

Be sure that the power source you are using does not result in any short circuits or surges of energy and that there is a steady flow of power. In places with significant vibration levels, it is important to check that all sockets, plugs, and terminal strips are connected safely and securely.

Put an end to the shaking.

Verify that the screws and bolts that are used to secure the I/O modules, as well as the PLC system itself, are in place. Check that they are in good shape and fastened securely enough to avoid rattling.

Protect against EMI and RFI interference.

Both electromagnetic interference (EMI) and radio frequency interference (RFI) have the potential to disrupt the operation of a programmable logic controller (PLC). Shield your PLC or position it, so it is not near any sources of interference.

Conclusion

When it comes to plc selection criteria, there are a lot of things you should consider. These things ranging from cost to size and a lot more will help you determine the type of plc you should get for yourself.

All the selection criteria you should consider have been discussed in this article. With a simple read-through, you will get all the necessary information.