CASE STUDY
From Manual to Semi-Automated: Laying the Groundwork for Scalable Manufacturing
Innovative Building Material Manufacturer
Building Materials Manufacturing
Control System Design; PLC Programming (ControlLogix); HMI Development (Ignition)
P&ID Development; Electrical Design Support
Overview
This building materials manufacturer was relying entirely on manual operation of their Form Mixing System, measuring and mixing both wet and dry materials by hand. To support increasing demand and reduce operational strain, they partnered with TMPC to implement the facility’s first step toward automation.
Problem
The facility had no existing automation for the Form Mixing System, relying on fully manual measurement and operation. This resulted in labor inefficiencies, high operator strain, and inconsistent batch processing, making it difficult to scale or optimize production.
Solution
TMPC designed and implemented a semi-automated system using a ControlLogix PAC and Ignition HMI. Working closely with the customer, TMPC helped select and integrate field devices including solenoid valves, flow and level transmitters. Logic-based sequence steps were programmed for operators to follow, allowing for better control, consistency, and monitoring of production processes.
Results
- Increased production throughput with improved timing and accuracy
- Reduced operator workload by automating the most labor-intensive steps
- Enabled clearer monitoring and control of ingredient addition
- Created a scalable platform to build future phases of automation
Future Collaboration Opportunities:
TMPC is positioned to support future automation phases as the customer looks to scale production. Potential additions include expanded network architecture, enhanced process controls, and further reduction of manual intervention.
“We really enjoyed working with your team.”
