The project involved full system integration and development of PLC Motor Control and Human Machine Interface cabinets, including drafting of schematics and managing their manufacture and on-site installation.

The operator interface included multiple color touchscreens set up on an industrial network in conjunction with lamps and pushbuttons. To implement the process requirements the system incorporates all necessary digital and analog hardwired I/O plus additional networked and hard-wired interfaces between existing areas of the plant. The project involved a fully automated ingredient delivery system, with an emphasis on intrinsic safety due to the volatile nature of the process ingredients.

Essential to the development of automated systems including the mixer is the delivery of a safety system in accordance with relevant Australian safety standards. Specific to this project, the interlocking circuit incorporated a system of captive key switches and motor motion sensors in order to achieve the level of safety required to ssatisfy the hazard identification and risk assessment passed on the system.

For advanced monitoring and diagnostics of the process, a SCADA package was developed and incorporated into the process to complement the control system. Including most basic operations such as process trending, real-time mimic pages, alarm logging and process overviews and descriptions. The higher order functionality of this system includes the external storage process data within external databases, using the SCADA system as the tool to pass process information from the plant floor to the database file, and using this data to produce process reports and maintenance analysis.