Automated Process Control System (APCS) for Water-Based Paint Production

Project Overview

A comprehensive automated process control system (APCS) was developed and implemented for a new water-based paint production facility. The system provides full control over the technological process — from raw material intake to precise component dosing.

Process Description

The control system automates key operations of the production cycle, including:

• Accurate dosing of technological components
• Continuous monitoring and regulation of process parameters
• Automatic activation of alarms and safety interlocks in emergency situations
• Control of shut-off valves and pumps during abnormal conditions
• Supervision of raw material reception and transfer operations

The system operates in two main modes — loading and unloading — each governed by its own algorithm for actuator control. All real-time process data and alarms are displayed on the operator panel.

Implemented Solution

Hardware Platform

• Controller: Mitsubishi Electric MELSEC FX2NC
• Operator panels: Mitsubishi Electric GOT930
• SCADA system: MX4 SCADA

Technological Equipment

• Electromagnetic flowmeters for measuring product flow rates
• Strain-gauge and hydrostatic pressure sensors for tank mass measurement
• Limit-level sensors for overflow protection
• Pneumatic valves and diaphragm pumps for process control

Functional Capabilities

• Automated liquid dosing through valve and pump control
• Real-time monitoring of process and emergency conditions
• Automatic prevention of incorrect operator actions
• Automated tracking of raw material dosing and consumption
• Full process visualization via the SCADA system

Results and Benefits

• Increased productivity through automation of technological operations
• Reduced defect rate by eliminating the human factor
• High dosing accuracy and repeatability of production results
• Scalable platform ready for future expansion of the production line