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Chemical industry

PCS7 – Comprehensive modernization of production lines for plastic plants

In 2000, PRO-CONTROL carried out a comprehensive modernization of PVC granulate production lines for plastic plants. For this purpose, the modern SIEMENS PCS 7 system was used.

Investor requirements: 

  • supervision over the operation of the entire installation,
  • server redundancy,  
  • Industrial Ethernet bus, 
  • teleservice
  • use of the existing ones,
  • automation elements, 
  • weight system

System description

Scope of implementation:
Storage and transport of loose and liquid raw materials;
• Production of granules – line A;
• Production of granules – line B;
• Production of granules – line E;
• Preparation of masterbatches;
• Transport and storage of granules.

Digital system:
SIMATIC PCS 7 from Siemens

System components:
• 2 operator stations,
• 5 process stations,
• 1 engineering station,
• 1 recipe station,
• 11 remote I / O cassettes,
• 8 SIWAREX weighing systems.

System bus:
• SIMATIC Industrial Ethernet,

approx. 1800 I / O signals


A fully integrated automation system enables the control of PVC granules production lines. Production orders entered into the system are carried out on the basis of recipes prepared on the recipe station integrated with the system.

The system validates the recipe, divides the order batches and sends them to reali-sation on the appropriate line according to plan pro-duction. The system monitors the entire batch process all the time, carries out complex sequences of dosing, weighing and mixing, maintaining the set time and temperature parameters.

The Siemens PCS7 system verifies the currently existing raw materials on production lines, sets the appropriate transport routes, and then sends them from storage tanks to appropriate daily tanks, ensuring the constant availability of raw materials necessary for production.

The finished product – PVC granules – is automatically transferred to the silos at the packing station or on the loading tank trucks and rail.

The flexibility of the system allows for its further expansion and connection with management systems and support business processes in the plant (such as SAP ERP).

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