Chemical Blending & Batching Automation with Rockwell PlantPAx

Cybertrol partnered with a chemical manufacturer to deliver an integrated process automation and manufacturing intelligence solution for a chemical production facility. The solution supports flexible blending and batching operations while providing centralized visibility, historian‑based reporting, and a scalable OT foundation to support ongoing operations.  

Engineering Challenge

The facility required an automation platform capable of supporting recipe‑driven batching and blending, tank Clean‑in‑Place (CIP) operations, and wastewater treatment monitoring within a unified control system. The scope included 11 outdoor bulk chemical tanks and 26 indoor bulk chemical tanks spanning both hazardous and non‑hazardous areas, along with 17 chemical mixing tanks, 24 chemical holding tanks, and 8 wastewater treatment tanks.

The automation solution coordinated bulk material transfer and distribution, controlled batch mixing and material routing, automated CIP sequencing across tanks and transfer paths, and continuous monitoring of wastewater systems. This integrated approach enabled consistent, repeatable batch execution while providing the operational visibility and traceability commonly required in large‑scale chemical manufacturing environments.

The system also required a robust OT and SCADA infrastructure designed to support distributed HMI/SCADA visualization, FactoryTalk®‑based historian data collection, SQL‑driven batch and CIP reporting, and secure remote access for operations and engineering support—enabling continuous visibility into both real‑time and historical process performance.

Solution

Cybertrol delivered a Rockwell Automation–based process control and information solution built on the PlantPAx® 5.0 system architecture. The implemented platform integrates process control, visualization, historian data collection, and reporting into a single, cohesive automation environment.

Controls & Visualization

• PlantPAx® (5.0) used as the core process control system

• Allen‑Bradley ControlLogix® controllers programmed using Studio 5000®

• FactoryTalk® View SE for distributed HMI and SCADA visualization

• Centralized program management and backup using FactoryTalk® AssetCentre

HMI development followed defined PLC and HMI standards to support device‑level control, consistent navigation, and alignment with PlantPAx object models.

Process Automation Scope

The automation platform provides centralized control and monitoring for the following process areas:

• Bulk Chemical Receiving and Storage – Controlled receipt, transfer, and distribution of raw materials from indoor and outdoor bulk storage tanks, including material routing and interlocks to support safe and reliable operation.

• Recipe‑Based Chemical Batching and Blending – Automated batch execution based on predefined recipes, supporting consistent product formulation, controlled ingredient addition, and repeatable batch execution across shared mixing assets.

• Automated Tank Clean‑in‑Place (CIP) – Sequenced CIP operations with defined steps, verification logic, and exception handling to ensure effective cleaning of tanks and transfer paths while minimizing operator intervention.

• Wastewater Treatment Monitoring – Continuous monitoring of wastewater treatment tanks, providing visibility into system status, operating conditions, and key process parameters.

• System Security and Access Control – Role‑based access control, managed operator interactions, and secure remote connectivity supporting both operational use and engineering support.

These process areas are integrated into a centralized control architecture, enabling consistent sequencing, interlocking, product and batch consistency, and secure operational visibility across the facility.

Historian, Reporting & Manufacturing Intelligence

The system includes comprehensive data collection and reporting capabilities to support operational review and traceability:

• FactoryTalk® Historian SE + Live Data Interface for time‑series process data

• Microsoft SQL Server® as the reporting database platform

• SQL Server Reporting Services (SSRS) for browser‑based report access

Delivered reports include:

• Detailed batch reports capturing batch ID, recipe, start/end times, setpoint vs. actual values, and relevant alarms or events

• Completed batch summaries by date range

• CIP wash reports combining historian trends with event‑based step history and exception tracking

Reports are accessible via standard web browsers and designed to support batch review and CIP validation workflows.

Example Enterprise CIP Wash Report – Detailed step-by-step event logs, historian trends (flow, temperature, conductivity), operator acknowledgements, and exception tracking (holds, inputs, alarms) provide complete visibility into process execution. 

OT Systems & Infrastructure

To support the automation environment, Cybertrol implemented a scalable OT foundation including:

• A VMware® vSphere–based virtual server environment supporting redundant SCADA and historian services

• A facility‑wide industrial Ethernet network structured around MDF/IDF architecture

• Segregation of OT and enterprise IT networks, supporting cybersecurity best practices, system reliability, and controlled data exchange between environments

• ThinManager® configured to support thin‑client HMI deployment, failover, and remote support capabilities

This architecture provides a resilient and expandable platform to support current operations and future system growth. 

Engineering, Commissioning & Support

Cybertrol provided complete controls engineering and commissioning services, including:

• Preliminary engineering and CAD services for control system design and documentation

• PLC and HMI development, simulation, and I/O checkout

• On‑site and remote commissioning support to validate system operation

• Ongoing support capability to maintain system performance, apply critical updates, and support operational needs

These services ensured a controlled system startup and a smooth transition from commissioning into sustained operation.

Results

The delivered solution provides a unified PlantPAx‑based automation platform supporting flexible chemical blending and batching operations. Integrated visualization, historian‑backed reporting, and OT infrastructure give operations and engineering teams clear insight into process performance, batch execution, and CIP activities.

The system establishes a scalable foundation for reliable day‑to‑day operation while supporting long‑term maintainability and future expansion.