Color Batch Mixing System using PLC & HMI
Mixer Automation using PLC was designed and implemented. Different sensors are used to control the color ratio, level and quantity. PLC is used to control the operation. PLC controls the switching and automation works such as inlet, ratio, color level and drainage of the mixer. In case of emergency
2025-06-28 16:30:51 - Adil Khan
Color Batch Mixing System using PLC & HMI
Project Area of Specialization Mechatronics EngineeringProject SummaryMixer Automation using PLC was designed and implemented. Different sensors are used to control the color ratio, level and quantity. PLC is used to control the operation. PLC controls the switching and automation works such as inlet, ratio, color level and drainage of the mixer. In case of emergency alarm was energized and the entire system turns off automatically. Ladder diagram of PLC is simulated using TIA portal software and other software can also be used. Batch mixing is the more preferred mode of mixing for many industries and applications producing in small to medium capacities. The factors that influence the selection of such mixers are mixing duration, the size and geometry of mixer, and the operating conditions.
Project ObjectivesMixing of liquids that are miscible or at least soluble in each other occurs frequently in process engineering (and in everyday life). An everyday example would be the addition of milk or cream to tea or coffee. Since both liquids are water-based, they dissolve easily in one another. The momentum of the liquid being added is sometimes enough to cause enough turbulence to mix the two, since the viscosity of both liquids is relatively low. If necessary, a spoon or paddle could be used to complete the mixing process. Blending in a more viscous liquid, such as honey, requires more mixing power per unit volume to achieve the same homogeneity in the same amount of time.
Project Implementation MethodMixer is essentially a closed chamber in which liquids are mixed. There are mainly two types of liquid mixers – liquid batch mixer and liquid continuous mixer. At first, liquids are inserted in the mixing chamber through the inlets valves. At a certain level the inlets are closed and the motor connected to mixing shaft starts the mixing process. After a certain time period (set by the operator) the motor stops, and the mixing process ends. When the motor stops there is a signal sent to the drainage valve and it is open for the flow of mixed liquids in order to drain them from the mixer to the storage chamber. There are many different types of mixer used for different purposes like paint mixing, food and beverages, sanitizing some area, mixing medical and pharmaceutical products etc.
Benefits of the ProjectProject is very beneficial for the color industry. By using the implemented project, manufacturing of new and desired shades of color by mixing the main standard red, yellow and blue colors and by mixing them in the color batch mixing chamber. Easy to use and less human effort is required all done by the software and programming and accurate results for better implementations. Project is beneficiary for todays color industies such as wall paints automotive paints and ither kinds of volor paint operations.
Technical Details of Final DeliverableIn this project, we use PLC programming of Siemens/Delta PLC. We can also use other PLCs for this application.
Two level sensors are used for detecting the level of material A and material B. Also one bottom level sensor used for detecting the bottom level.
To control level of this system, single acting valve is used which has two states, either fully opened or fully closed.
Particular is provided to mix the material A and material B in a tank. We can use on delay timer this function.
After successfully completion of mixing, outlet valve is operated to drain the mixed material.
When mixing process is completed, buzzer will be activated and it will remain ON and after 5sec it will be automatically OFF.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 66000 | |||
| PLC | Equipment | 1 | 20000 | 20000 |
| HMI | Equipment | 1 | 15000 | 15000 |
| Electric motor | Equipment | 1 | 10000 | 10000 |
| Sensors | Equipment | 5 | 700 | 3500 |
| Electrical equipment and wires | Equipment | 8 | 500 | 4000 |
| Electronics equipment | Equipment | 10 | 300 | 3000 |
| solenoid valve | Equipment | 3 | 500 | 1500 |
| Project structure | Miscellaneous | 1 | 9000 | 9000 |