BALIK process controls allow for a high degree of flexibility while offering an optimal fit into the production process. Operation safety is assured to the same degree as ease of use. Hardware and software are based on tried and proven modules, which are composed individually for every plant configuration.

Equipment ranges from a simple control panel combined with an SPS all the way to database-supported process control systems with client/ server structure.

Benefits of BALIK automation technology:

• Optimized processes
• High flexibility due to modular approach
• Simple operation, low error rate
• Modern, comfortable user menus
• Controlling ranging from simple small setups to complex total processes with automation concept
• Error elimination through verifiable error protocols
• Quality optimization through process documentation
• Process data management
• Hassle-free equipment updates
• System-independent data access from databases
• Network-compatibility

Process visualization

All visualization and control technology tasks in the production process are supported by one or more PCs. The operator PC has a special visual software (such as INTOUCH) installed. This software runs based on WINDOWS® NT. With that, the customer has a powerful and easy to use operator interface, which is operated either with keyboard and mouse or with a trackball. Operating instruction may be called up online with a comfortable and comprehensive help system.

The most important program modules include :

• Graphic display of the entire plant with flow chart
• Display of process status and production data
• Process images for detailed observation of processes and aggregates
• By request, the operating language can be projected and switched with the help of the database.
• Generation, changing, and archiving of formulation data
• Generation, changing and archiving or process parameters 
• Operation and observation of automatic product and cleaning programs 
• Administration of operation and error messages
• Full graphic trend function
• Display and archiving of historic data
• Operative data administration/ statistics / balances etc.

User administration

An easy process is available for administrating users of the process control system. Different access levels for automated operation, manual operation, parameter setting, service etc. can be set up.

Formulation control

An easy-to-use formulation and material editor is available for generating formulations. It includes the following functions :

• Generating and changing material/ ingredient lists
• Generating, changing and copying of formulations
• Administration of formulation-related parameters

The data are stored in a database. There is an additional function in visualization, which sends a formulation to SPS and takes over calculation for batch sizes, if required.

Planning system

This system offers the option to enter the formulation, the quantity to be produced and the the production sequence. Depending on their user rights, users can view formulation, or block them for production and plan new formulations. The data are stored in a database and may be called up from different work stations.

Resource planning

The following functions are included for resource planning :

• Release and blockage of raw materials and blends (raw material mixes)
• Consumption data for raw materials
• Container usage

Interfaces with goods management systems may have to be defined, and will be specified according to customer indications.

Protocols

Protocols of task-related or time-based process values in case of continuous dosing

Balance statements for raw materials and blends (based on data saved for consumption per batch and formulation as well as total consumption)

Operator information protocol databases.

Event-controlled; all messages (technical messages, alarms, errors) are saved in a message database.

Maintenance system

The service staff is provided with the necessary information. In addition, there is an option to freely edit all data and service instructions.

SPS controls - switchboard engineering

The SPS is responsible for control, regulation, monitoring and communication in the production process. Our standard product is Siemens SIMATIC S7.

The SPS program is generated with the software "SIMATIC STEP 7." Programming is done in "Instruction list" or "Function plan." All sensors and actors are connected with the SPS through input/output modules. All data and parameters required for the process are transferred by the PC.  Once a production program is started, the SPS program functions automatically. PC errors do not result in production interruptions.

SPS program modules include :

• Scaling of analogue sensors and actors
• Target/ current value comparison of all components (valves, motors)
• Monitoring of limit values
• Generation of operation and error messages
• Control of automated sequences for production and cleaning programs 
• Control of weighing programs (target/ current comparison of the weighing signal is done with separate hardware)
• Software control
• Data combination through network

All sensors and actors in the process are connected to a decentralized peripheral module system. The connection is based on bus systems. We normally use the systems "Profibus DP" or "Profibus PA."