Case Study 105: Polymer Process
Industry Sector: Process Control
Polymer Process Machine


Allen Bradley ControlLogix
Allen Bradley PanelView Plus HMI

Staneco Corporation designed a control system for polymer mixing machines. Polymer is used in the process to remove particles from both drinking water and treated sewage. The system involved monitoring the level of a polymer tank. When the level dropped to a pre-determined point, a new batch of polymer was added. First water was added to a mixing tank to a pre-determined level. When the tank reached this level, a polymer powder was weighed and added. As the powder was added, a mixer started blending the water and polymer. The pre-determined polymer concentration was calculated. The mixture was then sent to a second mixing tank where more water was added to get the polymer concentration down to the required level. Finally the polymer was pumped into the final polymer tank. The system was set up to operate in two modes, demand batching and bulk batching; each having different control characteristics.

System allowed for customization of recipes enabling quality control of the product. HMI alarm indication reduced operator error and increased the machine life cycle.