ISBN-13: 978-1537584836

Proceedings of ICAER-2016

AUTOMATION OF BATCHING PLANT USING PLC AND SCADA

Meghana.M 1 Asma Anjum 2 Jayashree Venugopal 3 P.Pramila 4
1,2-

Students-Venjay Institute 0f Automation

Jayanagar , Bangalore-560-011,India

3-

proprietor,Venjay Institute 0f Automation

Jayanagar , Bangalore-560-011,India
4-

Prof and HOD ,Department of Electrical And Electronics Engineering,

Bangalore Institute of Technology, Bangalore 560 004,India
1

meghangowda6@gmail.com, 2asmaanjm11@hotmail.com
3

krj50@hotmail.com, 4pramila_madhuri@rediffmail.com
chemical industries, steel and aluminum producing, cement
industries, bottling industries etc.

Abstract
This paper presents the need for effective automation using
PLC and SCADA in the process control in any competitive
industry. To overcome the demand for high productivity, greater
efficiency and to reduce the human intervention in industries,
automation is all of the prefer solution.

PLC is programmable logic control is used for internal storage of

instruction for implementing functions logic, sequencing ,timing,
counting and arithmetic, to control through digital and analog
inputs\outputs modules.

A flexible system that can be controlled by the user at the site

is preferred. Systems whose logic can be modified but still, used
without disturbing its connection to external world is achieved by
plc with automation

A PLC has inputs and outputs section to connect the PLC to the
machine with its sensors, solenoid, switches, electrical motors etc.
A PLC first checks each inputs\outputs to determine its status (OFF
or ON) the PLC executes the program one instruction at a time and
performs the required action. Finally the PLC updates the status of
the outputs and continuously keeps repeating the process.

Thus this paper takes an attempt to explain the automated

and process industries in general, with an example of batching
plant system methodology in particular, with PLC and SCADA .

SCADA (supervisory control and data acquisition) is a computer

system for gathering and analyzing real time data. It provides an
interconnection between PLC and the process which is taking place.
SCADA helps to provide to record and storing of large amount of
data from process.

1. INTRODUCTION
In current manufacturing companies, the purpose of automation is
increasing productivity, increasing quality, reducing cost and
achieving flexibility in manufacturing process to compete in todays
market.

The implementation of automation in batching plant using PLCs and

SCADA systems in the process of manufacturing is considered ,with
an attempt to explain its methodology, which provides knowledge of
the batch by batch process which is undergoing during the
manufacturing of concrete blocks in an actual practically working
automated batching plant.

In many plants continuous monitoring and inspection at frequent

intervals is required, there are possibilities of errors at measuring and
various stages involved with human intervention and also lack of
some features in microcontroller.
In order to automate a plant and minimize human intervention, the
need of automation is developed with PLC and SCADA which is
used for monitoring and controlling in process industries such as

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ISBN-13: 978-1537584836

Proceedings of ICAER-2016
The load given by the load cell is added inside the load cell
controller. The load cell controller gives an analog output, using
which the PLC will generate counts. After the completion of
weighing, the bucket elevator is turned On by the PLC until the load
on the bucket elevator reaches zero (indicates that material in the
bucket elevator is fallen into mixer).

2. METHODOLOGY
A batching plant, in which the process of manufacturing concrete
blocks by combining various ingredients which are accurately
weighed, mixing them in sequence and then delivers the mixed
concrete to compacting machine were concrete blocks are produced
batch by batch.

Cement weighing system, consist of cement container tank from

which the cement is supplied through screw conveyer using screw
motor and using a hopper with load cell controlled by PLC which
allows the fixed amount of material to enter into the mixer.

Batching plant has three sub systems

Aggregate weighing systems

Cement weighing
Water computing

Water computing, addition of water is an important process in

concrete technology which contributes to the strength of the concrete
products. Water should neither be less nor more, hence it is a
complex algorithm followed by keeping a track with cement and sand
ratio.

Aggregate weighing system, this section of plant has 4 bins

consisting of crushed dust, sand, and gravel. Each bin is provided
with motorized gate which is controlled by the PLC. The motorized
gates open and close one after other allows only prescribed weight of
the material to fall on the travelling bin which is measured using a
load cell by the PLC. The four load cells are used which supports the
bucket elevator as shown in fig-1.

Automation in any industry mainly deals with protection, control and

monitoring and supervision. Hence automation is always provided
with auto and manual mode for the safety purpose.
Automation of miniature batching plant with the PLC and SCADA
systems was taken up and the working of the plant process with batch
by batch was achieved by setting up its control and power wiring as
shown in the fig -2

Fig. 2: Control and power setup.

3. RESULTS

Automation of the concrete batching plant, SCADA

provides all the information on its screen of all the process
which is taking place in the plant. As shown in fig-3 the
SCADA screen provides full setup with all the three
process of Aggregate weighing systems, Cement weighing,
Water computing and also the mixer of the batching plant.
Thus automation with PLC and SCADA in a process
manufacturing industries provides flexibility to the
systems.

Fig. 1: Block diagram of concrete batching plant

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Proceedings of ICAER-2016
REFERENCES
[1] Prof. Burali Y. N., PLC Based Industrial Crane Automation
& Monitoring, ISSN: 2278-4721, Vol. 1, Issue 3 (Sept 2012), PP
01-04.
[2] M. Kanmani, J.Nivedha, G.Sundar. Belt Conveyor Monitoring
and Fault DetectingUsing PLC and SCADA, may 2014.
[3] Joanna Marie M. Baroro, Melchizedek I. Alipio, Michael
Lawrence T. Huang, Teodoro M. Ricamara, Angelo A. Beltran Jr
Automation of Packaging and Material Handling Using
Programmable Logic Controller,(ISSN: 2277 1581),Volume
No. 3, Issue No. 6, pp: 767 770. 1 June 2014.
[4] Chief Editor: Dr.K.R.Harane, Editor: Prof D.O.Patil, Prof
R.M.Sahu. , plc based power plant coal level sensing system
using ultrasonic sensor, International Journal of Innovative
Technology & Adaptive Management (IJITAM) ISSN: 2347-3622,
Volume-1, Issue-6, March, 2014.

Fig. 3: SCADA screen.

[5] Hemant Ahuja, Arika Singh, Saubhagya Tandon, Shreya

Srivastava, Sandeep Pal., Automatic Filling Management System
for Industries, February 2014.

4. CONCLUSION

[6] Shashank Lingappa M.1, Vijayavithal Bongale2, Sreerajendra3,

PLC Controlled Low Cost Automatic Packing Machine,, 2014.

By using automation based on PLC and SCADA we can increase

productivity and replacing human intervention which reduces
operation time and increases consistency output. Hence with the
example which is presented in this paper, the automation with PLC
and SCADA of a miniature portable concrete batching plant is
explained with a working block diagram and SCADA screen of the
plant.

[7] Sunil R. Kewate1, S.V. Karmare2, Nehal Sayankar3 and

Siddharth Gavhale4. Automatic Speed Control System by the
Color Sensor for Automobiles An Control System by the Color
Sensor for Automobiles An Innovative Model Based
Approach., ISSN 2250-3234 Volume 4, Number 2 (2014), pp. 223230.

Acknowledgement
Mrs. Jayashre Venugopal received her masters degree from
Visvesvaraya Technological University, Bangalore, Karnataka,
India and worked as Assistant professor in Electrical and
Electronics Engineering. Department, ACSCE, Bangalore.

The authors wish to thank the managing director of VENJAY

AUTOMATION, Mr. R. Venugopal for providing the facilities.
The encouragement gratefully acknowledged.

Meghana. M and Asma Anjum has completed their bachelors of

engineering in Electrical and Electronics Engineering from
RGIT, Bangalore.
Dr.P..Pramila
received
her
masters
degree
from
U.V.C.E,Bangalore, Karnataka, India and her Ph.d from
Vinayaka Mission currently working as professor and Head of
Electrical and Electronics Engineering, Department, BIT,
Bangalore.

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