SCADA Control System for a Cutting Line
At MG Electricidad, we have carried out the comprehensive engineering, electrical panel design, and programming of a custom SCADA control system for an impressive continuous nut cutting and processing line. Exported to Turkey, this facility boasts a processing capacity of 3,000 to 4,000 kg/h. The success of this project lies in the perfect fusion of metal power—with the design of a main industrial electrical panel and satellite panels—and software intelligence, achieving operational decentralization without losing centralized supervision.
The Challenge: Decentralized Control in a High-Length Plant
Operating an industrial line of this scale requires much more than a simple start/stop button. We are talking about a complex mechanical and thermal flow that ranges from storage silos and thermal conditioners to high-precision cutting modules, vibratory sieves, and a large final horizontal cooler. The main challenge was to prevent operators from having to walk dozens of meters to make adjustments. MG Electricidad’s solution was to implement a divided physical architecture, governed by a unified SCADA control system.
Industrial Control Panel: From the Main Panel to the Machine
To resolve the plant’s needs, we structured the power and control into two levels:
- Main Industrial Electrical Panel: Designed and assembled in our workshop, this cabinet houses the “brain” of the installation. It contains the main PLC (Programmable Logic Controller) and an extensive bank of variable frequency drives (VFD) that regulate the centrifugal fans, rotary valves, and bucket elevators with millimeter precision.
- Field Satellite Panels: We distributed small secondary cabinets along the line. These satellites allow technicians to perform local maneuvers (such as clearing jams or maintenance tasks on the cutting tables) safely, communicating in real time with the central core.
HMI Interface: The SCADA Control System in Action
Managing almost 4 tons of product per hour requires an intuitive, fast, and fail-safe visual environment. The development of our SCADA control system focused on the following key functionalities:
Synoptic and Flow Synchronization
Through the touch screens, the operator views the general status of the plant. The system coordinates the sequential start-up of all motors to prevent load accumulations. It receives constant signals from the IFM inductive sensors in the elevators and manages the opening of the proportional valves based on pre-configured recipes.
Precise Thermal Traceability
One of the critical phases of this cutting line is temperature management. Our SCADA control system processes the analog signals (4-20 mA) from the temperature probes installed in the horizontal cooler’s refrigeration unit. This allows dynamically adjusting the three-way valves (Belimo type) and ensuring the nuts exit with the exact humidity and temperature conditions.
Intelligent Diagnostics and Geolocated Alarms
Given the length of the line, if a safety hinge opens or a thermal relay trips, the HMI interface instantly shows exactly which module or satellite panel is experiencing the incident. This streamlines the maintenance team’s work and reduces the MTTR (Mean Time To Repair).
Benefits for the International Client
Thanks to the engineering developed by MG Electricidad, the plant in Turkey has achieved:
- Safety and Ergonomics: Absolute control from the control room combined with the safety of being able to intervene at the machine via the satellite panels.
- Final Product Homogeneity: Closed-loop control over the thermal conditioner and cooler guarantees zero deviations in batch quality.
- Continuous Supervision: The SCADA control system is prepared for remote diagnostics, making it easier for our team to provide top-tier technical support regardless of borders.
