Cliente — Adhesive Production

Complete design and implementation of a production facility with 9 production islands for polyurethane and neoprene adhesives.

Adhesives production plant
CASE STUDY

Project Overview

il cliente is a leading international company in the production of sprayable neoprene and polyurethane-based adhesives. To meet their growth and modernization needs, I designed and fully implemented an entire production facility consisting of nine distinct production islands, each with specific process requirements and rigorous quality parameters.

The project covered the entire lifecycle: from designing the Siemens PLC architecture to developing operator HMI panels, from process sensor integration to complete plant commissioning, through to the development of the cloud-based supervision system.

THE CHALLENGE

What the client needed

il cliente needed a complete production system that could manage the complexity of nine different production lines simultaneously, each dedicated to different chemical formulations. The main challenges included:

  • Managing complex production recipes with variable parameters for each adhesive type, ensuring precision and repeatability.
  • Implementing an automatic measurement system for viscosity, temperature, and pH for each production batch, with automatic quality certificate generation.
  • Ensuring complete traceability of every produced batch, from raw material to finished product.
  • Enabling real-time remote monitoring of production status, allowing managers to supervise the facility from external locations.
  • Designing a scalable and reliable system, capable of operating continuously without interruptions.
THE SOLUTION

What I delivered

I designed and developed the entire automation and supervision system, from PLC architecture to cloud monitoring software. The delivered solution includes:

  • Siemens PLC Automation: Complete programming of 9 independent production islands, each with dedicated control logic for managing production cycles, component dosing, and process parameter control.
  • Operator HMI panels: Intuitive graphical interfaces for each island, designed to allow operators to manage recipes, monitor parameters in real time, and intervene quickly in case of anomalies.
  • Recipe management: Flexible system for creating, editing, and archiving production recipes, with the ability to recall saved configurations and adapt them to each batch's specific needs.
  • Automatic quality certificates: Automatic generation of certificates for each produced batch, containing measured viscosity, temperature, and pH data, categorized and archived for traceability.
  • Cloud-based supervision: Internally developed monitoring system that allows the client to check production status in real time from any remote location via web browser.
RESULTS

Project impact

9
Operational production islands
100%
Per-batch traceability
24/7
Remote monitoring
0
Manual certificates needed

The implementation allowed il cliente to fully automate the production process, eliminating manual quality certificate generation and ensuring complete traceability for every batch. The cloud supervision system gave managers full visibility on production in real time, regardless of their physical location, significantly improving reaction times and decision-making capability.

TECHNOLOGIES

Tech stack

✓
PLC Siemens (TIA Portal)
✓
Siemens HMI
✓
Cloud-Based SCADA
✓
Process Sensors (Viscosity, Temperature, pH)
✓
Automated Recipe Management
✓
Automatic Quality Certification

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