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Siemens Industry Automation has worked with chemical and pharmaceutical intermediates manufacturer, Phoenix Chemicals, to provide process control solutions.

The solutions are said to have helped deliver three key benefits: enhanced production flexibility, improved product consistency and a reduction in costs.

The enhancements are based upon the Siemens PCS7 process control system.

The solution allows Phoenix engineering personnel to configure the control system to meet changing production requirements, without having to rely on outside expertise.

Siemens has to date installed four PCS7 process control systems at Phoenix’s processing facilities, with plans in place to add a fifth system in the future.

The company manufactures its products to meet the needs of customers across international markets, with a typical example being the production of APIs (active pharmaceutical ingredients) for the pharmaceutical industry.

Phoenix’s management team was seeking improvements in both the operational efficiency of its production processes, as well as a need to remove the potential for product inconsistencies during production due to operator actions.

The PCS7 automated process control systems installed on the various continuous production processes have, over the years, helped address these key operational objectives.

Phoenix now has an ability to take a more agile approach to manufacturing so that processes can be readily and speedily reconfigured for different products.

This supports an ongoing need to meet shorter times to market.

The PCS7 system has also resulted in the reduction in numbers of required operator personnel as remotely mounted operator stations deliver the same operational solution.

The control system has enabled the business to reduce its ongoing service, maintenance and training needs with an effect upon associate costs.

Such benefits are seen across the varied production processes implemented by Phoenix Chemicals, with typical process control automation applications including a wiped film evaporation plant and a multi-reactor API plant, while another PCS7 application is dedicated to laboratory work where chemicals are developed in micro-bore piping.

Integral to the PCS7 solution is its ability to use Profibus digital networks, which are used extensively on the manufacturing site to communicate with intelligent motor drives and field instrumentation, including those installed by other vendors.

With its integrated central database and specific Profibus management tools, offering the PCS7 control system alongside industrial PCs and network switches, as well as local Siemens’ technical support, means that Phoenix Chemicals has been provided with a completely integrated and supported package.

Siemens Automation and Drives

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