Rubber Transport and Dosing System – Chennai, India

Overview

Pac Technologies was engaged in the commissioning of a complex rubber transport and dosing system for a state-of-the-art tyre manufacturing facility in Chennai, India. The system automates the handling, conveying, and dosing of key raw materials including carbon black, silica, polymers, bulk chemicals, oils, and silanes. It integrates multiple subsystems across pneumatic transport, weighing, dosing, and mixing to ensure precision and consistency in batch production.

Scope of Work

Pac Technologies’ role focused on the commissioning, simulation, testing, and site implementation of the automation and control system.Although the base PLC and SCADA code were provided by others, Pac Technologies performed extensive on-site validation and modification to ensure reliable operation under real production conditions.Our team worked across both the transport and dosing subsystems, ensuring seamless communication, sequence alignment, and process integrity throughout the commissioning phase.

Key activities included:

• Full I/O verification and simulation of control logic for all system modules including Big Bag Unloaders, Dense and Dilute Phase Conveying Systems, Day Bins, Dosing Scales, Oil Dosing Units, and Diverter Assemblies.

• Functional testing and fine-tuning of PLC sequences for automatic and manual operation modes.

• Parameter optimization for product transfer pressures, dosing speeds, and stabilization times to achieve accurate and repeatable batch performance.

• Integration testing between PLC, SCADA, and field instrumentation to validate interlocks, permissives, and alarm functionality.

• On-site troubleshooting and modifications to accommodate local mechanical variations, pneumatic line lengths, and material behavior under production conditions.

• Operator support and training during start-up and transition to production.

Technical Highlights

• Allen-Bradley ControlLogix PLC system operating on Ethernet/IP with distributed I/O and multiple Allen-Bradley PanelView HMIs.

• Centralized SCADA monitoring and recipe management system using WinCC integrated with the plant’s production supervision layer.

• Implementation and testing of both dense-phase and lean-phase pneumatic conveying sequences for bulk material transfer.

• Calibration and validation of precision weighing and dosing systems, including dual-speed screw feeders and oil dosing skids.

• Verification of safety zoning and emergency stop circuits ensuring safe isolation of transport and dosing sections.

Outcome

Through rigorous testing and commissioning, Pac Technologies ensured the complete system operated reliably and within specification.The plant achieved stable and repeatable batch performance, smooth integration between subsystems, and compliance with operational and safety requirements.Our adaptive approach to troubleshooting and fine-tuning on site played a key role in transitioning the project from installation to full-scale production.