State-based approach of sugar boiling process automation in batch vacuum pan

In this paper, state base approach for implementation and design of A grade batch vacuum pan is proposed. Nexgenie NG16-ADL Programmable Logic Controller (PLC) is used to control the first batch vacuum pan. This design helps to improve operators’ interaction and with less intervention with ease. This system designed for auto mode and manual mode in order to have better control over the system. This enhances the good grain size development for the centrifugal process. The operator on the pan floor can readily take readings and control the process environment using this system in real time. The operator may set desirable set point for every parameter or can carry the execution with default set point during the sugar boiling process. Different states have different set points for every parameter. Using Ladder Diagram (LD) and Function Block Diagram (FBD) as the main programming language for PLC, fully automated centralized control system for batch vacuum pan is proposed.  Sugar boiling process in batch vacuum pans with state base design batch vacuum pans are automated, PID control loops are used for temperature, pressure vacuum, level, and brix. Every state uses different Setpoint to minimize operator intervention and also reduces the use of resources in the control environment. This leads to the better production of sugar crystals. The operator may take real time action using this.