Two-roll mill Buhler SZAE-900. Replacement of the control and drive system


Two-roll mill Buhler SZAE-900 for primary grinding of chocolate mass. The need to replace obsolete control system equipment (year of manufacture - 1993, controller discontinued)


Reduced downtime thanks to the reliability of the new control system

Save maintenance resources and reduce troubleshooting time from hours to minutes with control system diagnostics

Reduce troubleshooting time and reduce operating costs through the use of modern unified components

Creation of a unified system for monitoring performance indicators with the possibility of analytics and scaling


Modernization of the control system

Replacement of controller equipment: modern universal controller Siemens SIMATIC S7-1500 and touch operator panel Siemens SIMATIC Basic Panel

Replacement of low-voltage switching equipment: introductory machine, starting assemblies, intermediate relays

Replacement of sensors: mass sensor on shafts, pressure sensors


Control system in accordance with the international standard OMAC PackML (ISA-TR88.00.02), providing data for calculating OEE (Overall Equipment Effectiveness) and RCA (Root Cause Analysis of Stoppages); interface for communication with MES / MOM, a set of modes, states and parameters of the machine, the reasons for transitions between states, a standardized appearance

Siemens SIMATIC S7-1500 controller with stepper motor control for automatic shaft gap setting

The weight of the hopper is measured using a load cell connected to the Siemens SIWAREX controller module and the ability to calibrate from the operator panel

Specialized optical sensor for the presence of mass on the shafts


Development of a set of schemes


PLC: Siemens SIMATIC S7-1500

HMI: Siemens SIMATIC Basic Panel


Placement of new equipment in existing control rooms

Installation of sensors

electrical connection


Configuring Devices and Sensors

Calibration of the weighing system


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