This document discusses the automation of a batching plant using programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA). It begins with an introduction to automation and why it is needed. It then describes the methodology used, including the aggregate weighing system, cement weighing system, and water computing. It discusses how PLCs and SCADA were implemented to automate the batching plant process. The results section shows the SCADA screen that provides monitoring of the entire process. In conclusion, automation with PLCs and SCADA was able to increase productivity by replacing human intervention and provide consistent outputs for the concrete batching plant.

1. AUTOMATION OF BATCHING PLANT USING PLC AND SCADA
Meghana.M 1
Asma Anjum 2
Jayashree Venugopal 3
P.Pramila 4
1,2-
Students-Venjay Institute 0f Automation
Jayanagar , Bangalore-560-011,India
3-
proprietor,Venjay Institute 0f Automation
Jayanagar , Bangalore-560-011,India
4-
Prof and HOD ,Department of Electrical And Electronics Engineering,
Bangalore Institute of Technology, Bangalore – 560 004,India
1
meghangowda6@gmail.com, 2
asmaanjm11@hotmail.com
3
krj50@hotmail.com, 4
pramila_madhuri@rediffmail.com
Abstract—
This paper presents the need for effective automation using
PLC and SCADA in the process control in any competitive
industry. To overcome the demand for high productivity, greater
efficiency and to reduce the human intervention in industries,
automation is all of the prefer solution.
A flexible system that can be controlled by the user at the site
is preferred. Systems whose logic can be modified but still, used
without disturbing its connection to external world is achieved by
plc with automation
Thus this paper takes an attempt to explain the automated
and process industries in general, with an example of batching
plant system methodology in particular, with PLC and SCADA .
1. INTRODUCTION
In current manufacturing companies, the purpose of automation is
increasing productivity, increasing quality, reducing cost and
achieving flexibility in manufacturing process to compete in today’s
market.
In many plants continuous monitoring and inspection at frequent
intervals is required, there are possibilities of errors at measuring and
various stages involved with human intervention and also lack of
some features in microcontroller.
In order to automate a plant and minimize human intervention, the
need of automation is developed with PLC and SCADA which is
used for monitoring and controlling in process industries such as
chemical industries, steel and aluminum producing, cement
industries, bottling industries etc.
PLC is programmable logic control is used for internal storage of
instruction for implementing functions logic, sequencing ,timing,
counting and arithmetic, to control through digital and analog
inputsoutputs modules.
A PLC has inputs and outputs section to connect the PLC to the
machine with its sensors, solenoid, switches, electrical motors etc.
A PLC first checks each inputsoutputs to determine its status (OFF
or ON) the PLC executes the program one instruction at a time and
performs the required action. Finally the PLC updates the status of
the outputs and continuously keeps repeating the process.
SCADA (supervisory control and data acquisition) is a computer
system for gathering and analyzing real time data. It provides an
interconnection between PLC and the process which is taking place.
SCADA helps to provide to record and storing of large amount of
data from process.
The implementation of automation in batching plant using PLC’s and
SCADA systems in the process of manufacturing is considered ,with
an attempt to explain its methodology, which provides knowledge of
the batch by batch process which is undergoing during the
manufacturing of concrete blocks in an actual practically working
automated batching plant.
ISBN-13: 978-1537584836
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©IAETSD 201684

2. 2. METHODOLOGY
A batching plant, in which the process of manufacturing concrete
blocks by combining various ingredients which are accurately
weighed, mixing them in sequence and then delivers the mixed
concrete to compacting machine were concrete blocks are produced
batch by batch.
Batching plant has three sub systems
 Aggregate weighing systems
 Cement weighing
 Water computing
Aggregate weighing system, this section of plant has 4 bins
consisting of crushed dust, sand, and gravel. Each bin is provided
with motorized gate which is controlled by the PLC. The motorized
gates open and close one after other allows only prescribed weight of
the material to fall on the travelling bin which is measured using a
load cell by the PLC. The four load cells are used which supports the
bucket elevator as shown in fig-1.
Fig. 1: Block diagram of concrete batching plant
The load given by the load cell is added inside the load cell
controller. The load cell controller gives an analog output, using
which the PLC will generate counts. After the completion of
weighing, the bucket elevator is turned On by the PLC until the load
on the bucket elevator reaches zero (indicates that material in the
bucket elevator is fallen into mixer).
Cement weighing system, consist of cement container tank from
which the cement is supplied through screw conveyer using screw
motor and using a hopper with load cell controlled by PLC which
allows the fixed amount of material to enter into the mixer.
Water computing, addition of water is an important process in
concrete technology which contributes to the strength of the concrete
products. Water should neither be less nor more, hence it is a
complex algorithm followed by keeping a track with cement and sand
ratio.
Automation in any industry mainly deals with protection, control and
monitoring and supervision. Hence automation is always provided
with auto and manual mode for the safety purpose.
Automation of miniature batching plant with the PLC and SCADA
systems was taken up and the working of the plant process with batch
by batch was achieved by setting up its control and power wiring as
shown in the fig -2
Fig. 2: Control and power setup.
3. RESULTS
Automation of the concrete batching plant, SCADA
provides all the information on its screen of all the process
which is taking place in the plant. As shown in fig-3 the
SCADA screen provides full setup with all the three
process of Aggregate weighing systems, Cement weighing,
Water computing and also the mixer of the batching plant.
Thus automation with PLC and SCADA in a process
manufacturing industries provides flexibility to the
systems.
ISBN-13: 978-1537584836
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©IAETSD 201685

3. Fig. 3: SCADA screen.
4. CONCLUSION
By using automation based on PLC and SCADA we can increase
productivity and replacing human intervention which reduces
operation time and increases consistency output. Hence with the
example which is presented in this paper, the automation with PLC
and SCADA of a miniature portable concrete batching plant is
explained with a working block diagram and SCADA screen of the
plant.
Acknowledgement
The authors wish to thank the managing director of VENJAY
AUTOMATION, Mr. R. Venugopal for providing the facilities.
The encouragement gratefully acknowledged.
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Mrs. Jayashre Venugopal received her master’s degree from
Visvesvaraya Technological University, Bangalore, Karnataka,
India and worked as Assistant professor in Electrical and
Electronics Engineering. Department, ACSCE, Bangalore.
Meghana. M and Asma Anjum has completed their bachelors of
engineering in Electrical and Electronics Engineering from
RGIT, Bangalore.
Dr.P..Pramila received her master’s degree from
U.V.C.E,Bangalore, Karnataka, India and her Ph.d from
Vinayaka Mission currently working as professor and Head of
Electrical and Electronics Engineering, Department, BIT,
Bangalore.
ISBN-13: 978-1537584836
www.iaetsd.in
Proceedings of ICAER-2016
©IAETSD 201686