InBatch batch production system with production simulator at Stepan
The design and implementation of the InBatch batch production system with a process simulation platform marked the beginning of our long-term cooperation with Stepan, which continues to this day.
In the chemical industry, strict process safety requirements apply. Dosing, mixing, and processing of raw materials in chemical reactions take place in closed systems, which enhances operator safety. The control system plays a critical role by managing interlocks, ensuring precise process parameter control, maintaining high product quality, and guaranteeing stable plant operation.
Goals
- Increased operational efficiency
- Reduced control system maintenance costs through implementation of globally standardized solutions
- Lower maintenance and operational expenses
- Improved process parameter control
- Increased product repeatability and quality
- Shorter time-to-market for new products
- Reduced waste generation
Challenges
- Very short implementation and system switchover time
- Strict safety requirements in the chemical industry
- Implementation of Alarm and Interlock Management ensuring plant and personnel safety
- Development of a process simulator replicating the production plant and its operations
Solutions
- Wonderware InBatch
- Wonderware System Platform
- Wonderware InTouch
- Process simulation system
- Siemens SIMATIC S7-1500 controllers
- Danfoss VLT® FC302 drives
Benefits
- Increased production efficiency
- Reduced production cycle time by approx. 2 hours for selected products
- Precise control of production process parameters
- Improved product quality
- Increased production repeatability
Abour Stepan
Stepan operates in the chemical industry and is one of the world’s largest producers of aromatic polyester polyols. The company’s production facilities are located in North America, China, Germany, and Poland — in Brzeg Dolny.
With many years of experience, strong technological expertise, and innovative solutions, Stepan delivers high-quality products that ensure ease of processing and excellent final product properties. Its global and local portfolio includes polyester polyols used in the production of sandwich and insulation panels with PIR foam cores, spray insulation foams, technical insulation materials, C.A.S.E. products — coatings, adhesives, sealants, and elastomers — as well as flexible foams.
Employees of Stepan Polska
Decision to implement the system
The decision to implement a new control system was driven by the need to optimize production costs, reduce maintenance expenses associated with the existing system, and ensure scalability for future plant expansion.
A proven solution was considered, one that enables both operational efficiency and advanced process safety requirements. Wonderware is a standard platform used in Stepan facilities worldwide; therefore, the same technology was selected for the plant in Poland.
Stepan’s engineers were looking for a system integrator that met strict project requirements, including strong technical expertise, familiarity with global standards, and programming methodologies enabling efficient implementation of a complex control system. We met these requirements and initiated the project execution.
Control-Service engineers discussing the new solution
Role of Wonderware InBatch
Wonderware InBatch podczas realizacji produkcji wysyła sygnały sterujące do urządzeń, monitoruje ich stan i dynamicznie reaguje na zdarzenia występujące w procesie. Dzięki kompletnemu modelowi systemu, obejmującemu informacje o surowcach, InBatch odpowiada za zarządzanie produkcją wsadową, w tym dobór urządzeń, uruchamianie wsadów, kontrolę zużycia materiałów, prowadzenie szarż oraz precyzyjne raportowanie produkcji.
Takie podejście wspiera optymalizację procesu, zwiększa powtarzalność produkcji i umożliwia lepsze zarządzanie jakością produktu końcowego.
Production process simulator
One of the key elements of the implementation was the production process simulator developed by Control-Service. The software replicates the operation of the entire production plant and allows the control system to be tested before commissioning on the real installation.
The simulator enabled verification of control logic, optimization of process parameters, and operator training in a safe testing environment. As a result, we were able to reduce the risk of errors during system switchover, shorten commissioning time, and improve the quality of the first production batches after implementation.
Production process simulator developed by Control-Service
Key aspects of the implementation
Selection of appropriate software
The use of Wonderware InBatch enabled the implementation of a system tailored to batch process manufacturing in the chemical industry. The solution supports efficient batch management, increases equipment utilization, improves operational efficiency, and simplifies the introduction of new products to the market.
Collaboration with the Stepan team
A key factor in the success of the project was close cooperation with Stepan engineers. Their deep process knowledge, experience, openness to new solutions, and results-oriented approach enabled smooth and efficient project execution.
System integrator flexibility
During the project, we provided continuous technical support and responded flexibly to the needs of the Stepan team. As a result, the cooperation developed into a long-term partnership based on trust and joint development of industrial automation solutions.
Process simulation software
The simulator developed by Control-Service enabled realistic replication of plant operations, thorough system testing, and optimization of production parameters. This resulted in reduced production cycle times and improved product quality. The first production batch after system replacement achieved higher quality compared to batches produced using the previous system.
Summary
The implementation of the Wonderware InBatch batch production system with a process simulation platform enabled Stepan to increase operational efficiency, improve process parameter control, and enhance product quality and repeatability. The project also reduced control system maintenance costs and established a scalable foundation for future plant development.
The execution of the project marked the beginning of a long-term cooperation with Stepan, which continues to this day. Together, we are continuously developing automation, control systems, and batch production solutions for demanding chemical processes.
