When a global producer of industrial coating resins and additives located in Southeast U.S. sought to upgrade its aging Distributed Control System (DCS), minimizing production disruption was critical. A DCS system is a hub of a processor’s operations, monitoring key variables such as flow, applied temperatures, pressure, level and material conveying/handling.
The challenge was that replacing the manufacturer’s decades-old DCS had to be accomplished quickly while accurately maintaining the specifications of its final resin products. Failure do so would equate with lost revenue due to downtime or rejected product. Moreover, much of the documentation on the process was unavailable, and the tolerances were tight enough that there was a risk of product being produced out of specification.