פרוייקטים
Recipe-Controlled Weighing
The production system uses two weighing channels controlled from a common PLC.
The operator selects the required recipe and number of batches through a dedicated Crystal OPC interface. The control system then manages the weighing sequence and required quantities.
For this application, Crystal OPC was specifically adapted to communicate directly with the weighing controllers, bringing weighing data and status into the same interface used to manage the production process.
Major ingredients, including salt and magnesium chloride, are weighed automatically. Smaller ingredients are added manually, and the system guides the operator through the remaining handling steps, including moving the weighing vessel between stations where required.
Combining Weighing Expertise with Production Automation
CrystalVision developed the automation architecture, PLC and HMI software, electrical and control integration, drives, sensors, installation and commissioning.
The project was carried out in cooperation with Prizma, which contributed specialist industrial-weighing expertise. Mechanical design and fabrication were divided between CrystalVision and a local mechanical contractor.
Long-Term Production Use
The system has remained in production use for more than a decade, with CrystalVision continuing to provide support and implement modifications to the control and weighing equipment when required.
The next phase, now underway, extends the production line with additional salt-handling and grinding capabilities.
The Result:
The system gives Red Sea a practical semi-automated process for producing 500 kg and 1,000 kg batches according to defined recipes.
Automating the main weighing operations while retaining manual steps where appropriate has improved process repeatability and reduced the amount of manual weighing and labor required.
Related Solutions
Automated Weighing & Dosing System for Reef Salt Production
Automating raw-material weighing and recipe control at "Red Sea"
Client: Red Sea Fish Pharm Ltd.
Location: Eilat, Israel
Application: Reef salt production
System: Semi-automated weighing and dosing system
Project Summary
Red Sea manufactures specialized salt blends for marine and reef aquariums, combining several raw materials according to defined production recipes.
CrystalVision developed a semi-automated production system that combines recipe control, automatic weighing of major ingredients and operator-guided manual additions. The system supports production batches of approximately 500 kg and 1,000 kg.
The Challenge - Accurate, Repeatable Production with Less Manual Work
Producing a formulated salt mixture requires several ingredients to be combined in the correct quantities and sequence.
Red Sea wanted to improve weighing accuracy and repeatability while reducing operator effort and the amount of manual labor required in the production process.
From Pilot System to Production Equipment
The project began with the development of a pilot system for handling and weighing powdered raw materials. The concept included material feeding from a bulk bag, screw conveying and a weighing hopper supported by load cells.
The operator entered a target weight through a dedicated interface. A process controller operated the screw conveyor through a variable-frequency drive, using feedback from the weighing system to control the quantity delivered.
The pilot provided the basis for the larger production system.
Need to Automate a Weighing or Dosing Process?
CrystalVision develops weighing and dosing systems around the actual production process, combining automation, weighing technology and material handling where required.