Rubber dosing automation, Chennai manufacturing plant.

Pneumatic transport and precision dosing, end-to-end.

Pac Technologies commissioned a rubber transport and dosing system for a tyre manufacturing facility in Chennai, India. The system handles, conveys, and doses the key raw materials — carbon black, silica, polymers, bulk chemicals, oils, and silanes — tying pneumatic transport, weighing, dosing, and mixing into a single batch production line.

Industry

Manufacturing — Tyre

Service

Programming & commissioning

Location

Chennai, India

Year

2023

Control

Allen-Bradley ControlLogix · Ethernet/IP

SCADA & HMI

WinCC · Allen-Bradley PanelView

Many subsystems, one production line.

Tyre compound mixing is unforgiving on dosing accuracy: a few hundred grams of error across a batch can throw a recipe out of spec, and the line has to keep moving regardless. The facility brought together big-bag unloaders, dense and dilute pneumatic conveying, day bins, dosing scales, oil dosing skids, and diverter assemblies — each with its own behaviour, all expected to work together. The challenge was making that orchestra play in time, every shift, under real material conditions.

Commissioning, simulation, testing, and site implementation.

Pac Technologies' role focused on the commissioning, simulation, testing, and site implementation of the automation and control system. The base PLC and SCADA code came from another vendor; we did the on-site validation and the modifications needed to make it run reliably in production. The team worked across both the transport and dosing subsystems, checking communication, sequence alignment, and process integrity through commissioning.

Key activities included full I/O verification and simulation of control logic across the Big Bag Unloaders, Dense and Dilute Phase Conveying Systems, Day Bins, Dosing Scales, Oil Dosing Units, and Diverter Assemblies; functional testing and fine-tuning of PLC sequences for both automatic and manual operation modes; parameter optimisation for product transfer pressures, dosing speeds, and stabilisation times; and integration testing between PLC, SCADA, and field instrumentation to validate interlocks, permissives, and alarms.

On-site troubleshooting accommodated local mechanical variations, pneumatic line lengths, and material behaviour under production conditions. Operator support and training carried through start-up and the transition to production.

PLC

Allen-Bradley ControlLogix · distributed I/O

HMIs

Multiple Allen-Bradley PanelView

SCADA

WinCC — centralised monitoring & recipe management

Conveying

Dense-phase and lean-phase pneumatic sequences

Dosing

Precision weighing · dual-speed screw feeders

Safety

Oil-skid interlocks · E-stop circuits

Reliable, in-spec, in production.

The plant came online with stable, repeatable batch performance, the subsystems talking to each other, and the operational and safety requirements signed off. Most of the value came from on-site troubleshooting against real materials — the kind of fine-tuning that only shows up once the plant is running.