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Micro Instruments & Control Systems

Market Leaders in Process Automation of Sugar Mill

Market Leaders in Process Automation of Sugar Mill

MICS has been installing control and automation systems for Sugar plants since 1996. We have a growing reputation for providing easy-to-use, flexible, and innovative control systems, backed up by our excellent support service and expertise in the Sugar Mill Automation sector. The MICS control system is the market leader and has been installed in hundreds of Sugar Mill plants all over India. It has a modern architecture based on Microsoft Windows which allows it to be scaled from small on-size mills to larger multiple line compound Sugar mills.

 

We understand the challenges of the sugar mill industry. Our innovative products and solutions help meet economic and policy requirements for the safe production of sugar. Our wide-ranging suite of products, honed and improved through years of research and development, means we are perfectly situated to
assist in all stages; cane feeding, juice making, and Juice Sulphitation. We are present in activities ranging from onshore and offshore production facilities to refining and processing, to transportation, storage, and distribution.

 

Building on a wealth of experience, we know to offer you the best sugar industry process automation possible. We design and produce the __________________ control equipment that are used in the most vital parts of the oil and gas industries. In all cases, our products provide a high degree of durability, control, and safety.

 

How we work
MICS' products have been developed over many years implementing control systems for the Industry sector. Our engineers are highly experienced in PLC/DCS control installations and this is vital to ensure a successful project.

 

Product development has a continuous improvement plan with new features being added through our experience in different plants and customer requirements. New innovative features are designed with the flexibility to meet most mill's needs. This philosophy creates a solution that brings together the best in practice from a wide spectrum of the Process Automation industry.

 

Project implementation is performed in line with our ISO 9001 quality system. Generally, this is in the following stages:-

Quotation and overall design
MICS' engineers will study and discuss the customer requirements to suggest how these can be best achieved. For upgrades to existing plants, a site visit will provide an understanding of the plant and enable us to advise where the current system can be improved. We will provide you with an overall design at a fixed price.

Detailed design
MICS' engineers will design the layouts and submit these for customer comment and final approval.
A hardware layout and input/output list would be produced, detailing all electrical connections.

Hardware procurement
All hardware is standard off the shelf equipment available worldwide. Purchasing is monitored in line with our ISO 9001 quality system.

Configuration
MICSs engineers will configure the control system following the requirements using their extensive experience.

Office testing
All of our systems have built-in simulation to make testing thorough and highlighting any problems before installation. Our ISO 9001 quality system provides checklists to ensure a comprehensive test.

Customer acceptance test
The customer will be shown the system running in full simulation. Any issues can be discussed and resolved before installation.

Operator Training
The built-in simulation means that operators can be trained hands-on with realistic operation either in our offices or on-site.

Site installation and commissioning
For a refit/upgrade, we normally have one or more checking weekends before the main changeover weekend. This then gives you confidence for a short successful installation, minimizing downtime.

Support
MICS provides free 24 hours / 7 day support for the first year after installation and thereafter via a support contract. MICS' design means that there is always built-in redundancy and 'instant' remote access in case of problems.

If you are thinking of a new installation or an upgrade to your existing plant, contact MICS today for a no-obligation proposal and quotation highlighting all the advantages of a Micro Instrument and Control System.

 

Sectors
MIC Systems generally work in the Process Automation of Industries. This includes sugar mills, cement plants, power, distillery, paper plants, and other processing plants.

24x7 Support
MICS provides 24/7 support for all our control systems. This support is initially provided over the phone. Our engineers can connect remotely (from office or home) to our customers' systems via the internet. Due to the modular and configurable architecture of our software, issues are normally diagnosed and fixed over the remote connection.

 

Out of office hours support line
Our office hours are 10:00 to 18:00 GMT. MICS out of hours support line is permanently manned. When you ring you are identified by a caller group using the number you have dialed. This group then refers to a list of engineer's names (four per list – replacements are added to cover public holidays). At the top of this list, you will find at least one engineer who is familiar with your plant. The operator will try to connect you to the engineer at the top of the list. If he or she is unavailable, then the operator will proceed down the list. If all engineers on the list are unavailable, the operator will take down your details and attempt to call the engineers 10 minutes later. If they are all still unavailable then, the support is further escalated and one of the MICS directors will be contacted.

 

Support email
Minor issues can be sent to our dedicated email address; micro.controls@gmail.com. These, like all other issues, will be added to MICS excel based help desk system where an engineer is assigned the task. MICS' management team monitors the help desk system to check all issues are addressed promptly.

 

Warranty
Your system will be under warranty for 12 months from the start of meaningful production. This includes 24-hour support. MICS Systems will pass on any manufacturer's warranties that go beyond this for any hardware supplied.

After 12 months, the customer may take out a software maintenance contract to provide 24-hour software support. Support will be conditional upon the customer providing a suitable means of connecting remotely.
Service

MICS can provide training, calibration, maintenance, and mill utilization study services.

 

Sugar Mill Automation

Sugar plant automation and optimization
Worldwide, sugar mills are being modernized and automated in response to the vital need for more efficient production, to be able to compete globally.

 

Sugar processing is an energy-intensive industry that requires precise control and continuous reliability, especially during seasonal production cycles. We help connect independent production processes and suppliers with a distributed control system that provides a single interface to control production. And, we help you do more with less energy, from reusing centrifuge braking energy to replacing cane mill steam turbines with variable speed drives and induction motors. Along with energy savings, these solutions reduce maintenance costs, improve availability and provide precise speed control. 

 

Many known sugar brands around the globe turn to ABB with their requirements for distributed control systems (DCS), measurement & analytics, HMI, energy-efficient motors, drives, and PLC, manufacturing execution systems (MES), process and production intelligence software, robots, and more. They get access to state-of-the-art, proven tools, process knowledge, and partner network that help them reduce operating costs, get started on their digital journey, and unlock new business value.

 

20% Reduction of Power Consumption
For example, steam consumption can be calculated, monitored, and controlled to match the actual demand of individual parts of the plant, which have a direct impact on overall power consumption, resulting in a reduction of up to 20%. Or switching to a modern ABB rib cooled motor and drive package can reduce cane crusher energy consumption by 40% while improving reliability in harsh conditions.

25% Increase in Production output
After automation system modernization by ABB partner in India, the throughput of Baramati Agro sugar plant increased by 25%, plant availability improved by 15%, power consumption decreased by 10%, manpower costs reduced by 50%. Complete plant information, history and diagnostics help further improve sugar and cogeneration processes.

Why one should opt for Automation?
Automation in the industrial workplace provides the advantages of improving productivity and quality while reducing errors and waste, increasing safety, and adding flexibility to the manufacturing process. In the end, industrial automation yields increased safety, reliability, and profitability. 

 

8 Reasons You Need To Invest in Industrial Automation

  • Reduce Worker Fatigue and Effort or Labor Intensive Operation – Typically, humans dislike banal, repetitive tasks. However, computer systems perform them without complaint. Tasks that lack variability provide a place for automated systems to shine, but this also holds true for systems utilizing advanced sensors and integration. If the task requires conditions not suited to human comfort or focus, consider automation.
  • Prevent Products or Materials from Being Damaged or Destroyed – Humans make mistakes when they fatigue. This embodies the sentiment of the "human condition." Mistakes using tools mean damaging raw materials, components, assemblies, and end products.
  • Prevent Non-conforming Product from Shipping – Computers controlling robots do not forget steps. Neglecting to put in a screw requires a human touch. A machine not doing it yields an error to be addressed. Does the process require doing something in a specific order to improve yield? Automated systems will not violate the instruction set. Moreover, automated systems may employ inspection capabilities. Tune the system and allow the data to roll in without preference or bias.
  • Increase Efficiency – Improving processes for efficiency makes a company more competitive, but do people always do the same thing, in the same way, every time they do it? No, human variation exists. Automated systems allow for improvements that benefit from consistent execution. Perfect planning and training do not defend against the human touch.
  • Collect Better Data – Remove the accidental data entry or missed data point from logging. Make the method of collecting sensor and process data regulated.
  • Improve Metrics – Sending reliable data directly to a database provides an ongoing resource. Does the process improve with changes? Why do I see more failures now than in the past? Leveraging data can provide these answers beyond a simple list of pass/fail statistics from the past. Correlation of associated process data with pass/fail records provides insight rather than guessing "what is causing this?".
  • Devise the Right Process Improvements – Automated systems now collect reliable data. The database provides a searchable forum. What comes next? Equipped with copious amounts of reliable data, engineers make the most of this information. Where problems existed, light shines on the problem. Rather than just changing to seek "continuous improvement," make changes with better information.
  • Save Money – Why instrument that test stand? Why log that data? Why spend the money now? Simply, inventing in industrial automation yields cost savings through making processes more regular and collecting data for making confident decisions.

 

How automation leads to optimization in sugar manufacturing plants?
Control - Improved control of every stage of the process. Shared information, across the entire enterprise, for faster, smarter, more profitable decision making.

 

Every. Thing. Controlled.

  • Varying raw materials, unpredictable orders, and the demand for new product varieties require flexibility in production planning.
  • Rising costs of energy consumption and pollution control, complying with environmental standards call for energy and emissions monitoring and simplified reporting.
  • Ever-changing food safety standards emphasize the need for better raw material traceability, laboratory sampling, and product control.
  • Visualize - Empower your teams for their daily work on plant floors with real-time and historical data, by connecting and visualizing entire operations

 

End-to-end visibility

  • Consistent, easy, user-friendly, logical interface improves operator intuitive actions and productivity
  • Pre-determination of the required KPIs and relative measurements improve the efficiency of the cycle
  • Loops performance and quality measurements were reported to management to easily rectify faults and errors in the field or in the process, to achieve savings in loop time, fuel consumption, vapor generation, etc.
  • Less time to troubleshoot problems through accurate and easy diagnosis about where who and when problems happen
  • Optimize - Act on operational insights both from your own plant and the network of similar companies that advance continuous and batch process manufacturing

 

Data-driven manufacturing

  • Increase sugar/sweeteners production output and safety through more efficient utilization of company assets and capacities, and thus reduce the Total Cost of Ownership (TCO)
  • Introduce new sugar product varieties that are economically viable, consistent in quality, traceable, and available just-in-time for the customers
  • Reduce energy costs, utilize sugar manufacturing by-products as renewable energy sources, protect water security and meet local environmental regulations

 

You can also benefit from our 20+ years of experience in sugar processes. MICS is different
MICS's pre-engineered sugar control library can deliver precise handling of all steps of the process and ensure consistent and high-quality sugar products. We offer pre-studies, function specifications, system layouts, process applications, batch / S88, MES / S95, horizontal/vertical system integration, reporting, training and validation. We know the scientific, engineering and business reasons that underpin decisions. We incorporate this understanding into our end-to-end solutions.