Soudal High Performance Materials (Taixing) Co., Ltd. is a wholly owned subsidiary of Belgium based Soudal Group and serves as its key manufacturing base for high-performance sealing and bonding materials in China. The company specializes in the R&D and production of specialty chemicals including silicone sealants, modified silane adhesives, polyurethane adhesives and foam sealants.Wellthinic Technology delivered a fully integrated automation project for its Taixing plant, helping the customer build a standardized and scalable automation system. The solution lays a solid OT layer foundation for future plant digital transformation and upper level MES system interconnection, enabling safe, efficient and continuous production for fine chemical production lines.
Solution Description:
The plant-wide distributed control system for fine chemicals is constructed based on the SIMATIC S7-1515 PLC series and the TIA Totally Integrated Automation Portal. Adopting a distributed control and centralized monitoring architecture, each production line is deployed with an independent S7-1515 CPU together with ET200SP remote I/O to manage field equipment including reaction tanks, agitators, pumps and valves.Standardized equipment function blocks are programmed in accordance with the IEC 61131-3 standard. Open TSEND/TRCV communication enables millisecond-level data interaction. Segregated OT and IT networks are implemented alongside VLAN isolation and MRP ring redundancy to guarantee stable communication.The system reserves standardized OPC UA interfaces for deep integration with the MES (Manufacturing Execution System), supporting recipe download, process interlocking and real-time upload of operating data. It is equipped with comprehensive mechanisms for fault diagnosis, safety interlocks and multi-level access control. The solution balances system reliability, maintainability and horizontal scalability, complying with fine chemical safety production requirements and the industrial cybersecurity standard IEC 62443.Built upon SIMATIC S7 1515 PLC series and the TIA Totally Integrated Automation platform, a plant wide distributed control system is constructed for fine chemical production. Adopting a decentralized control and centralized monitoring architecture, each production line is equipped with an independent S7 1515 CPU paired with ET200SP remote I/O modules to manage field equipment such as reaction tanks, agitators, pumps and valves.Programs are developed with standardized equipment function blocks complying with IEC 61131-3 standards. Millisecond level data exchange is realized via TSEND/TRCV open communication. OT and IT dual network segmentation is implemented together with VLAN isolation and MRP ring network redundancy to ensure stable communication.Standardized OPC UA interfaces are reserved for deep integration with the MES manufacturing execution system, enabling recipe download, process sequence linkage and real time upload of operating condition data. Equipped with comprehensive mechanisms for fault diagnosis, safety interlock and multi level access control, the solution balances system reliability, maintainability and horizontal scalability, and complies with fine chemical safety production requirements as well as IEC 62443 industrial cybersecurity standards.
Implementation Effect:
Build a unified plant wide automation control foundation to realize centralized monitoring and coordinated scheduling of multiple production units.
Deliver precise closed loop control of process parameters throughout operations. Automatic fault alarming and fast fault location greatly reduce on site manual inspection and operation costs.
Enable data connectivity between the underlying automation system and upper-level MES, achieving full process traceability of production data and significantly improving the continuous and stable operation capacity of production lines. It fully supports the plant upgrade toward digitalized, refined and safe smart manufacturing.
