Specialty Chemical

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Chemical Manufacturing Process Automation

Asset utilization, quality, regulatory compliance, long-term ownership costs and the viability of legacy-installed systems. These factors are always on the minds of chemical manufacturers. A common thread to the success of any chemical producer is reliable automation infrastructure to meet the needs of today’s specialized chemical processes.

Malisko has wide-ranging experience with specialty chemicals and can help you lay the ground work for all facets of your automation solutions. Our experts provide you with the necessary chemical engineering process automation your business needs to thrive and excel.

Applications for Automated Chemical Processing

Amines
Automated Process Control and Information Systems for Paints, Finishes, Resins, Lubricants
Batching & Pre-weigh
Blending / Mixing
Bulk Material Receiving
Bulk-Chemical Systems
Catalysts
Chillers
Clean in Place (CIP)
Custody Metering and Transfer
Endothermic Reactions
Exothermic Reactions
Filtration
High-Pressure Pumping
Monomers
Pigging
Reactors
SIL (Safety Integrity Level) Compliance
SIS (Safety Instrumented Systems) for HAZOP and LOPA
Surfactants
Tank Farms for Ingredients, Intermediates and Finished Product
Truck and Rail Car Unloading and Loading
Ultra-Filtration
Vacuum and Exhaust Systems
Waste Water Pretreatment Plants
Water Systems (DI)
Validation

Validation is an Essential Part of Automation and Control in Chemical Processing

We believe a complete system sets you up for success, and that includes making sure that your system not only works, but also meets regulations. Validation of your systems is an essential part of automation and control in chemical processing facilities. We take care of all the paperwork to properly validate your system. Your system will be secure. And you will have comprehensive documented evidence to show auditors. We build your system to protect data through a collection of technological and procedural controls. You will have extensive electronic records, and they will be authentic and incorruptible.

Essential Documentation for Controls Engineers in Process Industries

Discover the essential documentation every controls engineer needs in process industries. From User Requirements Specifications to Detailed Design Specifications, Malisko clarifies the key documents crucial for project success and alignment with regulatory standards.

Heat Exchangers Offer Big Processing Paybacks

While it may not be as prominent as many other dairy processing technologies, the heat exchanger is far from lowly. The equipment, which is used to transfer heat between two or more fluids during the cooling and heating processes without mixing the fluids together, can have a major impact on processing efficiencies and operating expenses.

Case Study: Pharmaceutical Company Begins Manufacturing New Generic Therapeutic Drug with The Help Of Advanced Process Automation System

A pharmaceutical manufacturer needed to finalize production of a new generic therapeutic drug. As part of their initiative, they wanted to include a state-of-the-art, robust, expandable, and supportable automation system to control, data archive and report on their world-class process.

Our Approach to Automated Chemical Processing

We recognize that no two chemical processing plants are the same. In our experience, production processes can vary widely, and this greatly influences the needs of your particular facilities. Malisko delivers quality chemical process automation designed around your plant’s specific needs and goals. Whether you need to start from scratch or enhance existing systems put in place by another firm, Malisko is here to help.

Our approach to automated chemical processing has delivered proven results for our clients over the last 25 years. Our goal is to provide our clients with consistent and reliable automation systems, and deliver measurable ROI. Here’s more on how we achieve those goals.

Site Assessment

Before we can design your new system and implement automation solutions that save you money and improve efficiency, we have to understand your challenges. To achieve this, we can engage with you to perform a site assessment. We listen to your operators, maintenance staff, engineers and operations personnel to fully understand your process, how your business operates, the problems you want to solve and what success means to you. Most important, we take the time to understand the best ways to collaborate with your in-house engineers throughout the automation process as we become familiar with your facility and the systems that make it run.

Our site assessment follows a tried and true process and is the first step in implementing an automation solution. During each site assessment, we will:

  • Identify Existing Automation Controls
  • Identify Potential Cost-Saving Solutions
  • Identify Opportunities
  • Business Justification
  • Presenting Automation Solutions
Front-End Engineering Design (FEED)

Successful engineering has to align everyday production with the big picture. Each processing unit and work cell must come together with your automation system to form not only an efficient production process but also one that matches your business goals and realities. When we present an automation solution to you, we make sure it matches your budget, your timeline, your current production realities and your goals, all while minimizing risk.

Our Front End Engineering Design (FEED) sets the foundation for a successful project accomplished on time, on budget and in a way that fits your in-house team.

If the needs of your business, plant and production line change over time, our systems come ready to change along with them. And if you need, we’ll even tweak the system design to fit the skill sets of your support team. We believe the best systems change for you. It shouldn’t be the other way around.

Once the FEED is completed, you will receive:

  • Outlined Business Objectives
  • Project Timeline & Budget
Detailed Engineering and Design

In our detailed engineering and design service, we transform the conceptual into the final design. We use all the knowledge we gain from the automation solutions site assessment and Front End Engineering Design (FEED) to minimize your risk, get you running quickly, and align our work with your business realities. Here we will also flush out project risks, planning for them by nailing down a realistic project budget, execution plan and timeline.

Malisko both designs your automation system and implements it. Our detailed engineering and design service picks up right after our FEED services leave off, and our system integration execution picks up right after our detailed engineering and design. We can handle the complete package: specification, design, procurement, development, on-site execution, troubleshooting and support of the control, network, security and MES layers.

During this phase, we can provide you with:

Project Execution

After we’ve completed our thorough automation solutions site assessment, Front End Engineering Design and Detailed Engineering Design, we have the information we need to document, code and integrate your automated system. We keep in mind your business goals. We factor in the strengths and limitations of your team, and we prioritize your most important objectives.

We design your system on a foundation of understanding so that we can rapidly implement it with absolute precision. We program each function in your system and set up an intuitive Human Machine Interface (HMI) and reporting that allows your team to adopt your system efficiently. We outfit your system with the reporting you need to stay on top of your production. Prior to installation, we run your system through several rounds of intensive testing in a simulated environment to make sure it works. Once we have programmed your machines, set up your HMI, created a useful reporting program and tested the functionality and performance of your system, it is time to install your system in your facility. When on-site system installation is complete, our team again extensively tests the operation, performance and functionality of the new system holistically from the field devices through to reporting.

During this phase, we can provide you with:

  • Programming & Logic Development
  • Human Machine Interface (HMI) Development
  • Reporting
  • System Integration Testing & Simulation
  • On-Site Process Commissioning
Validation

Computer System Validation (CSV) is a must in FDA-regulated industries. We design and implement your system to deliver consistent, efficient production that also meets CSV for FDA. And we prove it too. If you operate in a regulated industry, we take care of the paperwork related to CSV and reduce your Regulatory risk. We can provide a Validation Master Plan (VMP) and use it to guide our work. We document requirement specs, design specs, functional specs, test plans, installation and operational protocols, trace matrices and summary reports. We execute the protocols as well. We assist with keeping your records up-to-date via change control and help keep your system in compliance. Minimizing risk is ingrained in our company because we are committed to delivering you ROI.

During this phase, we can provide you with:

  • Computer System Validation Documentation
  • Executed Validation Protocols
  • Electronic Records
Post Project Support

If any troubles emerge with your system, we have you covered, whether it is warranty or support under a formal service contract. When you work with Malisko Engineering, you don’t just get a system, you get a whole team to support it. If you have a full maintenance and system support staff on hand, we will provide assistance to fill the cracks. As much as practical, we can help your team be properly equipped to maintain and troubleshoot your process and automation system. If you need full support services, we are available 24/7 to make sure your system works.

During this phase, we can provide you with:

  • Post-Commissioning Technical Support
  • Remote Support

Malisko Can Help With All of Your Chemical Manufacturing Automation Needs

Learn how your automation and validation needs can be fulfilled by Malisko’s team of automation experts. Contact us today.  

Why Hire a Systems Integrator?

Can’t decide between a systems integrator and a general contractor for plant automation? Learn how systems integrators save you money, add value and ensure quality. Download our White Paper to learn more.

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