process - SiemensUnilever modernized one of its production units at the North Rocks site by upgrading the process control systems to Simatic PCS 7. The project has been highly successful,

New MarketsStrategies for meeting the global cement market challenges

Simatic WinCC in the pharmaceutical industry:

Recipe-basedDryingQuality and availability improvements at Unilever:

A Beautiful Combination

Simatic WinCC in the pharmaceutical industry:

Recipe-basedDryingQuality and availability improvements at Unilever:

A Beautiful Combination

New MarketsStrategies for meeting the global cement market challenges

Systems and Solutions for the Process Industry

processnews

11th edition July 2|2006

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The entire Guangzhou Heidelberg Yuexiucement factory is automated with Cematbased on Simatic PCS 7 and serves as a shiningexample for the whole industry in China

Cement factories require a solid drivetechnology that is durable and robust,and that offers high availability such asthe drive solutions and gears of FlenderHeavy Duty

Siemens equipped the newNovoSeven drug manufacturingwith state-of-the-art safety andenvironmentally compliantbuilding control technology

nprocess news 2/2006

Cover photo:Heidelberger ZementPhoto: Peter Körber

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3 EDITORIAL

4 NEWS

Standard for Water

Strong Position

Integrated Balance

Powerful and Efficient

Hands-on Experience

COVER STORYCement Industry

6 Global Solutions for Local GrowthSolutions for the challenges of the cement industry

CASE STUDIESCement Industry

8 Showcase ProjectSimatic PCS 7 and Cemat in China’s most modern cement factory

Cement Industry12 Targeted Process Optimization

More economical production due to Cemat MIS

Cement Industry13 Exact Grinding

Sitrans FC flowmeter provides optimum dosing

Pharmaceutical Industry18 Award Winner

Environmental conditions in the ”Facility of the Year 2005” are controlled by Siemens building technologies

Pharmaceutical Industry20 Recipe-Based Drying

GEA Lyophil uses Simatic WinCC flexible forstandardized and adaptable visualization solution

Chemical Industry22 Model Project

Pilot plant update combines batch system and emergency shutdown

Consumer Goods24 A Beautiful Combination

Quality and availability improvements at Unilever Australia

Pharmaceutical Industry26 Migration in Record Time

Modernization of the HMI systems at ZLB Behring in Marburg

Semiconductor28 Pulling It All Together

Siemens supplies comprehensive solutionspackage for new Infineon fab in Malaysia

CONTENT2

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This issue of Process News highlights oursolutions for the cement industry. The focus is onCemat, with which we have become today’s worldmarket leader in process control system for thecement industry.

As the system’s reputation for excellence hasgrown, the plumb bob – our symbol for Cemat onads, brochures and other communicationsmeasures – has gained a high level of recognitionin the cement industry. We at Siemens see thissymbol as a representation of the greatimportance and consistency of Cemat in theindustry: the plumb bob is both simple andeffective, and has a long tradition as one of themost important tools in the building trade. We arefollowing this tradition with Cemat in the CementCompetence Center. The latest version of Cemat,version 6.0, based on Simatic PCS 7, continuesthis success story. We always ensure compatibilitywith existing Cemat systems to protect ourcustomers’ investments and contribute to theirsuccess. See pages 6 and 7 of this issue for moreinformation.

The articles in this issue provide a taste ofsome of our many success stories, and offerinsights into the roles of a few of the individualswho are responsible for the high quality andsuccess of Cemat today.

We also introduce you to one of our partners,GIA, with whom we are implementing solutionsfor our industrial customers. We have alsodeveloped an innovative, trend-setting HMIsolution for the pharmaceutical industry for GEALyophil.

Enjoy the read!

Unilever modernized one of its productionunits at the North Rocks site by upgrading theprocess control systems to Simatic PCS 7. Theproject has been highly successful, winningthe Chemicals & Petrochemicals category ofthe 2006 PACE Zenith Awards

newsprocess news 2/2006

Thomas WaltherLeiter des Competence Center CementSiemens Automation and Drives

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Test Systems30 Dynamic Response and High Accuracy

Coriolis flowmeters optimize engine test bench

TECHNOLOGIESDrive Technology

11 Hard CaseFlender drive solutions for the cement industry

Process Instrumentation and Analytics14 Made to Measure

Process instrumentation and analytics for the cement industry

TRENDSPartners

10 Success Through ContinuityKMI Engineering relies on Cemat and Simatic PCS 7

Partners16 Active Partnership

Karl-Heinz Horst, CEO of GIA, talks about the Siemens Solution Partner program

31 DIALOGUE

Dear readers

3EDITORIAL

process news 2/2006

4 NEWS

Eastime Automation Engineering Co.,Ltd. and Siemens have signed an

agreement whereby Siemens is toacquire the business activities of East-ime Automation Engineering, Shang-hai, China. With the acquisition of Eas-time Automation Engineering, Siemenswill consolidate its market position inChina with a company that possessesespecially good local know-how andsound technical knowledge in the sys-tem integration of process analyticsdevices into overall solutions andplants.

Eastime Automation Engineeringhas more than 30 employees and isactive especially in chemicals, petro-chemicals and the iron and steel sector.The takeover is planned for August2006, when the company will changeits name to Siemens Process AnalyticsLtd., Shanghai (SPAS) and become apart of the Automation and DrivesGroup regional company Siemens Ltd. inChina. �

Acquisition of Eastime AutomationEngineering

Strong Position

Find out more:www.siemens.com/processinstrumentationE-mail: [email protected]

Weighing tasks with differential pro-portioning and control scales can now

be easily automated with the Siwarex elec-tronic weighing system. The combination ofscales and weighing electronics can be inte-grated seamlessly into the Simatic automa-tion network. The benefits of the automateddifferential proportioning scales includeaccurate weight recording and flow meas-urement in the main application areas of thechemical, pharmaceutical and food andbeverage industry. The automated controlscales are especially suitable for high-speedweight recording, even under difficult envi-ronmental conditions.

Differential proportioning scales can beintegrated into the automation system by

means of the Siwarex FTC electronics. Scalesof this type are suitable above all for con-tinuous proportioning with constantly highaccuracy, and they offer long-term stabilitywith low maintenance costs.

The Siwarex FTA electronics system isused for control scales. Here, Siemens coop-erates with the German company WipotecWiege- und Positioniersysteme GmbH, asystem supplier of ultra-high-speed preci-sion load cells and weighing systems forhigh-speed applications. �

Automated proportioning and control scales

Integrated Balance Weighing tasks with differentialproportioning and control scales cannow be easily automated

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Biberach in Germany is one of BoehringerIngelheim’s production sites

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Sitrans F C MASSFLO MASS 2100 at Boehringer Ingelheim

Standard for Water

Boehringer Ingelheim has awarded Siemens a contract for thirty-nine Sitrans F C MASSFLO MASS 2100 Coriolis mass flowmeters

as a part of the revamping at its production plant in Biberach. Theflowmeters will be used to measure water flowrates in the pro-duction area. Thereby, particular requirements of the pharmaceu-tical industry had to be fulfilled as a defined ratio of delta-ferrite.It has been decided that Sitrans F C is to be fitted as standard inthe production area, which means that further orders from OEMswill follow. �


Find out more:www.siemens.com/siwarexwww.wipotec.deE-mail: [email protected]

process news 2/2006

5

Südbayerische Portland ZementwerkGebr. Wiesböck & Co. GmbH recently

completed a modernization project in theRohrdorf cement factory with the commis-sioning ceremony for a new deduster and anew raw mill. Essential components of themodernization were new control technol-ogy and new drive controls for the processfan and the rotary kilns, supplied and com-missioned by Siemens.

To increase fuel efficiency through unin-terrupted plant operation and at the sametime minimize emissions, the companychose the Simatic PCS7-based Cemat control

system for the modernization of the fourcement mills in 2002, and combined the dis-tributed plant control stands in a central con-trol room. The existing Simodrive P4 andSimadyn D control for the two 450-kilowattdrives of the rotary kilns, which uses three-phase current technology, was converted toSimovert Masterdrive with technology con-trol. This solution is much more fail-safe thanthe previously used three-phase currenttechnology. The modernization measureshave contributed considerably to an increasein clinker production of about 10 percent, or3,300 tons per day.

Modernization at the Südbayerische Portland Zementwerk successfully completed

Powerful and Efficient

Siemens Milltronics has opened a newLearning Center at its Technology Drive

facility to offer specialized courses in indus-trial level measurement and weighing tech-

nologies. The spacious floor plan covers 200square meters and includes a large class-room, workstations for hands-on training, astudent lounge and washrooms. The com-


The visual design of the new Learning Center is inspired by the Fibonacciseries, which conveys the mathematics of growth

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With these investments, the company hascreated not only a future-safe basis for thecontinuing success of the cement factorybut also an energy-saving and more envi-ronmentally friendly production facility, asthe Bavarian environmental minister WernerSchnappauf underscored at the commis-sioning ceremony. Rohrdorf was also admit-ted to the Bavarian Environment Pact thisyear, in recognition of the improvement. �

Find out more:www.siemens.com/cementE-mail: [email protected]

Siemens Milltronics Opens New Learning Center

Hands-on Experience

pany expects to train about 200 salespeopleand customers a year.

The courses combine technology theoryand hands-on experience with equipmentthat industrial operators actually use in thefield. There are six workstations for levelmeasurement training where students canlearn to install, set up and program ultra-sonic, radar and capacitance devices. Forthe weighing technology sessions, there arethree weighfeeders, a dry solids flow systemand six belt scales. Courses are limited to 12attendees to ensure opportunities for par-ticipation. Instructors are Siemens Milltron-ics product and market experts who havetechnical knowledge as well as field appli-cations experience. In addition, the Learn-ing Center offers courses for operators ofwater and wastewater plants.

The Siemens Milltronics training concepthas been very successful so that Siemenshas also set up training programs in Ger-many, Russia and in China, and is reviewingopportunities in other countries as well. �

process news 2/2006

T he so-called emerging markets inAsia and Russia have seen verystrong growth, particularly among

the top 10 cement manufacturers. Whilethe two largest manufacturers, Lafarge andHolcim, continue to lead the cement mar-ket with capacities of 163.8 million tons and160.4 million tons per year respectively, theMexican Cemex company has climbed tothird place with its takeover of the RMCgroup. But the Chinese company AnhuiConch made the biggest jump, finishing insixth place. By 2010, the company intendsto reach a capacity of approximately 100million tons per year. Anhui Conch is a typ-ical example of the emerging cement mar-kets and consolidations in China, India andRussia.

Global markets and local know-how: LafargeLafarge was founded in 1833 and is active in 75 countries, with approximately 80,000

employees. The cement division in particular profits from the broad international pres-

ence of the company. With about 140 locations worldwide, including 114 cement facto-

ries in 43 countries, the cement division makes a major contribution to the success of

Lafarge. To provide optimum support for Lafarge on the global markets, Siemens has

appointed a global account manager for the company to coordinate activities on-site at all

Lafarge locations, in the local Siemens offices as well as with the Siemens partners. Thus,

all of the Siemens expertise is available to Lafarge all over the world. In the last few years,

Siemens has supplied automation, drive and power supply solutions for several factories

at Lafarge. Recently, Lafarge placed two orders with Siemens that continue this success

story: Siemens is responsible for the turnkey modernization of a production line at the

Kanthan site in Malaysia; and in Morocco, Siemens is supplying the automation solution

with Cemat based on Simatic PCS7 for three projects in Meknes, Tetouan and Bouskoura.

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Solutions for the challenges of the cement industry

Global Solutions for Local GrowthThe cement industry faces new market opportunities as well as significant challenges such asincreasing competition pressures, rising energy costs and stricter regulations for environmentalprotection. With the right mixture of local presence and global industry know-how, along withintegrated solutions for all areas of cement production, Siemens helps its customers to succeed bothin facing the challenges and in taking advantage of opportunities.

COVER STORYCement Industry

6

process news 2/2006

Consistently successful: HolcimBy focusing on consistent development, linking long-term profitability with social commit-

ment and through the conservation of resources, the Holcim Group has established itself

as one of the two largest companies in the cement market. Since 1912, when the first

factory was founded in Holderbank, Switzerland, Holcim has developed into a globally

active supplier of cement and aggregates as well as further activities such as ready-mix

concrete and asphalt, including services. The company is active in more than 70 countries.

Because of its worldwide presence, Holcim naturally looks for internationally active,

reliable suppliers of electrical equipment for its cement factories. The company has

already been working successfully with Siemens for many years. Numerous cement

factories worldwide have been equipped with drives and control technology from

Siemens. Holcim Group Support Ltd. recently qualified the latest version of Cemat based

on Simatic PCS7 as one of the company’s preferred automation solutions. In the course of

implementing the system, Siemens adapted various functions specifically to meet the

“Holcim Standard Design Criteria,” making a “Holcim Standard” available for Cemat. First

successes have already been achieved. Factories in France, Bulgaria, Rumania, and the

Andina region (in northern South America) are being equipped with Cemat based on

Simatic PCS7. To give Holcim even better support, the Competence Center Cement

recently appointed an account manager for this key customer.

World Total 2650

Total top 10 793

Percentage top 10 30

1 Lafarge FR

2 Holcim CH

3 Cemex MX

4 HeidelbergCement DE

5 Italcementi IT

6 Anhui Conch CN

7 Taiheiyo JP

8 Buzzi Unicem IT

9 Eurocement RU

10 Grasim/Ultratech IN

0 50 100 150 200

Source: Dr.-Ing. Joachim Harder, OneStone Consulting Group GmbH, Consultants, Buxtehude.

All data in million tons per year.

within the cement industry. Because of itsexcellent local presence in the boomingregions and long years of experience in thecement industry, Siemens is a reliable andcompetent partner to the industry world-wide – an opinion confirmed by the latestmarket research of the OneStone Consult-ing Group. With Cemat, Siemens has become

Local konow-how and global expertise

Siemens has bundled its industry and tech-nology know-how for its customers in thecement industry in the Competence CenterCement. Project experts in the CompetenceCenter Cement have many years of experi-ence and therefore, very good contacts

the market leader in control technology forthe cement industry, and ranks second inprocess instrumentation and large drives.

Decades of experience in integrated solutions

The Cemat process control system wasdeveloped by Siemens especially for thecement and building materials industries,and has proven its value in operation underharsh conditions for many years. It meetsall of the requirements of cement produc-tion and exploits the knowledge gainedfrom more than 35 years of experience inthe industry. The new version 6 of Cemat isbased on Simatic PCS 7, which, as an inte-grated part of Totally Integrated Automa-tion, offers a unique, open architecture formodern, future-safe, economical solutionsfor the cement industry.

Among Cemat’s many highlights is itsuncomplicated, fast engineering. Simpleoperation and quick troubleshootingthrough detailed and, above all, plaintexterror messages are critical when it comes tomanaging downtime costs as well as risingenergy costs: Receiving a detailed and un-ambiguous error diagnosis before startingplant sections makes “test starts” super-fluous, saves energy and considerably im-proves the exploitation of capacity. Cematdesigners keep an eye on the future to guar-antee compatibility with continuous tech-nological innovation. Even older versionsof Cemat – from version 1.8 in 1987 to ver-sion 5 in 2000 – can either be connected tothe new version or easily upgraded to thisor later versions.

Costs and resources at a glance

Working seamlessly with Totally IntegratedAutomation, Cemat enables the cementindustry to fully exploit the advantages ofintegrated processes. From process instru-mentation to drive technology and powersupply systems, all aspects of cement pro-duction can be perfectly adapted to eachother. The results are considerable costadvantages in utilization and maintenanceas well as improved use of resources – anarea of increasing concern today, as energycosts continue to rise and emission regula-tions tighten. �


163.8

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Market on the move: Cement capacities 2005

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8 CASE STUDY

Simatic PCS 7 and Cemat in China’s most moderncement factory

ShowcaseProject

Cement Industry

The Guangzhou Heidelberg Yuexiucement factory in Guangzhou isthe most modern cement factoryin China. Siemens IndustrialAutomation Shanghai automatedthe cement production completelywith Cemat based on SimaticPCS 7. At the time the order wasplaced, the project was the firstinstallation of the new Cematsystem in China and served as ashining example for the wholeindustry in that country. The ChinaInstrument and Control Societyshares this opinion and awardedthe process control system at theGuangzhou factory the ExcellentIndustrial Control System award.

HeidelbergCementand CematHeidelbergCement has been using

Cemat since the 1980s.

It is therefore only natural that the

technicians at HeidelbergCement have

influenced the development of Cemat.

This cooperation is mutually beneficial:

Siemens profits from the experience of

the users, and the users benefit from

the improvements to Cemat’s user

interface and locks based on their input.

Today’s Cemat standard for Heidel-

bergCement only differs from the

Cemat “normal standard” in a few

details. These deviations mainly con-

cern the on-site operation of drives,

which is normally implemented with

three signals, but at HeidelbergCement

uses only two. Other, more minor

details have emerged over the years,

such as unlocked single operation.

9

W ith the completion of a new cementfactory with a capacity of 6,000tons of clinker per day, the city of

Guangzhou and the province of Guang-dong fulfilled their goal of replacing theold factory and improving the quality ofthe air in and around the city with a popu-lation of one million. The project is alsopart of the tenth five-year plan, whichintends to promote and modernize the Chi-nese cement production industry. The newfactory also gave the Guangzhou Heidel-berg Yuexiu Cement Co. – a joint venture ofHeidelbergCement, Yuexiu Investion Co.Ltd., Guangzhou Cement Co. Ltd. and theHuada cement works – the opportunity toexpand its production capacity to 2.27 mil-lion tons of Portland cement per year,which is equivalent to 7,000 tons per day.

Experience and expertise

The general contractor of this large-scaleproject was CBMI Construction Co. Ltd., thelargest company to engineer and buildcement factories in China. CBMI awardedthe contract for the planning, implemen-tation, and commissioning of the processcontrol system in the modern plant toSiemens Industrial Automation Ltd., Shang-hai (SIAS). Cemat has an excellent world-wide reputation and is the leading controlsystem in the cement industry. Heidel-bergCement has been using Cemat for 25 years. The company’s experience withCemat helped to further the development ofthe system. Moreover, HeidelbergCementhas made major contributions to the func-tions of the latest version of the system.

Cemat is based on Simatic PCS 7 Version6.1 and provides all the advantages of To-tally Integrated Automation to the cementindustry. By combining these advantageswith highly efficient, industry-specific soft-ware packages aimed at special tasks in limeand cement factories, Cemat optimizesoperational procedures, operations infor-mation gathering and reporting, mainte-nance and asset management. Along withSIAS’s competence as a project partner,these advantages were critical factors inthe decision to automate with Cemat andthis cooperation.

Implementing an integrated solution

With more than 17,000 inputs and outputs,the cement factory in Guangzhou is one ofthe largest in the Chinese cement industry.The entire production is automated with

process news 2/2006

the Cemat process control system on thebasis of the Simatic PCS 7 and includes 14Simatic PCS 7 automation systems, threeredundant server pairs, five operating sta-tions and one engineering station. Thismakes the plant one of the largest SimaticPCS 7 installations in the region. SIAS wasresponsible for planning the control sys-tem architecture, the engineering and theon-site installation as well as for commis-sioning and staff training in Guangzhou.The strong support of the Competence Cen-ter Cement helped SIAS fulfill its responsi-bilities. SIAS received the order for theautomation in July 2004 against toughcompetition. Clarification of the tasks, pro-gramming, and parameterization, as wellas the creation of the plant diagrams, werecompleted by January 2005 in the SIASEngineering Center in Shanghai.

The Guangzhou plant was the firstcement project with such large dimensionsand the first with such a tight schedule thatSIAS had tackled. During the commission-ing period from January to the end of July2005, six Chinese engineers, working coop-eratively in a close-knit team, were respon-sible for the individual testing of the 17,000signals and the function tests and forpreparing the various drive groups for pro-duction. This relatively short commission-ing time was ultimately achieved by con-sistent standardization with the Cematstandard specifically created for Heidel-bergCement.

Important showcase project

The new cement factory started productionon schedule, and has been operating with-out any problems ever since. This projectgave the new Cemat version and SIAS a per-fect start in the booming cement market inChina. Both Guangzhou Heidelberg YuexiuCement Co. and CBMI Construction Co. Ltd.are very pleased with their cooperationwith SIAS and the installed control tech-nology. The modern plant has drawn inter-est in the Chinese cement industry and isconsidered a showcase project of nationalimportance.

Another indication of the project’s sig-nificance is the Excellent Industrial Con-trol System award that the China Instru-ment and Control Society bestowed on SIASfor automation of the plant. Peter Chen,general manager of SIAS, accepted theaward on behalf of the project team, headedby project manager Han Zhenyu. �


The heat exchanger of the new cement factory

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10Partners

TREND

KMI Ingenieurgesellschaft für Auto-matisierung mbH, headquartered inOberursel near Frankfurt, has been

serving its clients for 15 years. Being closeto the international hub of the Frankfurtairport makes it easier for the company tolook after its cement customers all over theworld. KMI relies on continuity – even in theprocess technology. KMI equipped its plantswith Cemat from the very start and now usesthe current version 6.0.

Continuity secures expertise

This long-term product continuity pays offfor the service provider, as Martin Messer,managing director of KMI, confirms: “Cematallows us to pass on to our employees theplant and system expertise that we havebuilt up for different customers. The plantswe support are distributed widely around

KMI Engineering relies on Cemat and Simatic PCS 7

Success ThroughContinuityThe cement industry thinks in terms of long life cycles.Those who want to be successful in this field must protecttheir investments. At least, that is the view of KMI, whichrelies on Simatic PCS 7-based Cemat.

the globe, and it is important that the pro-gram structures are identical and recog-nizable everywhere.”

Lothar Knöbel, also a managing directorat KMI, underlines the industry-specificfunctions of the process control system.“Cemat is distinguished by a sophisticatedautomation structure,” he says, “which takesthe demands for a uniform and clearlystructured operation in a cement factoryinto account from the very start, and pro-vides the same in easily applicable func-tions. After all, the process control systemis there to help and not hinder. PCS 7 andCemat give us more freedom to concen-trate on the actual engineering.”

Part of a successful partner network

The partnership with KMI is a convincingdemonstration of how specialized engi-

neering companies and Siemens are able todevelop and offer tailor-made, future-safesolutions for automation and drive tech-nology as well as energy distribution usingtheir common experience and extensiveproduct, system and industry know-how –for the maximum benefit of end users allover the world. With its continuous devel-opment of both expertise and cooperationon sales, strategy and technology, and itsabsolute orientation toward customers’needs, the Siemens Solution Partner pro-gram stands for confidence and quality – animportant pillar of success not only in thecement industry, but in other markets aswell. �

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Lothar Knöbel (left) and Martin Messer (right), man-aging directors of KMI: “PCS 7 and Cemat give us morefreedom to concentrate on the actual engineering.”


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Easy migration reduces costsOne application example is the Dutch cement factory ENCI in Maastricht. In this facility, the existing control systems running with different Cematversions were to be centralized and the latest version, 6.1, based onSimatic PCS 7, was to be implemented throughout. ENCI replaced theexisting controllers with Simatic S7-400 controllers but retained thecomplete periphery. Because the basic functionality of Cemat has notchanged in years, the control programs could be implemented withoutexpensive modifications, which meant that the entire system changeoverwas completed within a very narrow time frame.

The ENCI project also clearly demonstrates the long-term investmentsecurity that Siemens ensures with Cemat. Thanks to optimum backwardcompatibility, investments in planning and programming made in theinstallation of a plant are not lost when the conversion is made to thenew system version but provide the basis for reduced upgrade costs .

process news 2/2006

11TECHNOLOGYDrive Technology

Turning stone into finished cement re-quires not only several chemicalprocess steps, but also a large num-

ber of physical process steps. The imple-mented drive systems must therefore beable to withstand the harshest applicationconditions, and transfer great force andpower. In addition, grinding mineral raw ma-terials is a very energy-intensive process –the drive technology used must beoptimally adapted to the specific prop-erties of the conditioning process inorder to allow economical operations.

From rock to cement

The raw material used to makecement is ground into a very finegrain in an initial working processstep in vertical mills before beingmilled into an extremely fine pow-der by impact and friction in hori-zontal mills. These horizontal millsare up to 20 meters long and requireup to 30 megawatts of power. Thenthe processed material runs thougha separator, which returns material that istoo coarse to the mill. Then the pulverizedstone is calcinated in rotary kilns up to 100meters long.

The bulk material is transported by con-veyor belts (which are up to several mileslong and which move at speeds of up to 10

meters per second) or pan conveyors forvertical bulk material movements. The panconveyors cover differences in height of upto 200 meters.

Know-how and experience

With the Flender drive systems, Siemenscan now deliver drive solutions that incor-porate not only more than a hundred years

of experience, but also the know-how of ateam of experts who is familiar with theindustry and can therefore assemble tai-lor-made systems.

Heavy-duty gears and motors from Flen-der offer the right solution for drive tasksin the cement industry. The product line

includes special bevel gear/planetary gearunits with a power rating of up to 9,000 kilo-watts for vertical mills, extremely efficientdrive systems for horizontal mills (includ-ing safety devices and diagnostic systems),and compact drive technology for rotary fur-naces consisting of electric motors with hel-ical, bevel-helical or planetary gear units,supplemented by auxiliary gears with an

overrunning clutch and centrifugalbrake, a holding brake, an auxiliarymotor and several clutches. Ofcourse, the Flender portfolio alsoincludes rugged systems for trans-port belts and pan conveyors withmotors, clutches and gears, supple-mented by auxiliary drives, nonre-verse ratchets and brakes.

Cost-effectiveness andavailability

Flender drive systems stand for max-imum performance and operationalreliability, as well as for rapid avail-ability. The high efficiency of the

components ensures good energy exploita-tion. In sum, Flender technology supportscost-effective cement production. �

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Drives for horizontal mills must be extremely high-powered

Flender drive solutions for the cement industry

Hard CaseMost plant units of a cement factory –for example, the mills, furnaces andtransport systems – require a soliddrive technology that is durable as well as robust, and that offers highavailability, such as the drive solutions and gears of Flender Heavy Duty, a member of the mechanical drives division of Siemens since July 2005.



process news 2/2006

12Cement Industry

CASE STUDY

The cement works Phoenix Zemen-twerke Krogbeumker in Beckum,northern Germany, was founded in

1914 and produces up to 500,000 tons ofcement per year with a staff of approxi-mately 100 people. The company startedusing the Cemat 2.0 system for control-ling the processes in 1993. It then changedover to Cemat 6.0, based on the SimaticPCS 7 process control system, for the con-trol of the cement mills in 2001 and for thecyclone preheaters and drying ovens in2004.

New system for data acquisition

In mid-2005, Phoenix decided to install anintegrated management information system(MIS). Operations manager Kai Wagnerexplains, “We were looking for a safe way toacquire and archive production-related datafrom different sources, for automatic report-ing, and for tools for analyzing process dataand alarms.” The company also wanted a sys-tem that could calculate the power indicatorsin the ongoing production process. The Cemat6.0 MIS, which is based on Simatic IT, fully met

these requirements. This solution alsooffered the advantage that it could be inte-grated smoothly into the existing infrastruc-ture.

Continuous reporting

An important feature of Cemat MIS is theintegrated reporting system. Both currentand archived data are displayed directly inExcel tables and are therefore available forcontinuous monitoring and for logs. As aresult, not only is it possible to visualize thedevelopment of individual parameters atany time, but various analyses can also beeasily conducted. Kai Wagner is thrilled bythese possibilities: “Decisive process vari-ables can now be displayed in Excel withminimum effort. At the same time, thestatistical evaluation of alarm situationsallows us to analyze the causes of operatingfaults and to plan our maintenance workaccordingly.”

Optimized processes

Close analysis of the current operating datagives Phoenix totally new process controlpossibilities. For example, the energyrequirements of the factory can be opti-mized and fuel and power consumptionreduced. “With the new system, we can ana-lyze different influential variables quickly,without having to have the data processedby the employees first at great effort,” Wag-ner explains. The company plans to extendthe system to include the lab data and toacquire and evaluate carbon dioxide emis-sions data in the future. �

More economical production due to Cemat MIS

Targeted ProcessOptimizationUp-to-date and transparent data are necessary to maintain completecontrol of all process parameters in cement production. With CematMIS, the Phoenix cement works in Beckum is now able to use processdata specifically for process optimization and thus improve theenvironmental friendliness and cost-effectiveness of its cementproduction.

The energy requirements of the plant can be optimized through closeanalysis of current operating data

Phoenix cement works produces up to500,000 tons of cement annually

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Sitrans FC flowmeter provides optimum dosing

Exact Grinding

process news 2/2006

13CASE STUDY

Grinding the quarried stone is a veryimportant step in the process chainon the way to producing finishedcement. With Sitrans FC massflowmeters, the Wietersdorfer &Peggauer cement works hassucceeded in considerably increasingthe flexibility of its production.

A t the center of the cement produc-tion operation is the grinding pro-cess, where the raw material clinker

is ground according to different recipeswith additives such as gypsum, slag andlime. The efficiency and economy of thisprocess are influenced quite significantlyby so-called grinding aids, which mustbe accurately dosed to achieve optimumgrinding behavior in terms of quality andenergy consumption.

Automatic dosing

Previously, these grinding aids were dosed

only volumetrically at Wietersdorfer & Peg-

gauer. To achieve higher dosing accuracy, the

company decided to equip this process step at

the Peggau site near Graz, Austria with an

automatically operating mass flowmeter. The

system had to be able not only to dose even the

smallest volumes of grinding aids exactly, but

also to cover a wide measuring range to serve

the various product recipes. Of course, the

system also had to be able to withstand the

difficult process conditions with aggressive

materials, and to cope with the considerable

drop in pressure in the pipelines, which are up

to 80 meters long.

Precise and maintenance-free

After extensive comparisons of the available

options, the company chose the Sitrans FC

mass flow measuring system as a sensor for

the dosing. The solution consists of MASS

6000 transmitters connected with MASS 2100

D13 and D16 sensors. Two measuring systems

are used in Peggau, each assigned to one

grinding system. The dosing system is con-

nected to both plants. Wietersdorfer & Peg-

gauer can now produce with two mills using

grinding aids. This considerably increases

production flexibility.

Because the entire system has no mov-ing parts, it is absolutely maintenance-free.Hubert Thaller, who is responsible formaintenance at Wietersdorfer & Peggauer,underlines this aspect: “The Sitrans FCflowmeters have been installed now formore than a year and have always dosed thegrinding aids correctly.” �

Cement Industry

Find out more:www.siemens.com/cementwww.siemens.com/processinstrumentationE-mail: [email protected]

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Sitrans FC: Measurement by theCoriolis principleB mass flow determination by the Coriolis principleB high measuring accuracy of 0.1 percent over a wide

measuring rangeB suitable for liquids and gases at high and very low

flow ratesB additional information on density, fraction and tem-

perature of the measured mediumB numerous diagnostic functions

process news 2/2006

14Process Instrumentation and Analytics

TECHNOLOGY

H igh temperatures, vibrations, dustand volatile materials are just someof the challenges cement plant

instrumentation faces. Devices such as theSitrans LR 400 radar level monitor aredesigned specifically for such demands.Others, such as Siemens Pointek CLS 300capacitive level switch devices, offer hightemperature resistance and accuracy lev-

els that provide detailed information aboutcurrent status and reliability.

Integrated weighing technology

In extractive processes, weighing technol-ogy plays a key role – whether to monitordaily production rates, control crusherinflow or ensure right first-time loading.Siemens provides a systems portfolio rang-

ing from beltscales and weighfeeders tosolids flowmeters. Retrofits with minimumdisruption to the process are also available.

For plants operating in Simatic PCS 7 orS7 environments, Siwarex weighing sys-tems provide optimum integration into theautomation structure of the process. Inother situations, the Milltronics BW500integrator offers an optimal link into theprocess, including rate, totalized weight,PID, belt loading, speed and batching datavia advanced communication links.

Analysis solution for demandingapplications

An increasingly stricter environmental reg-ulation, the widespread use of alternativefuels, safety issues and the need for accu-rate reporting and monitoring, means thatsystems for gas analysis are a key part ofcement plant infrastructure.

In addition to satisfying legal regula-tions, accurate and fast gas analysis cangenerate considerable cost savings byreducing false alarms and downtimecaused through automatic shutdowns.Siemens offers scaleable solutions rangingfrom single analyzers to entire cabinets,

Process instrumentation and analytics for the cement industry

Made to MeasureFrom in-situ gas analysis and temperature measurement to level monitoringand weighing systems, Siemens offers a range of products tailored to thedemands of the cement industry. The latest generation of process instrumentsand analytical devices support advanced, predictive maintenance, allowingmaintenance cycles to be optimized, helping to minmize the risk of equipmentfailure and, ultimately, to reduce costly downtime.

Laser diode technology improves cement plant safetySafety – whether personal, plant or environmental safety – applies to many areas in a cement plant with potential risks, including dustfilters, bag houses, electrostatic precipitators and coal mills.Increased safety in one or more of these areas also results in a moreeffective process with less downtime, less repairs, fewer fines andless injuries.The ultimate result is that costs are reduced and that theplant is more profitable.

The most dangerous risk in an industrial plant is an explosionbecause this can cause enormous damage and people to be injuredor even killed. In cement plants, the main high risk areas are the onesthat have a potentially high CO content, like dust filters, bag houses,electrostatic precipitators (ESP) and coal mills.

Traditional extractive gas analyzers with infrared absorptiontechnology are normally used to monitor CO levels. This methoddelivers reliable and accurate readings. However, it can take up to 30seconds to treat one sample, which is too long for early detection ofexplosive conditions.

Fast in-process measurement

The ideal solution calls for a fast, reliable gas analyzer, preferably onethat requires very low maintenance and no recalibration such as theLDS 6 laser diode spectrometer. It can measure a gas componentsuch as CO as reliably as a traditional infrared gas analyzer with avery fast reaction time.

The LDS 6 features a low-maintenance design with no consum-able parts. The transmitter and receiver are mounted directly in-situat the location where the gas component needs to be measured andthe laser light is transmitted continuously through the medium.Accurate CO measurement is available within just one second.

The control unit has a reference cell which continuously monitorsthe signal status of the unit and automatically makes the necessaryadjustments to the laser unit, so no recalibration is necessary. Toavoid impacts on the measurement at heavy dust loads in theprocess, air purging inlets can be applied in front of the sensor optics.Additional diagnostic features, including remote access, contribute tolow device downtimes and maintenance costs.

process news 2/2006

15

enabling accurate control and reportingthroughout the plant.

The range extends from extractive con-tinuous gas analysis to kiln inlet monitor-ing and laser spectrometry. The gas analy-sis range is ideal for the rigors of thecement industry, where the increasing useof alternative fuels means accurate controlis vital for maintenance of product quality,and where corrosive gases are the norm.

Up to the task

Robustness, advanced communications andremote intelligence run through the entireSiemens product range for the cementindustries – whether temperature, flow,pressure, valve positioning, level, processprotection, weighing or gas analysis, thedevices offer a solution for even the mostchallenging measurements within thecement plant. �


High accuracy single and dual idler beltscales and weighfeeders from SiemensMilltronics are ideal for applications suchas the tracking of daily production,management of mill feed rates andbatching operations

Sitrans LR 400 radar levelmeasurement has been developedfor more difficult solids and liquidlevel measurement applications,such as in high dust levels

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Loaded flue gas, containing CO

Clean flue gas

ElectrostaticPrecipitator (ESP)

LDS 6

Successful team: GIA and SiemensIn collaboration with Siemens, GIA implemented an automation solution for

a plant producing 100 tons per day of a preliminary product for the manufac-

ture of inks for a leading global player in the printing ink industry. The focus

was on high-quality ink packaging and ink publication products. The plant

had to be modified while in operation. Both operator stations and I/O mod-

ules also had to be constructed in a hazardous area. Moreover, the project

had to be completed within a tight time frame.

The production plant requires complex automation to reduce energy costs

and to optimize personnel deployment. Following a system analysis by the

contract partners, the customer decided on a solution based on Simatic PCS 7

with Simatic Batch. Within the scope of the project, Siemens supplied the

lion’s share of the automation package, while GIA, as the systems integrator,

was responsible for the software development.

Comprehensive tests of the typicals as well as the newly compiled face-

plates in an early project phase ensured that the factory acceptance test

carried out at GIA’s premises in Leverkusen went smoothly. As the tests took

place on the customer’s system platform, all parameters were already set, so

the components using software could be installed without changes following

acceptance by the final customer.

process news 2/2006

16Partners

TREND

Karl-Heinz Horst, CEO of GIA, talks aboutthe Siemens Solution Partner program

ActivePartnership

GIA is a leading specialist in processautomation and IT services. As anindependent engineering company, itoffers its customers turnkey solutionsin the fields of process automation,vertical integration and IT services aswell as qualification and validation.GIA works with Siemens automationproducts in all of these areas. Wespoke with Karl-Heinz Horst, CEO ofGIA, about how this partnershipworks.

Mr. Horst, since 1990 your company hasbeen implementing automation projectsacross all sectors and industries – withgreat success. What do you believe arethe main reasons for this success?

Karl-Heinz Horst: We are a very customer-oriented company. Our solutions are pre-cisely tailored to the requirements of therespective application. Our employees arequalified and motivated, and we work withexperienced partners. We focus consis-tently on quality, and naturally our servicescomply with all applicable standards. We

process news 2/2006

17

And how is the special cooperationwithin the Siemens Solution Partnerprogram?

Karl-Heinz Horst: Siemens employeesreally get involved in the partner program.We feel very confident about working withSiemens, and this ultimately manifestsitself in greater satisfaction for our cus-tomers. We can rely on Siemens and cantherefore be sure that we can keep the prom-ises we make to our customers. Siemensalso performs well in other areas: on-sitepresence, availability and support in gen-eral, such as order processing and the sup-ply of spare parts, are noticeably betterthan elsewhere. In addition, as a partner,we are taken seriously and we are involved.This gives us direct access to current trends.For example, GIA has used the beta versionof some Siemens productssuch as the Hsystems of Simatic PCS 7. Errors weredetected and rectified in collaboration withSiemens, and, of course, the final customerand we could contact the respective spe-cialists any time we needed them. Thisstrengthened the bond of mutual trust andhas enabled us to feel that we also have aninfluence on innovation.

So, overall, you are satisfied?

Karl-Heinz Horst: Naturally, there isalways room for improvement. For exam-ple, we still haven’t found the optimal solu-tion for certain technical features.

Find out more:www.siemens.com/automation/partnerE-mail: [email protected]

have the expertise required to implementturnkey solutions for a wide range of indus-try sectors ranging from aluminum andsteel production to water treatment. Fromthe outset, pharmaceutical companies wereamong our most important customers –so, of course, we would like them to knowthat we offer full and complete support forour integrated range of services, includ-ing validation and qualification, as well asautomation.

You have been using Siemensautomation technology in your solutionsfor many years. What do you see as thekey advantages of the Siemens systems?

Karl-Heinz Horst: Naturally, as an engi-neering firm, we must maintain a certainlevel of neutrality with regard to the selec-tion of automation suppliers. However,Siemens is clearly the preferred partner forour company. Its broad, well-rounded prod-uct line and the high level of integrationoffered by its systems are important pointsin its favor. Other suppliers have also offeredgood control systems, but the degree ofintegration and standard componentsoffered by Totally Integrated Automationhave enabled Siemens to stay one stepahead. There are obviously fewer inter-faces, and the idea behind TIA has nowdeveloped into a very uniform and inte-grated automation platform. It is our opin-ion that Siemens is definitely on the righttrack.

The Siemens SolutionPartner programThe new Siemens Solution Partnerprogram comprises the former partnerprograms of Siemens Automation andDrives. Globally, more than 500 systemintegrators and vendors are alreadySiemens Solution Partners, which givesthem access to comprehensive tech-nology and process expertise.

A specific selection and qualificationprocess for Automation Solution Partnersand Power Distribution Solution Partnersguarantees the high professional qualityof the Siemens Solution Partners.

The partner program is divided intoindividual technical modules, and part-ners are able to acquire various certifi-cates based on the nature and extent oftheir specialization. For example, onlythose partners who can demonstrate anestablished expert knowledge of andmany years of experience working withthe Simatic PCS 7 process control systemmay use the title PCS 7 specialists. Thistitle provides partners with extendedsupport services from Siemens, whichcontribute to the optimal implementa-tion of control technology projects andguarantee the highest project quality forthe final customer.

Karl-Heinz Horst, CEO of GIA:

“We can rely onSiemens and cantherefore be surethat we can keep thepromises we make toour customers.”

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And what’s the support from Siemenslike in this context?

Karl-Heinz Horst: Our engineers are alsoable to handle the classic automation issuesthemselves, of course, but they know thattheir technical questions will be addressedprofessionally at Siemens – as shouldalways be the case in a true partnership.And therefore I am certain that, workingwith Siemens, we will find the right solu-tion for our customers.

Mr. Horst, thank you very much fortaking the time to speak with us.

The NovoSeven facility inHillerød, which was named“Facility of the Year” in 2005

process news 2/2006

18Pharmaceutical Industry

CASE STUDY

To equip the new facility with safetycontrol technology that would alsofulfill all environmental regulations

for pharmaceutical manufacturing plants,NNE selected Siemens, a company NNE had

been working with successfully for a longtime. The Siemens contribution to the proj-ect included a fire protection system offer-ing highest-level fire safety combined withthe lowest probability for false alarms. The

fire prevention concept is based on veryearly detection of developing fires, provid-ing ample time for production shutdownand safe evacuation of staff. In addition,the critical production environment calledfor a high level of immunity against decep-tive phenomena through the use of cus-tomized detection algorithms for each ofthe 350 smoke detectors. As a result of theopen architecture of the new facility, some20 air sampling smoke detectors were alsoinstalled at the site. As a recognized inno-vation leader in the field of fire detectiontechnology, Siemens was able to dramati-cally reduce the probability of productionstoppages through false alarms at theHillerød plant site.

Comprising a total of 14,000 squaremeters of production space, Siemens alsosupplied the new NovoSeven facility witha total of 18 air handling units (AHUs). All AHUs are equipped with independent

Environmental conditions at the “Facility of the Year2005” are controlled by Siemens building technologies

Award WinnerWhen the Danish healthcare company Novo Nordisk A/S commissioned NNE todesign and construct its new NovoSeven hemophilia drug manufacturing plantlocated in Hillerød, Denmark, it did not expect to garner a prize, let alone to bepresented with the “2005 Facility of the Year” award. Among other things, thefacility also received top honors for its safety and environmental compliantbuilding control technology supplied by Siemens.

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The modular approach of NNE and thesolutions approach of Siemens BuildingTechnologies ideally compliment one an-other. With highly satisfying results, as BobBest, president and CEO of the Interna-tional Society for Pharmaceutical Engi-neering (ISPE), summarizes: “Creative de-sign within a super fast-track timeline forproject execution, application of modularengineering for greater control and flexi-bility and dramatic and pleasing architec-tural features throughout the facility: Thenew NovoSeven site is proof positive of thegrowing worldwide status of facility designand engineering.” �

tive tasks are executed with integratedscheduler functions, and plant perform-ance is easily analyzed with the help oftrend graphics and event logs. In the eventof an alarm, the system automaticallyroutes the information to the selected tar-get groups.

Built in 18 fast-track months

The Siemens solution was entirely basedon pre-designed and proven applications.Also, each module was tested in detailbefore it was shipped to the site. By employ-ing modular engineering and a fast-tracktailored design, NNE was able to hand overthe project only 18 months after its com-mencement, marking a milestone not onlyfor the NNE engineers, but also for thepharmaceutical industry at large. Undernormal circumstances, a project of thismagnitude would have taken twice as longto complete.

process news 2/2006

19

Proven track recordThe Siemens Building Technologies Group (SBT) looks back on a long proven track record

in supplying pharmaceutical production facilities and related critical environment

operations with state-of-the-art solutions, services and industry-specific expertise. In

addition to plant control, supervision, alarm and environmental monitoring systems, SBT

also specializes in risk-based validation support to meet GAMP guidelines. The industry-

specific portfolio includes advanced data monitoring and archiving solutions to document

process conditions, as well as sensor calibration and recalibration services for accurate

quality control measurement. The lineup of individualized value-added services comprises

everything from risk assessment to remote service, software updates and staff training

support. The pharmaceutical offering also extends to various lab management services,

including safety, efficiency and comfort.

Hillerød in Denmark is the location of some of Novo Nordisk’s most advanced production units

automation stations and based on provenand pre-tested standard applications. Byemploying this approach, it is now possibleto engineer, commission and maintain thedifferent plants independently while alsoincreasing the availability of each plant.

Moreover, Desigo Insight building man-agement systems handle the entire opera-tion and supervision of the building infra-structure. The systems are clearly sepa-rated between GxP-related systems withapproximately 500 data points and whichrequire validation and qualification, as wellas non-GxP systems with approximately900 data points which follow good engi-neering practice (GEP).

With the Desigo Insight systems, opera-tors now have access to all necessary infor-mation in real time. They can view plantgraphics with all of the relevant measuringinformation and also, for example, changeset points where it is authorized. Repeti-

Find out more:www.siemens.com/pharmawww.nne.bizE-mail: [email protected]

Novo Seven facility:facts and figures

� Designer: NNE

� Process consultants:

NNE, Novo Nordisk

� Constructor: MONNET

� Project management: NNE

� Commissioning consultants: NNE

� Validation consultants: NNE

� Building automation supplier:

Siemens

� 500 GxP and 900 non-GxP data points

� Fire safety supplier: Siemens

� 350 smoke detectors

� Total area: 14,000 square meters

� Total cost: approx. 100 million Euro

� Construction time: 18 months from

approval of basic design to handover

Gentle preservationFreeze-drying, or lyophilization, is a gentle

conservation method that preserves the

properties of a temperature-sensitive

product almost completely. The moisture

is extracted from the frozen product in a

vacuum.

Freeze-dried substances are characterized

by very good solubility, and freeze-drying

makes many medicines easier to handle

and more quickly available.

In many cases, it is also possible to

dispense with a cooling chain.

process news 2/2006


CASE STUDY

GEA Lyophil has made a name foritself in freeze-drying. The com-pany specializes in plants for the

pharmaceutical industry and is one of theleading manufacturers worldwide. Its prod-uct portfolio ranges from pilot plants for

research and development to complete sys-tems for the industrial manufacture ofpharmaceutical products. GEA Lyophil washeavily involved in the development ofautomatic loading and unloading systemsto help freeze-drying plants achieve com-

pliance with the strict requirements of thehealth and regulatory authorities withregard to sterile production conditions andcontamination prevention.

In May 2006, at Achema in Frankfurt,GEA Lyophil presented two completely new

GEA Lyophil uses Simatic WinCC flexible forstandardized and adaptable visualization solutions

Recipe-Based DryingAt Achema 2006, GEA Lyophil presented the first of its freeze-dryingmachines that uses a new, standardized visualization concept. Thesolution, based on Simatic WinCC flexible, enables GEA to equip itsfreeze-dryers with a standardized visualization system that compliescompletely with GAMP 4 and FDA requirements and at the same time,allows easy and flexible adaptation.

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21

production line developments that bothuse the Simatic WinCC flexible HMI soft-ware. The new freeze-dryers consist of acombination of fixed modular components.The appropriate control and visualizationsoftware is parameterizable for the avail-able variants. Thus, Lyophil can not onlyoffer a range of freeze-drying plants basedon a tested product line and modules, butit can also shorten delivery times andreduce the engineering effort.

Modular, GAMP 4-compliant solution

Lyophil was looking for a modular, uniformcontrol architecture to suit the modularplant concept that could be adapted to dif-ferent tasks easily, quickly and at low cost.Of course, the solution had to meet the lat-est GAMP 4 requirements and FDA regula-tions. The centerpiece of the requirementslist of Lyophil was an easy-to-use operatingsystem that offers a great deal of informa-tion. All procedures had to be clearly trace-able and all essential process data had to bedocumented. The system also had to beable to generate batch reports and otherstatistics for process documentation.

Because GEA Lyophil had already suc-cessfully equipped its units with Siemensproducts and systems in the past, the com-pany decided to also use Siemens technol-ogy in the new machines. The visualizationand the recipe handling is managed bySimatic WinCC flexible. The batch reportsare created using the PM-Quality softwareadd-on. On the hardware side, Lyophil usesan Industrial PC IL43.

Many advantages

This solution offers GEA Lyophil numerousadvantages. WinCC flexible 2005 can beintegrated seamlessly into the Siemensprogram packages for S7, and applicationsfor panels and PCs can be created with a

single, uniform software program. WinCCflexible also supports audit trails, the ver-sioning of projects and the takeover of proj-ects from ProTool – which helps to protectthe expertise that has been acquired at GEALyophil. The PM-Quality add-on offers auser-friendly solution for the batch-ori-ented recording and display of data via PM-Quality (batch reporting). It was not onlythe technical excellence of the products thatled GEA Lyophil to choose Siemens, how-ever; the excellent worldwide support fromSiemens and the high level of acceptance ofSiemens technology throughout the worldwere also important factors in the decision.

Rapid project execution

GEA Lyophil was very pleased with the con-structive cooperation from Siemens. Theconcept development began in March 2005,and the decision was made in May. Imple-mentation began immediately, and theproject was completed in December 2005.During the development of the prototypes,

experts from GEA Lyophil and Siemensworked together to find the optimum solu-tion. One of the greatest challenges of theproject was the development of a com-pletely new applications base. There wasalso the task of linking WinCC flexible 2005smoothly with PM-Quality and forming atrouble-free system solution.

GEA Lyophil praises the support pro-vided by the Siemens team and stressesthat highly qualified contacts were avail-able at all times to provide assistance inevery phase of the project. The softwaresoon reached a high level of maturity andin many respects surpassed even the high-est expectations. The first demonstrationmachine was completed and tested in timefor the trade fair in May 2006 and is nowavailable on the market. �

Find out more:www.siemens.com/pharmaE-mail: [email protected]

With Simatic WinCC flexible, thefreeze-dryers can be operated via a

standardized modular user interface.This includes detailed views of

individual plant components such asthe compressor (top), clearly

arranged faceplates for the plantstatus (center) and a user managerwith password-protected accounts

for access to plant data (bottom)

22Chemical Industry

CASE STUDY

process news 2/2006

23

Formerly a major manufacturing site,Dow Chemical Company’s facility inPiscataway, New Jersey now consists

of a research and development and busi-ness center, which includes a pilot plantwhere small batches of new products aredeveloped and tested prior to commercial-quantity production at larger Dow manu-facturing plants. The pilot plant makeswater-soluble polymers for three busi-nesses within Dow. These polymers includeCellosizeTM HEC (hydroxyethyl cellulose),used as a thickening agent for paintsalong with a number of other applications;PolyoxTM WSR (polyethylene oxide), whosewater-soluble resins find use in applica-tions such as pharmaceuticals, building ma-terials, soaps and detergents; and UCARETM

Polymers, conditioning polymers for hairand skin cleansing and other personal careapplications. The facility produces limitedquantities of product samples for cus-tomers who will eventually order commer-cial quantities from Dow’s plants aroundthe world.

New system integrating separatefunctionalities

According to Mark Trampe, Dow process re-search specialist, the pilot plant has 13recipes that it regularly uses to make vari-ous products. The aging control system in-stalled in the plant was nearing 12 years ofservice and had separate controllers to pro-vide an independent emergency shutdown(ESD) system. This control system simplycould not provide enough functionality for

Pilot plant update combines batch system and emergency shutdown

Model ProjectBy replacing the existing process control system andemergency shutdown system, Dow Chemical Company wasable to achieve significant improvements in the operation of apilot plant at its Piscataway site. After successful completionof the upgrade project, Dow intends to use the pilot plantsystem as a model for other projects.

Dow’s new and sophisticated products, sothe company decided to replace it.

Following the successful upgrade of thepilot plant, Dow also plans to upgrade oneof the labs and its two aging batch reactorsystems, using the pilot plant system as amodel. Beyond the initial upgrade and theplanned lab upgrades, Dow wants to installa second, completely new batch reactor sys-tem in the pilot plant.

About a year ago, management decidedthat, for both safety and aesthetic reasons,it was time to move the control room. Thisafforded an excellent opportunity to up-grade the control system during the move,a project that involved changing the con-troller and the HMI, and acquiring up-to-date ISA S88-compliant batch software.

Dow decided to replace the existing con-trols and HMI with Simatic PCS 7-basedHMI software, Simatic Batch software andAPACS+ controllers. A real plus was that itwould no longer be necessary to retain theold 382 controllers, since the new systemincludes ESD functionality as well as batchcontrol, eliminating much of the complex-ity involved in running two physically sep-arate systems.

Easy to use in everyday operation

Though the new system has been opera-tional for only a few weeks, Dow is alreadyseeing the benefits and is expecting evenmore from it. With the new system, JohnWatkins of Dow’s lab automation groupfinds it easy to maintain and program theGUI-based batch system. Most importantly,

operators no longer need to switch hard-ware configurations to make recipe changes.With Simatic Batch, says Watkins, there isonly one controller configuration, and itremains unchanged while operators chooseto run different batch recipes. With this im-proved ease of use, operators can makerecipe changes without calling on Watkinsfor any programming.

Dow’s other expectations include im-proved planning capabilities, better batchrecipe management of its several lines ofproducts and their variations, and betterdata from the system. The upgraded func-tionality has already enabled Dow to runbatches that it could not run on the oldsystem.

Since it is rare for the pilot plant to runthe same batch for more than a day or two,the ability to track all batch parameters isextremely important. The new batch soft-ware’s expandability and ease of use haveproven to be time-savers as new processesand products are planned. Collected datasuch as temperature and pressure profilestypically flow into Excel spreadsheets,where other groups in the company can ex-amine it.

Technical assistance and training fromSiemens were beneficial in getting the sys-tem up and running at peak efficiency. PIDtuning was a weakness with the older sys-tem, but was easy to implement on the newsystem with the help of Siemens engineers.Training on the batch capabilities of theOS and batch software was provided atSiemens’ Springhouse, Pennsylvania loca-tion, about an hour and a half’s drive fromthe Piscataway site. Total training time wasspread out over several visits and lastedabout a week. Training included instruc-tion in programming the GUI-based batchsystem to allow operators to make the mostof its capabilities.

Tangible benefits

The Simatic PCS7/Simatic Batch system withAPACS+ controllers has made the work flowmuch smoother at the pilot plant. While itmay be too early in the implementation toquantify actual dollar savings, there is noquestion that time has been saved, and inany language, time is money. �

Find out more:www.siemens.com/chemicalsE-mail: [email protected]

24Consumer Goods

CASE STUDY

Quality and availability improvements at Unilever Australia

A Beautiful Combination Unilever Australia is a leading supplier of fast-moving consumer goods,providing foods as well as home and personal care brands for Australia and New Zealand. The company’s long-term success requires a total commitment to exceptional standards of performance through the combination of economicgrowth and sound environmental management. With this in mind, themanagement of the North Rocks site in Sydney decided to improve theperformance of their health & beauty and aerosols mixing plant by upgrading the process control systems to Simatic PCS7. The project has been highlysuccessful, winning the Chemicals & Petrochemicals category of the 2006 PACEZenith Awards, which recognize companies that have shown leadership inengineering and technological excellence and innovation.

North Rocks is responsible for themanufacture of personal health andbeauty products, aerosols and liq-

uid detergents and cleaning products.With the market for fast-moving consumergoods becoming more and more competi-tive and cost sensitive, maintaining opti-mal productivity and availability is criticalto the future of every site. “There is a sig-nificant need to improve the efficiency ofthe plant while at the same time reducingcosts. This is critical when looking to securethe long-term viability of the plant,” saysMatthew Leys, project engineer at NorthRocks.

Downtime, quality issues and bottlenecks

Such pressures led Unilever to review thecontrol strategy for North Rocks in 2002.Led at the time by Fiona Fong, Unileveridentified a number of areas for improve-

ment. Of particular concern was the healthand beauty products mixing plant, whichwas suffering from downtime and varia-tion in product quality. The plant had alsobeen identified as a bottleneck restrictingthe overall throughput of the facility. Thereview revealed a need for standardizationacross the site to ensure that existing andfuture operations personnel were fully con-versant with the automation and opera-tions environment. However, despite suchcompelling reasons for change, there wasonly a limited budget available.

Protecting investment

Having evaluated several control solutions,Unilever decided to proceed with imple-menting the Simatic PCS7 process controlsystem while utilizing the existing I/O de-vices. Faced with a limited budget, Unileverdecided to develop the application code in-house, with Siemens providing support.

This made sense for Unilever, which waslooking not only to control the costs of theproject, but who also wished to develop itsown in-house expertise. This approach alsoensured that the company could confi-dently look beyond the health and beautymixing project and take a site-wide view ofupgrades and standardization centered onPCS 7. Unilever also made the decision touse the ISA S88-compliant Simatic Batch inorder to improve product consistency andreduce cycle times. The batching systemproved central to generating process im-provements and ensuring compliance withTherapeutic Goods Administration require-ments. Unilever was, however, looking wellbeyond current requirements and imple-menting a solution that could handle futurelegislative change. The flexibility, traceabil-ity and reporting power that PCS 7 andSimatic Batch provided were seen as ideallysuited to handle change.

At the North Rocks site, Unilevermanufactures personal healthand beauty products, aerosolsand liquid detergents andcleaning products

25

Confidence and significant returns

After successful delivery of the first projectwithin a 12-month time frame, Unilevermoved on to the next phase of its plan, up-grading the aerosols plant. Although thesystem was smaller than that of the healthand beauty plant, it presented the challengeof having only one-third the time for com-pletion. Again the decision was made byUnilever to deliver the project through itsin-house engineering team. With standardsthat had been developed during the firstproject, the team set to work on the aerosolsproject buoyed by the knowledge that “theprocess of design is fairly intuitive withPCS7”, says Matthew Leys.

This project was also delivered on timeand within budget, and Unilever is satis-fied that the company is now reaping the re-wards of integrated process control andbatch architectures. Not only does Unilever

now have a common operator environmentacross the two plants (with the benefit of re-duced training costs), it has also seen a sig-nificant reduction in the time required toidentify and resolve process problems. Re-porting and the provision of live plant datato ERP systems has also been simplified,thus providing a higher degree of accurateprocess data for planning purposes. Thequality of the product has improved, withthe right-first-time figures showing an in-crease of more than 15 percent, plus a risein overall mixing efficiency. Batch cycletimes for shampoo have also been reduced,showing an improvement of 13 percentover the previous system – not only demon-strating greater efficiency, but also provid-ing Unilever with the opportunity to in-crease overall productivity.

Probably the most telling result has beenthe dramatic improvement in plant avail-ability. Monitoring of computer and control

The reliability and flexibility ofPCS 7 and Simatic Batch hashelped boost plant performance

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system downtime has provided an accurateassessment of the improvements sincePCS7 was installed; these data show a re-duction in downtime of nearly 90 percent.Such returns have given Unilever the con-fidence to expand the system into otherareas in the future. “Due to the reliabilityand flexibility of PCS7 and Simatic Batch,we have decided that the most sensible wayforward is to incorporate additional processequipment into the system,” says MatthewLeys – an approach that goes a long way to-ward meeting the commitment to excep-tional standards of performance expectedby this forward-thinking organization. �

Find out more:www.siemens.com/pcs7E-mail: [email protected]

The health and beauty products mixingplant was modernized with Simatic PCS 7to improve batch cycle times

process news 2/2006


CASE STUDY

ZLB Behring employs approximately6,000 individuals worldwide andoperates production sites, plasma

collection centers and research and devel-opment departments in Europe and theUnited States. One of the company’s keysites is the Görzhäuser Hof in Marburg,

Germany which has about 1,600 employ-ees. Among the pharmaceutical productsmanufactured there is clotting factor VIII,used for treating hemophilia A.

The factor VIII production facility playsa central role at ZLB Behring. When itbecame necessary to modernize the pro-

cess control system in this division, ZLBBehring looked for experienced and reli-able partners to implement this project.

ZLB Behring decided to place all theproject execution in the hands of theSiemens team in Marburg. The main rea-sons for this were the competence andsuperior plant expertise of Siemens, saysZLB Behring project manager Jürgen Dersch. Another advantage was the localpresence and availability of Siemens staff atthe Siemens branch office in Marburg.

Narrow time window

The migration project involved the upgrading

of all of the HMI systems from Simatic PCS

to Simatic PCS 7, as well as the integration of

a separate archiving server for the long-term

archiving of process data, including data

analysis features.

In addition, the local operating stationsin the production section had to be con-verted to meet clean-room conditions, andwere commissioned under clean-room con-ditions. The control level with the proven

Modernization of the HMI systems at ZLB Behring in Marburg

Migration in Record TimeZLB Behring is one of the world’s leading manufacturers of vital, life-savingdrugs made from human plasma. The safety and quality of the products is thecompany’s prime concern. ZLB Behring makes strict demands on theautomation technology in its production facilities – demands that SimaticPCS 7 can easily fulfill. After a modernization of the HMI systems based onSimatic 505, ZLB Behring is impressed by the advantages of Simatic PCS 7 –and by the performance of the project team that commissioned the new HMIsolution in just four weeks.

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The solution at ZLBBehringB Redundant PCS 7 servers

B 6 PCS 7 clients in the clean-room area

B Redundant domain controller for

Simatic Logon

B Redundant optical network

B Simatic IT Historian with RAID system

B 7 Simatic 505 controllers

B 2,245 I/Os

B 5,100 tags

B 1,043 action requests

B 1,475 alarms

B 412 operating screens

B Creation of GMP-compliant test

documentation (FAT and SAT),

execution of the qualification phases

(phase 1: simulation on the test

system, phase 2: regression test on the

live system, phase 3: power test on the

live system) for compliance with FDA

regulations (21 CFR Part11)

One of the most important company locations is the Görzhäuser Hof in Marburg

Simatic 505 controllers was not changed.This meant that the existing control pro-grams could remain in use – one of ZLBBehring’s key requirements. In addition,the entire commissioning, including thequalification of modifications, had to becompleted within a shutdown window ofless than four weeks.

Meticulous preparation and close coop-eration enabled this tight schedule to bemet by the project team during the con-figuration of the new control system. Withthe agreement of ZLB Behring, the major-ity of the qualification was executed in thefactory acceptance test. During this phase,and also during the design of the displayand operating interface, the Siemens teamworked under the management of StefanSchmidt in close cooperation with JürgenDersch and his staff. This excellent cooper-ation was one of the main reasons for therapid implementation of the new solution.

After the submission and approval of thespecifications in November 2004, the sys-tem was designed, and a test plant with the

control level and the old and new HMI levelset up so that the factory acceptance testcould be carried out on schedule in April2005, together with the first phase of qual-ification. Parallel to this, the project teamalso compiled the GMP-compatible docu-mentation for validation and qualification.

Commissioning of the plant then beganin July 2005. After passing the site accept-ance test, including the necessary valida-tion measures, the plant was handed overto ZLB Behring in August 2005.

Excellent results

Thanks to the thorough preparation, the com-

missioning was completed ahead of sched-

ule, allowing ZLB Behring to perform water

runs and to start up production without any

problems.

ZLB Behring not only benefits from theSimatic PCS 7-based solution’s very highsystem availability, but the company canalso save on system maintenance and serv-icing thanks to standardized components.The open architecture of the Simatic tech-

nology also guarantees that the companycan expand the process control system inthe future.

Modernization of the systems at ZLBBehring continues: preparations for themigration of a water treatment plant forproducing ultrapure water are presently inprogress. This upgrade will be integratedduring a shutdown this summer. �

Find out more:www.siemens.com/pharmaE-mail: [email protected]

The factor VIIIproduction facilityplays a central roleat ZLB Behring.ZLB Behringbenefits from thesolution based onSimatic PCS 7, notonly in terms ofvery high systemavailability, butalso from savingson maintenanceand service of thesystem

Siemens supplies comprehensive solutions package for new Infineon fab in Malaysia

Pulling It All TogetherConstruction on the new fab – which will employ some1,700 individuals – got under way in spring 2005, withcommissioning slated for 2006. “The construction timelineis relatively tight,” as Dr. Werner Reczek, COO InfineonTechnologies Austria AG and project head of the Kulim fab,points out. “This is a fast-track project, and the schedule isdefinitely tighter than other projects.”

28Semiconductor

CASE STUDY

Currently, construction is in its finalstages and has already successfullymet the ready-for-equipment dead-

line in March 2006. Designed for a maxi-mum capacity of 100,000 wafers permonth, the 200 millimeter wafers manufac-tured at the new plant are designated forPower IC and Power discretes production.With the first production plant solely dedi-cated to producing wafers for power appli-cations, Infineon is well positioned to meetthe rising demand of the automotive indus-try and industrial applications. “When wedecided to build the new fab in Malaysia,we had the Asian market in mind, which isone of our main business areas,” Reczekadds. “Malaysia was our first choice also be-cause we already have one successful fab inoperation at Malacca.”

Quality systems for quality products

Power ICs are used in critical applications,which is why the plant must fulfill the moststringent criteria. “When you have a chipcontrolling a safety feature such as an anti-lock braking system, defects are simply un-acceptable,” Reczek explains. To reduce

project risks, Infineon once again chose toselect a proven partner in M+W Zander asthe general contractor, which had alreadybuilt other plants for Infineon. With Infi-neon assuming responsibility for produc-tion equipment and, in cooperation withits partners, all layouts, including the detailengineering, M+W Zander contracted outpower supply and distribution, automa-tion, process control, and facility manage-ment systems. Infineon chose to award theinstallation of the fab facility and IT infra-structure, including cabling, data and voicecommunication, network components, tele-phone systems as well as access controls, toan outside supplier – Siemens.

Thanks to its proven systems and solu-tions, Siemens managed to secure an orderfor several packages at the new fab, includ-ing the entire medium- and low voltage dis-tribution system, the building and processautomation of all of the buildings and sys-tems as well as the technical constructionsystems and process supply. Siemens willalso supply the turnkey IT infrastructuresolution consisting of active and passivenetwork components as well as the telecom-

munications system. Simatic controllers andthe Simatic PCS 7 process control systemwill be used as a plant-wide automation sys-tem for all building and process automationtasks – from the cleanroom to utilities suchas high-purity water, wastewater, chemicalssupply and technical gases.

The automation solution must ensure ahigh degree of availability as well as con-stant round-the-clock ambient conditionsand media supply for heating, cooling, airconditioning and compressed air.

In addition, Siemens will supply the ac-cess control and public address systems, awalkie-talkie system, as well as a closed cir-cuit TV system. Fire alarm and protectionsystems, building automation systems andheating, ventilation and air conditioningproducts from Siemens are also being con-sidered.

Systematic fast-track project support

Siemens began coordinating its activities inMalaysia in late 2004 already in order to beable to optimally support Infineon. Pro-ject planning also involved a close cooper-ation with M+W Zander in Germany andMalaysia to enable Infineon to fully lever-age Siemens entire semiconductor-specificexpertise from its local Malaysia office.

As a result, Infineon was not only able tobenefit from Siemens comprehensive so-lutions portfolio, but also from its exten-sive local know-how. Both of the projectheads of M+W Zander and Infineon stressedthe importance of an integrated approachfor the project. Having just one point ofcontact for various packages such as powersupply, automation and facility manage-ment systems facilitates a fast and trouble-free project execution. To date, the projecthas gone exceptionally well, and WernerReczek as well as the entire project teamat Infineon are very satisfied. With theKulim fab, Siemens has not only proventhat it can provide key support for large-scale global semiconductor projects withits knowledge and expertise, but has alsomade a very good impression in the grow-ing Asian semiconductor market, whereseveral similar projects are expected in thecoming years. �

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29

Find out more:www.siemens.com/semiconductorE-mail: [email protected]

Infineon in MalaysiaThe Kulim site is Infineon’s second plant in Malaysia. A fab in Malacca, set up some

30 years ago, now produces more than eight billion components for various semi-

conductor solutions in four high-technology product groups.

While seeking another Power IC production site, the company once again selected

Malaysia because of the country’s skilled labor force, attractive cost position and good

infrastructure. Certainly, the positive experiences made at Malacca also played a role.

The site of the new fab, the Kulim High Tech Park in the Kedah province of Malaysia, is

already home to production facilities of Intel, Fuji, Entegris and AIC Semiconductors.

Infineon’s presence is expected to attract further multinationals, especially from Europe.

process news 2/2006

30Test Systems

CASE STUDY

Family-run FEV Motorentechnik GmbH,the recipient of various innovationawards, is a global leader in power-

train development and in the test systemsbusiness. Test systems for engine develop-ment is one important business sector.

Demanding requirements for flowmeasurement

The interdependence of the differentinput variables is crucial in the develop-ment of an internal combustion engine.Therefore, a great number of parametersare measured in the engine tests, includingfuel consumption. Since the power spec-

trum of the engines ranges from approxi-mately 1 kilowatt up to the megawatt range,there is a need for accordingly steppedflow-measuring ranges with a fast dynamicresponse and a high degree of accuracy.Sitrans F C Coriolis flowmeters, which covera range from 0.05 to 600 kilograms perhour with accuracy as high as 0.1 percent ofthe measured value, are the ideal solutionfor this task.

Positive experiences

When asked what he appreciates mostabout the Sitrans F C mass flowmeters,besides the high accuracy and availability,

Bernhard Biermann, who is responsible forsales and marketing at FEV Test Systems,said he especially appreciates the extensivediagnostic capabilities, the fast response toactual customer applications, and the highlevel of flexibility with regard to bus inter-faces and process connections.

He is also fully satisfied with the service,advice, prices and delivery reliability. Inaddition, he uses special functions such asthe integrated totalizer – for example, forthe summation of the fuel consumptionover a freely selectable viewing period.

Over the course of the two companies’long and close relationship, a great deal oftrust has been established between FEV andSiemens which is beneficial to both parties.The requirements from the various mar-kets flow into product development andlead to a strengthening of the market posi-tions of both companies. For example, anew series of Coriolis flowmeters is cur-rently being created on the basis of the newSiemens FC300 series with an even betterdynamic response and zero point stability.In the future, this will allow optimum cov-erage of the application range – from thefuel-saving minicar to the heavy commer-cial vehicle – with just one sensor. �

Coriolis flowmeters optimize engine test bench

Dynamic Response and High AccuracyIn engine development in the past, the measurement and optimization ofstationary operating states was often sufficient. Today, however, increasinglystrinct emission legislation combined with shorter development cycles requiresan ever-earlier examination of dynamic actions in the development process.With the latest generation of fuel-consumption-measuring technology basedon Siemens Coriolis flowmeters, FEV Motorentechnik GmbH is able to meetthese critical requirements.

Find out more:www.siemens.com/processinstrumentationwww.siemens.com/flowE-mail: [email protected]

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The FuelRatemeasuring part of the

engine test benchcontains the

MASSFLO Coriolisflowmeter (right),

with the MASS 6000signal converter (left)

positioned next to it

Technical Symposium & Exhibitionfor the International CementIndustry in JakartaThe ASEAN Federation of Cement Manufacturers (AFCM) will beholding its 20th Technical Symposium & Exhibition for the Inter-national Cement Industry in the Jakarta Convention Center fromSeptember 5 to 9, 2006. The symposium and exhibition will pro-vide an excellent opportunity to meet, discuss and exchange informa-tion, experience and ideas, attracting keen international delegatesand participants from cement plant and machinery manufactur-ers, material suppliers, process-engineering specialists, cementmanufacturers, trades, engineering consultants and contractors,shippers, investors, energy consultants and managers, as well asother related bodies such as universities and cement technologicalresearch centers.

The 30 speakers that are expected to highlight the latest trendsand technologies in cement production will include ThomasWalther, head of the Competence Center Cement from Siemens,who will talk about improving competitiveness with Totally Inte-grated Automation.

www.asi.or.id

infosinfosDo you want to know more about the systems and solutions forthe process industry from Siemens Automation and Drives?Simply visit our information portal on the Internet:

www.siemens.com/processautomation

onlineonline

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31DIALOGUE

process news 2-06PublisherSiemens Aktiengesellschaft,Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 NurembergGermany

www.siemens.de/automation

Group Executive Management Helmut Gierse, Hannes Apitzsch, Dr. Peter Drexel, Anton S. Huber

Responsible for ContentPeter Miodek

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, A&D CC P MCSiemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21/5 95-25 91Fax: +49 (0) 7 21/5 95-63 [email protected]

Editorial CommitteeAlexandre Bouriant, Sigrun Ebert-Heffels, Michael Gilluck, Birgit Gottsauner, Walter Huber,Keiren Lake, Bernd Langhans, Bernd Lehmann,Silvana Rau, Rüdiger Selig, Roland Wieser, Wolfgang Wilcke

Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate Publishing ZeitschriftenP.O. Box 3240, 91050 Erlangen, GermanyTel.: +49 (0) 91 31/91 92-5 01Fax: +49 (0) 91 31/91 92-5 9

[email protected]

Editor in chief: Kerstin Purucker

Layout: Jürgen Streitenberger

Copy editing:Irmgard Wagner

DTP: Doess, Nuremberg, Germany

Printed by: Stürtz GmbH, Würzburg

process news is published quarterly

Circulation: 34.500

Jobnumber: 002100 RPE62

© 2006 by Siemens Aktiengesellschaft Munich and Berlin, Germany

All rights reserved by the publisher.

This edition was printed on environ-mentally-friendly chlorine-free paper.

ISSN 1430-2292 (Print)

The following products are registered trademarks of Siemens AG:CEMAT, DESIGIO, Insight, MASSFLO,MILLTRONICS, PCS 7, ProTool, S7-300, S7-400,SIMADYN, SIMATIC, SIMOCODE, SIMODRIVE,SITRANS, SIWAREX, TOTALLY INTEGRATEDAUTOMATION, WinCC

If trademarks, trade names, technicalsolutions or similar are not listed above,this does not imply that they are notregistered.

The information provided in this magazinecontains merely general descriptions or characteristics of performance whichin case of actual use do not always applyas described or which may change as a result of further development of theproducts. An obligation to provide therespective characteristics shall only existif expressly agreed in the terms of contract.

Order No.: E20001-M6206-B100-X-7600

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If success is a chemical reaction, what will it take to start one for yourbusiness? How about productivity growth with stable quality and profit-ability? Let us get the right reactions started for one of your processes –or your entire facility. Our comprehensive automation technology istailored to fit your specific needs. We’ll use open standards to integrateyour processes right to the management level and do everything to ensureyour competitive edge for the long term. Our secret formula? It’s calledTotally Integrated Automation.

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Documents

process - SiemensUnilever modernized one of its production units at the North Rocks site by upgrading the process control systems to Simatic PCS 7. The project has been highly successful,