In the ever-evolving polyurethane sector, FSI continues to lead the way in innovation and efficiency. When the company sought to implement a new batch mixer with mobile control capabilities, partnering with Unitronics was a natural choice. This collaboration resulted in a solution that not only met FSI’s needs but also enhanced their productivity and operational flexibility.
About FSI: A Legacy of Innovation
Founded in 1972 in a suburban home, FSI quickly grew into an industrial powerhouse, driven by the innovative mindset of its founders. Over the decades, FSI has achieved several industry firsts, including:
- The first computer-controlled “in-line” blender.
- The first patented CFC-free rigid foam technology.
- Early adoption of environmentally sustainable technologies, such as Ecomate®, the industry’s first high-performance, zero-GWP, VOC-free blowing agent.
Today, FSI stands as a leading independent provider of polyurethane systems with a global presence, consistently at the forefront of technological development.
The Challenge: Meeting Modern Production Needs
To maintain its leadership in polyurethane production, FSI needed a reliable control system for a semi-autonomous chemical batch mixer. This system required:
- Support for recipe management in polyurethane production.
- Seamless communication with various devices involved in running batches.
- Remote access and mobile control for greater flexibility and efficiency.
The Solution: Unitronics Vision 700 PLC + HMI
Jeff Havlin, a controls engineer at FSI, selected the Unitronics Vision 700 PLC + HMI, equipped with snap-in I/O modules. The system’s capabilities, combined with the Unitronics Remote Operator mobile app, provided the perfect solution. Key features include:
- Batch Recipe Management: Operators can configure and edit recipes in real-time through secure mobile access.
- Seamless Integration: The Vision 700 communicates effortlessly with bulk tanks, pneumatic ball valves, solenoid valves, and system pumps via 0-10v analog signals. It also integrates with the Rice Lake 1280 scale using Modbus TCP to measure chemical weights accurately.
- Remote Access: The Remote Operator app enables operators to monitor and control the batch-making process from anywhere, streamlining workflows and freeing up time for other tasks.
Benefits: Driving Productivity and Efficiency
The implementation of Unitronics controllers brought significant advantages to FSI:
- Increased Productivity: Remote control capabilities allowed operators to manage multiple tasks while monitoring batch processes.
- Cost and Space Savings: The Vision 700’s compact design reduced wiring requirements, while its ability to communicate with multiple scales via Modbus TCP eliminated the need for additional indicators.
- Enhanced Flexibility: Analog and digital I/O options provided the versatility needed for complex production processes.
Jeff Havlin highlighted the impact of the solution, stating:
“The combination of a Vision PLC + HMI + snap-in I/O, combined with Unitronics Remote Access app, saves us time and money—while simultaneously boosting production.”
Why FSI Chose Unitronics
FSI’s decision to partner with Unitronics stemmed from their shared commitment to innovation and excellence. The Vision 700 PLC + HMI proved to be the ideal choice for meeting FSI’s demands for efficiency, reliability, and cutting-edge technology in polyurethane production.
Conclusion
By adopting Unitronics’ advanced control systems, FSI has reinforced its position as a leader in polyurethane innovation. This partnership exemplifies how the right technology can transform production processes, ensuring quality, consistency, and operational excellence.
