Rockwell Automation and SINCI develop a process control system

SINCI is a technology company dedicated to the implementation of innovative solutions for digital transformation with a focus on process control, information systems and OT/IT convergence that link business management solutions to Industry 4.0 manufacturing.

The company began operations in 1989 in Guadalajara, Mexico, with the mission of offering complete “turnkey” projects for automation and industrial process control. It has developed projects in various locations in Mexico and currently has four offices: Guadalajara, Monterrey, Querétaro and Mexico City. The company has also implemented nearly 5,300 projects for more than 470 customers and is currently active in over 10 different types of industry.

One of its end customers is a US multinational dairy company that distributes natural cheese, processed cheese, cream cheese and yogurt under its own label, with operations in Mexico dating back more than 30 years. 

In 2022 the company opened an industrial plant in the State of Guanajuato. This is where the multinational has a wastewater treatment plan (PTAR) where a series of physical, chemical and biological processes are carried out with the aim of eliminating contaminants present in the wastewater.

Treatment plants usually operate four major processes including pretreatment (collection of wastewater using drainage); primary treatment (sedimentation in which the water passes to tanks where the solids settle on the bottom and the non-solids rise to the top); secondary treatment (degradation of biological content using aerobic and anaerobic treatments together with activated sludge); and tertiary treatment (complete elimination of microorganisms using filtration, ionization and decontamination).

Nearly four years ago in this plant, SINCI and Rockwell Automation initiated a greenfield project locally that consisted of the integration of a process control system capable of monitoring all the variables in the plant.

Experience and ability

It should be noted that this was the first initiative of its kind that the two companies (which have worked together for 32 years) had developed for the wastewater treatment sector, whether public utilities or private firms.  

According to Salvador Navarro (Bajio Zone Manager at SINCI), one of the first challenges was to adapt the preliminary design (developed in the US) to one suitable for this site, validate the capacity of the mechanical equipment and coordinate with the supplier of storage tanks, as well as with the plant specialist. 

“The major challenges with this kind of implementation are a need for a comprehensive knowledge of the process and being able to recognize the types of variables that we will encounter. Once familiar with these variables, getting them to a control system requires substantial experience and capabilities in liquid waste processing,” he explained. 

“The analytical instrumentation variables are a very specific and relevant element in wastewater projects, as are conductivity, dissolved oxygen, water hardness and pH, among others,” he added.

It was exactly this comprehensive experience and their knowledge of control automation that led the customer to choose the Rockwell Automation and SINCI proposal. It was also necessary to find a supplier with the technical and human resources to implement a proposal locally that was originally designed in the US. 

In this respect, said Navarro, “the prestige of the Rockwell Automation brand, along with the fact that SINCI had the highest certifications in the country, were key factors that significantly influenced the end user to select both companies to carry out this initiative.” “Basically what every customer is looking for from the company it hires is the certainty that the project will be executed on time and to spec,” Navarro added.

Precise measurement

The main benefit of this automation and control solution is that the customer has a precise measurement of water quality at all times. This helps them avoid penalties as a result of surprise inspections by government agents as allowed by law. “In this way, the possible fines or penalties that could arise from noncompliance with environmental standards can be avoided,” Navarro pointed out. 

It should be emphasized that the process control solutions offered by Rockwell Automation for wastewater treatment are highly reliable and flexible. They are not only capable of maximizing productivity, they also reduce implementation costs, minimize life cycle costs, validate compliance and provide for future expansion. 

Specifically with regard to the PowerFlex frequency drives, Navarro pointed out that these have been important due to their flexibility and precision in managing the dissolved oxygen process, which is an essential aspect to this type of plant. “Another important attribute is the processing of analytical instrument signals,” he added.

The general manager of SINCI stated that the technical support and backup of the Rockwell Automation brand ensures a major competitive edge for his company. This helps him face end customer requirements with greater reliability and confidence. “In this respect, our certifications and the power of the sales channel provided by the brand make us very strong,” stated Navarro.

“As a result of this type of project, we realized that there were several business lines that we hadn’t explored. Our idea now is to replicate it with other customers across different businesses,” concluded Navarro.