Design and Development of Multi-Station Industrial Process Control System

DOI

https://www.doi.org/10.59256/ijsreat.20260603019

Published In

Volume 6, Issue 3 (2026)

Published Online

May-June 2026

Pages

136-142

Article Type

Original Article

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This project presents a PLC-based industrial process control system for a multi-stage liquid processing application. The system automates operations such as liquid mixing, heating for a specific duration, cooling, and storage in a tank using a Siemens PLC CPU 1214C (AC/DC/RLY) and WinCC (SCADA). For laboratory implementation, the real industrial process is simulated using LEDs, timers, and analog inputs instead of actual liquids and heating elements. The PLC controls the complete sequence of operations, ensuring proper timing, process flow, and safety. An IoT-based prototype using ESP32 is developed separately to monitor process parameters such as liquid temperature, quantity (in ml), tank levels, machine status, and alarms in real time through a remote dashboard. The IoT module is used only for monitoring purposes and does not control the process. The system also includes safety features like over-temperature protection, emergency stop, and production control. This project demonstrates the integration of PLC-based automation with IoT-based monitoring, improving visibility, safety, and efficiency in industrial processes.