PLC System

RICHI PLC system acts as the brain of your production line to keep everything running. It coordinates every piece of gear from pulverizers to packaging units through smart automated programs. You get precise control over all parameters which keeps the system stable and efficient for feed or biomass lines.

Product Overview

The PLC system controls the entire feed line by linking controllers, touchscreens, and sensors. It automates the production flow and maintains precise settings for mixing and pelleting temperatures. You get high accuracy with batching errors kept under 0.1% for any scale up to 30 tons per hour. The system stores formulas, logs data, and triggers instant alarms if a fault occurs. It supports both single units and full-plant networks to ensure smooth, intelligent operation. This setup cuts down on manual work and keeps your production consistent.

Capacity: 1-30 T/H

Accuracy: ±0.1%

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Technical Structure of PLC System

Our modular design organizes every core component into a smart control brain. It ensures stable lifting and easy maintenance for your entire production line.

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Central Unit

This Siemens host pulls in data from every sensor on your factory line. It runs the pre-set program to calculate exactly how fast to lift grain. The unit sends out real-time orders to each motor to keep them in sync. It manages the timing for the entire path from the intake to the silo. You can trust this hardware to coordinate every move without a delay. This part connects all your machines into one single organized flow.

Operation Panel

The touchscreen lets your workers change the line settings with a tap. You enter your feed formulas and set the lifting speed on this panel. It shows you the current status of every bin and motor in the plant. This unit handles the start and stop commands for the whole system. Your team can look up past data or check for faults in just seconds. PLC system puts the control of every tall elevator right at your fingertips.

Detection Sensors

These sensors track the weight and temperature of your grain in bulk. They send a signal to the host if a belt slips or a bin gets too full. The unit monitors steam pressure and material levels every second. This live feedback stops the feed intake before any clog can happen. You get a clear view of the material flow inside the steel casings. These parts provide the data needed to keep the entire line running.

Drive Components

The drive units of PLC system take orders from the host to power your heavy motors. Frequency converters adjust the belt speed to match your batch size. These parts control the valve switches and the cylinder movements. They ensure the buckets start up gently to protect the mechanical belt. Every component works to deliver power exactly where it is needed. This unit handles the physical work of moving your grain up high.

Safety Interlock

Safety units use limit switches to guard every door and moving part. They cut the power instantly if the system detects an overload risk. This setup links all the machines so a fault stops the whole line fast. It protects your crew from accidents during a busy production shift. These devices prevent gear damage by stopping the motor right away. You get a secure setup that watches over your people and your shop.

Service Port

The modular layout of PLC system lets you swap out parts without a lot of downtime. You can reach the internal wiring and blocks in just a few minutes. This simple structure keeps your repair costs down through the year. It allows your team to perform quick checks on the drive components. Your plant stays on schedule because every part is easy to replace. It is the best design for keeping a busy factory floor organized.

Central

Panel

Sensors

Drive

Interlock

Service

Technical Parameters

The technical data for the PLC system demonstrates its advanced automation and real-time monitoring capabilities. This ensures a highly coordinated production process by precisely managing machine parameters, providing a smarter and more stable operation for the entire feed processing line.

Item	Technical Specification
Core PLC Brand &Model	Siemens S7-1200/S7-1500 Series
Rated Working Voltage	AC380V 50Hz (Main),DC24V (Control)
I/O Point Range	32-64 (Single-machine),128-1024 (Whole-line)
Communication Protocol	Modbus-TCP/RTU,Ethernet, 4G RemoteMonitoring
Batching Accuracy	≤+0.1%
Adaptable Production Capacity	1-30 t/h Feed &Biomass Lines

Operational Principles of PLC System

The PLC control system realizes automatic control of the whole production line through closed‑loop signal collection, logic judgment and command output.

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Input Signal Collection

The host scans every field sensor to grab raw data on material weight. It constantly tracks bin levels. You get analog signals from steam pressure gauges and motor sensors flowing into the main unit.

This hardware digitizes every physical input. It creates a live map of your production flow now. The system captures valve positions and conveyor speeds every millisecond. This stage provides the foundation for the entire automation logic to follow.

Logic Processing and Calculation

The PLC system is responsible for high-speed logic processing and calculation.The CPU compares these incoming signals against your formulas. It runs the internal program to determine the next step for every machine. The logic checks if batching weight matches your target. It handles the math.

This computing core triggers specific subroutines based on live data from the sensors. It generates digital decisions for the output modules without any real delay. This processing cycle repeats thousands of times per minute to keep the plant stable.

Output Execution and Control

The PLC sends control signals to frequency converters and contactors to move. It switches solenoid valves. This hardware manages relays to open gates and adjusts motor speeds to finish the cycle. It drives the machinery.

You see the system converting logic into physical electrical actions. This execution stage ensures the equipment follows your digital commands to the letter. It delivers the power exactly where it belongs to complete the pelleting process.

Key Advantages of PLC System

The PLC control system delivers precise control and intelligent coordination, proving to be an indispensable auxiliary equipment
with distinct advantages in production accuracy, work efficiency, cost control, and quality traceability.

High Batching Accuracy

This system manages batching automatically through high-precision weighing sensors. It keeps errors within a tight range of ±0.1% to ensure consistency.

Strictly following your pre-set formulas eliminates human mistakes completely. Every batch maintains the exact nutritional content you require. It works.

You see a much higher product qualification rate because the PLC never misses a measurement. This hardware stabilizes your entire output quality. It guarantees that every bag of feed meets your professional standards without any manual guesswork involved on the factory floor.

Fully Automated Linkage

The PLC system realizes automatic operation across every single stage of your line. It handles raw material conveying and crushing while managing the mixing and pelleting cycles. You avoid frequent manual intervention. This reduces downtime significantly.

Production efficiency jumps by over 30% because the machines never stop to wait for an operator. It lowers your labor costs immediately.

The whole system runs in a synchronized loop from the intake to final packaging. It keeps the flow moving fast. You get more finished product out the door with much less effort from your crew.

Lower Energy Consumption

The host automatically adjusts operating parameters based on live material conditions. It controls pulverizer speed and manages pelleting steam volume or fan air volume. This prevents idling. It stops your motors from overloading during heavy shifts.

You cut electricity and steam consumption by running the gear at optimal levels. Long-term use reduces your production costs by a massive margin.

The system saves energy by matching power output to the actual load. It is a smart way to protect your equipment. You lower the utility bills while keeping the machines running at peak performance.

Full Data Traceability

The PLC system records every bit of production data like material consumption and equipment status. It tracks production time and technical parameters for every batch. You can view or export these files as Excel reports whenever you need them. This makes quality inspections very simple.

It supports standardized factory management by giving you a clear paper trail of the entire operation. You stay in control of the numbers. It allows for quick troubleshooting if a problem ever pops up. This traceability ensures your plant stays compliant and efficient throughout the entire year.

Global Case Study

RICHI’s PLC systems are applied to feed and biomass pellet plants worldwide, solving automation bottlenecks and boosting customer benefits.

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Intelligent PLC System Solution in Thailand

The customer produced pig feed with manual batching that caused high errors and low efficiency. After installing the RICHI PLC control system, batching accuracy reached ±0.1% for every batch. Daily output increased by 25% through full automation of the mixing line. This hardware eliminates human mistakes during the busy shifts. It keeps the nutrient levels stable. You get a much smoother flow. The owner sees a huge jump in total profit because the machines handle the heavy work without stopping.

PLC Integrated Control System Project in Canada

This facility uses wood chips and straw as raw materials with severe dust pollution issues. We installed a centralized PLC system to manage crushing, drying, and pelleting units together. Dust removal is centrally controlled now. The continuous operation rate reaches 95% because the equipment stays perfectly coordinated. Energy consumption drops by 18% as the system prevents idling. It is a very clean setup. You get a reliable way to turn waste into fuel while keeping the air inside the plant clear for your workers.

PLC Automation Control System in Egypt

The customer produces high-quality fine fish and shrimp feed with diverse formulas. We customized a PLC control system storing over 50 formulas with quick switching functions. Mixing uniformity meets all standards. You see a great improvement in pellet water stability. The hardware adjusts the steam and pressure to match each specific recipe. It makes the transition between products very fast. This flexibility allows the plant to handle multiple orders from different customers throughout the week.

Reliable PLC Control Solution in Kazakhstan

Located in a high-latitude cold region, this site requires stable low-temperature operation. The RICHI PLC system adapts well to the freezing environment. It automates the whole process without any lag. The production line has run stably long-term without any mechanical failures. You get a system that ignores the cold. It protects your motors and sensors. This setup keeps the grain moving even when the outside temperature drops well below zero for months at a time.

Application Scope of PLC System

The PLC control system covers various production scales from small workshops to large-scale industrial feed and biomass factories. Its application range extends across diverse animal nutrition sectors and multiple raw material processing environments.

Industry Applications

Small Production Lines: Used for automated control of single-machine lines (1–5 t/h). System fits small workshops requiring basic automation for grinding or pelleting.

Medium Complete Lines: Applied in complete feed lines with capacity of 5–15 t/h. Setup manages multiple units for balanced and continuous material flow.

Large Industrial Plants: Used for industrial factories with output of 15–30 t/h. It fits complex systems requiring centralized monitoring and full process automation.

Target Animals

Poultry & Livestock: Applied in production control for feed like pigs, chickens, and ducks. PLC system manages grinding and mixing for standard animal formulas.

Ruminant Feed Lines: Used for automated processing of fiber feed for cattle, sheep, and rabbits. Application fits factories requiring control over bulky material intake.

Aquatic Feed Units: Specifically used for aquatic lines producing pellets for fish and shrimp. It fits environments requiring management of micro-ingredients and pellet stability.

Processing Materials

Standard Grain Materials: Handles automated batching for corn, soybean meal, and wheat bran. System fits monitoring of dry grain during main processing stages.

Biomass & Fiber: Used for controlling production of straw, wood chips, and rice husk pellets. Application covers material handling in high-intensity energy pellet plants.

Liquid & Solid Additives: Supports dosing of additives like fish meal, bone meal, and oils. It fits formulas requiring control of micro-solids and liquid ingredients.

Buyer’s Guide & Support Center

All your questions are answered here! Below are answers to frequently asked questions about the PLC system, providing you with comprehensive answers.

How many formulas can the PLC control system store?

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The standard version easily handles 100 formulas. If you need more space, we can expand it to over 500 on request. You can call up or edit any recipe in seconds. It makes switching between different feed types incredibly fast and simple for your operators.

Does the system support remote monitoring?

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Yes, it does. You can connect the system to your network to check on everything from your phone or computer. You can change parameters or diagnose a fault without even being in the factory. It puts the whole management of your plant right in your pocket.

Can the system adapt to other brands of feed equipment?

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Absolutely. Our system uses universal interfaces, so it talks to pulverizers and pellet mills from almost any brand. It doesn’t matter if your machines are new or old. We can use this system to give your old production lines a complete automation makeover.

How does the PLC control system handle equipment failures?

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The system keeps a constant watch on everything and stops the line instantly if it finds a problem. The touchscreen tells you exactly where the trouble is and why it happened. You also get a loud alarm and flashing lights so your team can fix things and get back to work quickly.

How long is production data saved? Can it be exported?

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We keep your data safe for 1–3 years. You can plug in a USB flash drive and export everything as an Excel report whenever you like. It is perfect for keeping track of your production numbers or showing your quality control team that everything is on track.

What is the service life of the PLC system?

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The core parts are built to last 8–10 years. You will usually need to look at the touchscreens and sensors after 3–5 years of steady work. The best part is that you can upgrade individual parts as technology moves forward, which keeps your whole system running like new for a very long time.

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