Specialty Chemical
At DSI Innovations, we provide tailored automation solutions for the Specialty Chemical industry, ensuring precise control over complex chemical processes. Our expertise in batch process automation and advanced analytics empowers manufacturers to optimize production while maintaining strict safety and environmental standards.
From chemical blending and mixing control to hazardous area systems and safety instrumented systems (SIS), we design and implement exceptional solutions that streamline operations, enhancing your productivity, and ensuring compliance with industry regulations. We’re committed to supporting you every step of the way…so you can trust us to deliver reliable automation systems that help you stay competitive in this fast-paced sector.
Our Specialty Chemical Capabilities
Process & Control Automation
- PLC/HMI/SCADA Programming: Designing and implementing control logic, custom graphics, alarm management, and operator interfaces.
- Batch & Continuous Process Management: Developing solutions for precise control of batch operations, recipe management, and seamless transitions to continuous processes.
- Advanced Process Control (APC): Utilizing model predictive control, fuzzy logic, or other advanced algorithms to optimize throughput and product quality.
- Integration with MES/ERP: Linking plant-floor controls to business systems for real-time data transfer, production scheduling, and inventory management.
- Real-Time Data Acquisition & Historian: Collecting and archiving critical process data for trend analysis and regulatory compliance.
- CIP (Clean-In-Place) & SIP (Sterilize-In-Place) Automation: Automating cleaning cycles to reduce downtime and ensure safe, contamination-free operations.
- Automated Recipe & Formulation Systems: Ensuring accurate blending and consistency for complex chemical formulations.
- Redundancy & High Availability: Implementing fault-tolerant architectures for critical processes with minimal downtime.
Instrumentation & Field Services
- Instrument Selection & Specification: Choosing the right sensors/transmitters for flow, pressure, temperature, pH, etc., tailored to chemical processing environments.
- Calibration & Configuration: Providing on-site calibration, loop checks, and instrument tuning for accuracy and compliance.
- Installation & Commissioning: Setting up field instruments, conducting functional tests, and ensuring integration with control systems.
- Advanced Flow Measurement: Employing Coriolis, ultrasonic, magnetic, or vortex flowmeters for precise dosing and mixing.
- Analytical Instrumentation: Integrating gas analyzers, liquid chromatographs, or other specialized equipment for process quality control.
- Routine Maintenance & Troubleshooting: Offering preventative maintenance, diagnostics, and rapid response for instrument repair or replacement.
- Instrumentation Documentation: Providing P&IDs, loop diagrams, calibration certificates, and as-built documentation..
Control Panel Design & Fabrication
- Custom Panel Engineering: Designing UL- or CE-certified panels (or country-specific standards) according to application requirements.
- Enclosure Selection: Ensuring correct NEMA or IP-rated enclosures for harsh or hazardous locations.
- Component Specification: Selecting PLCs, I/O modules, relays, drives, and other hardware from trusted vendors.
- Wiring & Terminal Layout: Organizing panels for efficient cable routing, labeling, and minimal risk of wiring errors.
- Factory Acceptance Testing (FAT): Conducting thorough in-house testing of I/O, interlocks, and functionality before shipment.
- Site Acceptance Testing (SAT): Verifying final system performance in the field after installation.
- Hazardous Area Solutions: Designing panels with purge/pressurization or intrinsic safety for Class I Div 1/2 or ATEX environments.
Electrical Design
- Electrical System Architecture: Developing single-line diagrams, load calculations, and power distribution schemes.
- Motor Control Centers (MCC) & VFD Integration: Designing and integrating motor starters, drives, and soft starters for pumps, agitators, and other equipment.
- Arc Flash & NFPA 70E Compliance: Performing studies to ensure safe work practices and proper PPE requirements.
- Grounding & Bonding: Mitigating static discharge and ensuring operator safety in flammable or explosive environments.
- Conduit & Cable Schedules: Planning and detailing routes for efficient installation and minimal downtime.
- Lighting & Power Layout: Ensuring code-compliant, energy-efficient lighting and power distribution throughout the facility.
- Electrical Load Management: Monitoring and optimizing power usage to reduce operational costs.
Safety Systems & Regulatory Compliance
- Safety Instrumented Systems (SIS): Implementing SIL-rated solutions (IEC 61508/61511) to protect personnel and equipment in critical applications.
- Process Hazard Analysis (PHA): Conducting HAZOP, LOPA, and other studies to identify and mitigate risks.
- Emergency Shutdown (ESD) Systems: Designing robust interlock logic to safely halt operations during malfunctions or safety breaches.
- OSHA PSM & EPA RMP Compliance: Aligning with regulatory requirements for handling hazardous chemicals.
- Fire & Gas Detection Integration: Implementing flame detectors, gas sensors, and alarms for early hazard detection.
- Documentation & Validation: Developing and maintaining SOPs, compliance records, and change management logs.
- ATEX/IECEx Certification Support: Assisting with design and documentation for international standards and hazardous area certification.
Software & Data Integration
- PLC/HMI/SCADA Development: Creating customized code and operator interfaces with platforms like Rockwell, Siemens, Schneider, etc.
- Historian & Data Analytics: Storing large volumes of process data and using analytics tools for performance optimization and root cause analysis.
- Database & Server Integration: Linking plant-floor data to SQL databases, cloud servers, or ERP systems.
- Batch Management Software: Employing ISA S88 standards for recipe handling, scheduling, and traceability.
- Cybersecurity & Network Hardening: Conducting vulnerability assessments, implementing firewalls, VPNs, and secure remote access.
- Custom Reporting & Dashboards: Generating real-time KPI dashboards, OEE metrics, and compliance reports.
- Mobile & Web Integration: Allowing remote monitoring, control, and data visualization on tablets, smartphones, or web portals.
Project Management & Consulting
- Front-End Engineering Design (FEED): Determining scope, feasibility, and conceptual layouts for automation projects.
- Budgeting & Scheduling: Creating detailed project plans with milestones, cost estimates, and resource allocations.
- Vendor & Contractor Coordination: Managing subcontractors, suppliers, and cross-functional teams for seamless project delivery.
- Risk Assessment & Mitigation: Identifying project risks early and implementing proactive solutions.
- Regulatory & Compliance Guidance: Advising on local, federal, and global standards (OSHA, EPA, FDA, EU, etc.).
- Change Management & Documentation: Maintaining thorough records of design changes, ensuring traceability throughout the project lifecycle.
- Training & Knowledge Transfer: Conducting operator and maintenance team training to ensure a smooth handover.
Upgrades, Retrofits & Migration
- Legacy Migrations & Obsolescence: Removal of end-of-life hardware and unsupported systems to prevent downtime risks, ensure replacement parts availability, and secure long-term reliability through modern, vendor-supported solutions.
- Hardware & Software Upgrades: Incorporating new controllers, drives, sensors, or automation software to boost system reliability, integrate modern features, and future-proof operations.
- Retrofits & Expansions: Enhancing or reconfiguring existing equipment and systems to meet evolving production demands, address obsolescence, and capitalize on new market opportunities—all while managing costs and downtime through planned rollouts.
- Parallel Testing & Commissioning: Running new solutions in tandem with existing setups to minimize operational interruptions and verify functionality before full cutover.
- Hardware & Software Standardization: Unifying multiple control platforms, operating versions, and communication protocols to simplify maintenance, reduce training overhead, and streamline spare parts management.
- Phased Implementation Strategies: Scheduling major updates—mechanical, electrical, or software-related—over planned outages or staggered deployments, ensuring production continuity and optimized resource usage.
- Post-Upgrade Support & Optimization: Providing ongoing support after modernization, including system tuning, operator training, and performance reviews to ensure a smooth transition and long-term success.
Maintenance & Support Services
- Preventive Maintenance Programs
Regularly scheduled inspections and servicing to minimize downtime and extend equipment lifespan.
- 24/7 Technical Support & Emergency Response (with Support Contract)
Round-the-clock assistance to address urgent issues, available to clients who opt for a support contract.
- Post-Project Support
Included with every project to ensure a seamless handover and immediate troubleshooting once the system goes live.
- Field Services
Rapid dispatch of technicians to diagnose equipment issues, perform repairs, and restore functionality—minimizing disruption and downtime.
- Remote Monitoring & Troubleshooting
Real-time tracking of system performance to detect and resolve potential issues before they escalate.
- Staff Augmentation
Access to skilled professionals to fill short-term or specialized staffing needs for ongoing or complex projects.
- Software & System Upgrades
Regular updates to maintain optimal performance, ensure compatibility, and address emerging security concerns.
- Employee Training & Knowledge Transfer
Comprehensive support for in-house teams, covering best practices and hands-on training.
- Compliance & Safety Support
Guidance on meeting regulatory requirements and maintaining best practices for safe operation.
- Lifecycle & Asset Management
Proactive planning for equipment upgrades and replacements to optimize total cost of ownership.
Featured Projects
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STREAMLINED BATCH PROCESS CONTROL: Delivering Efficiency & Accelerated Production to a Chemical Plant’s New Reactor Train
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BRIDGING THE GAP: Control System Integration For Efficiency
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STREAMLINING CONTROL: Calcium Delivery System Upgrade
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