Superform Chemistries Limited – Redundant DCS Implementation
Reliable Process Automation with Siemens PCS 7
The Challenge:
Superform Chemistries Limited, a leading Indian specialty chemicals company spun off from UPL Ltd. (formerly United Phosphorus Limited), specializes in high-performance and sustainable chemical solutions for non-agricultural industries such as lubricants, mining, and healthcare. With a strong focus on innovation and complex chemistry, Superform continues to expand its manufacturing capabilities. As a part of this growth journey, Superform Chemistries set up a new pilot plant for pesticide manufacturing. Given the critical nature of the process and the need for uninterrupted operations, the company required a proven, highly reliable Distributed Control System (DCS) with a fully redundant architecture. The key challenge was to implement a control system that could.
- Ensure zero unplanned downtime
- Handle complex process operations
- Deliver high system reliability with long-term support
The Solution:
Velox Automation delivered a state-of-the-art redundant DCS solution based on Siemens PCS 7 V10.0, tailored to Superform’s operational philosophy. Redundant Siemens 410 Smart CPUs are considered for high availability. A redundant industrial network was established using Siemens Scalance switches. Engineering Stations (ES) and Operator Stations (OS) were configured on a redundant network for reliable plant operation. Complete application software development, system integration, and commissioning carried out by the experienced Velox team.
Why Velox Solutions Makes Sense
For the client:
The implementation delivered measurable and lasting benefits. Zero unplanned downtime as the fully redundant DCS architecture ensures uninterrupted plant operations, even in the event of hardware failure. High system reliability as modern IT infrastructure with the latest Windows operating system improved system stability, performance, and cybersecurity readiness. Operational confidence in the form of fast and reliable local support from Velox reduced operational risk and simplified the daily management of the plant. With the successful commissioning of the Siemens PCS 7-based redundant DCS, Superform Chemistries now operates its pilot plant with enhanced reliability, operational confidence, and future-ready automation—supporting innovation and safe process execution.
For the environment:
At Velox, sustainability is at the heart of everything we do—it's not just a side project but a core principle. Through the modernization of Superform's Jhagadia facility, we integrated energy-efficient technologies and optimized system design to reduce environmental impact and increase operational performance. The results include lower energy consumption, a minimized carbon footprint, and reduced waste through better resource management. At Velox, we are supporting businesses and contributing to a more sustainable planet.