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Food & Bakeries

Silo Transfer System

Overview Control system

UCS Automation designed and manufactured a complete system to control the Filling and transfer of 4 Silo’s to 5 ‘Day Bins via Diverters and Sifters as detailed in the clients specifications document.

For the Silo Transfer system we supplied a multi-bay PLC/MCC Control Suite comprising a PLC section populated with the Allen Bradley ‘Compact Logix’ PLC Hardware, the CPU incorporated an Ethernet port to facilitate the communication to the remote ‘Point I/O’ system located in the Remote Mixing Panel. The PLC section also housed the Load cell Amplifiers, control relays and circuit breakers etc. The MCC section is fitted with a suitably rated door interlocked ‘Defeatable’ isolation switch along with the a 24V DC PSU, Safety relays, Blower Fan Star/Delta Starters, Bin Vibrator & RJF DOL starters & ‘Powerflex 40’ VSD’s for the Rotary Seal & Sifter Drive Motors. Thermister relays are fitted on the Blower & Rotary Blowing Seal Motors.

The Remote Filling Panel is a Stainless Steel ‘304L’ enclosure fitted with  a weather cowl. The panel door is fitted with an Allen Bradley PanelView Plus6 1250 12” HMI along with a 4 Position selector switch, ‘Power On’ lamp and start / stop buttons. Internally, the enclosure contains terminals to accommodate the connections to all local devices.

The Remote Mixing room panel is again supplied as a Stainless Steel ‘304L’ enclosure. The panel door  fitted with an Allen Bradley PanelView Plus6 1250 12” HMI along with an Emergency stop button,  ‘Power On’ lamp, ‘Control on’ lamp, Sifter illuminated reset pushbuttons & a ‘Silo being filled’ lamp. The panel also contains a ‘Point I/O’ remote rack to accommodate all wiring from all local devices including, Diverters, Sifters & Magnets. Pepperl + Fuchs Galvanic Isolation Barriers are provided for the Sifter Pressure & Temperature sensors.

The PLC & HMI software was designed to the clients Functional Design Specifications ‘FDS’, and all HMI screen layouts agreed during discussions with the client and supplied to suit their direct requirements.


UCS Automation carried out the electrical installation of the Silo transfer system which included the installation of a cable tray containment system routed via all devices associated with the plant, including –

Blowers 1-4

‘Blower Motor’ XLPE/PVC/SWA 7C/4MM via 6-pole + Aux Isolator;

‘Blower Isolator’ XLPE/PVC/SWA 3C/1.5MM;

‘Blower Thermistor’ XLPE/PVC/SWA 3C/1.5MM;

‘Blower Filter Blocked & Pressure switch’ XLPE/PVC/SWA 5C/1.5MM (Via JB);

‘Blower Pressure Transducer’ XLPE/PVC/SWA BS5308 1PR/1.0MM;

Silos 1-4

‘Bin Activator Motors’ XLPE/PVC/SWA 7C/1.5MM via 4-pole Isolators;

‘Rotary Seal Motor’ XLPE/PVC/SWA 4C/1.5MM via 4-pole Isolators;

‘Rotary Seal Isolator’ XLPE/PVC/SWA 3C/1.5MM;

‘Rotary Seal Thermistor’ XLPE/PVC/SWA 3C/1.5MM;

‘Explosion Panel’ XLPE/PVC/SWA BS5308 1PR/1.0MM (Blue Sheath);

‘Loadcell’ 6C+SCR;

‘Lighting Supply’ XLPE/PVC/SWA 3C/1.5MM to Weatherproof Fitting;

‘Local Silo JB’ XLPE/PVC/SWA 19C/1.5MM;

Silo Local JB to Silo Devices, including –

Inputs – Filter Blocked, Hi Level, Fill Valve Open / Closed,, Buffer Hopper Hi Level.

Outputs – RJF, Fill Valve, Buffer Hopper Fluidiser Solenoids, Buffer Hopper RJF.

Filling HMI Panel

‘HMI’ Industrial Ethernet comms cable;

‘Heater Power’ XLPE/PVC/SWA 3C/1.5MM;

‘Digital I/O signals’ 19C/1.5MM;

Filling HMI Panel to local Devices, including –

Tanker Earth Signals, Filling Point Connections.


‘Supply’ XLPE/PVC/SWA 4C/2.5MM;

Signals’ XLPE/PVC/SWA 7C/1.5MM;


‘Supply’ XLPE/PVC/SWA 3C/1.5MM;

Diverters 1-3

‘Solenoids & Feedback’ XLPE/PVC/SWA 7C/1.5MM;

Mixing Room HMI Panel

‘HMI’ Industrial Ethernet comms cable;

‘Digital I/O signals’ 27C/1.5MM;

Sifters 1-3

‘Sifter Motor’ XLPE/PVC/SWA 4C/1.5MM via 4-pole Isolators;

‘Sifter Motor Isolator’ XLPE/PVC/SWA 3C/1.5MM;

‘Sifter Motor Thermistor’ XLPE/PVC/SWA 3C/1.5MM;

‘Temp / Pressure’ XLPE/PVC/SWA BS5308 2PR/1.0MM (Blue Sheath) via local JB;

‘Sifter Main JB’ XLPE/PVC/SWA 19C/1.5MM;

Sifter Main JB to local Devices, including –

Safety Guard switches, Guard Switch aux, Guard Switch Release Solenoid & Oversize Hi-level.

Day Bins

‘Filter Fan’ XLPE/PVC/SWA 7C/1.5MM via 4-pole Isolator;

‘Explosion Panel’ XLPE/PVC/SWA BS5308 1PR/1.0MM (Blue Sheath);

‘Day Bin JB’ XLPE/PVC/SWA 7C/1.5MM;

Day Bin JB to local Devices, including –

Hi-Level, Mid-Level & Isolation valve open.

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