Client Overview
A mid-sized chemical manufacturing company in Central Europe, producing specialty chemicals and solvents. The facility required a safer, more efficient way to control over 500 manual valves in hazardous processing zones.
Our Approach
Steps included:
- Retrofitting manual valves with electric and pneumatic actuators
- PLC and DCS integration for centralized valve sequencing
- Deployment of valve position feedback sensors
- Implementation of emergency shut-off logic
Challenge
The existing manual valve operations posed:
Valve Automation
India
Key pain points included:
- High safety risks due to human intervention in high-temperature/pressure zones
- Inconsistent process control and delays during batch changes
- Risk of incorrect valve sequencing causing product loss or cross-contamination
- Limited operational data from valve states
- Compliance challenges with ISO and safety audits
Solutions Delivered
Smart Valve Automation & Sequencing
Upgraded 500+ valves with actuators, enabling automated sequencing for safer batch operations.
Centralized HMI & Emergency Control
Provided live monitoring, manual override, and fail-safe shut-off through a unified HMI interface.
Digital Audit Trails & Compliance Logs
Implemented traceable valve logs for ISO, safety, and environmental audit requirements.
SCADA & MES Data Integration
Connected valves to SCADA historian and MES via OPC UA for condition-based insights.
Technologies Used
Business Impact / Results
The valve automation initiative delivered measurable improvements in operational safety and efficiency:
What Our Clients Say
"QeMatic's RPA team transformed our manual loan processing system. What once took days now happens in hours. Their deep platform knowledge and process-driven approach helped us reduce turnaround time by over 60% while staying fully compliant."
“We engaged QeMatic to integrate AI with our existing automation efforts. The results were outstanding — predictive quality control and demand forecasting brought a new level of intelligence to our operations. They truly understand the future of automation."
"QeMatic's Time and Motion Study uncovered hidden inefficiencies in our patient onboarding flow. Their insights led to a 30% improvement in staff productivity and better patient experience. The free consultation alone was eye-opening."
Key Highlights (Summary Box)
| Metric | Before Implementation | After Implementation |
|---|---|---|
| Manual Valve Adjustments | ~2,500/day | <150/day (supervised only) |
| Safety Incidents | 3 annually | 0 (in 18 months) |
| Batch Changeover Time | 90 mins | 63 mins |
| Audit Compliance | Paper Logs | Digital Audit Trails |
| Operator Workload | High | Moderate with remote access |
